2004 Ford F-150 structure problems

“The underbody frame is 95% rusted out, this vehicle is available for inspection upon request. I could have been fatally injured, not knowing the under frame was gone, until vehicle was taken in for new tires. The vehicle was inspected by Firestone tire and Gene Butman Ford. There were no warning messages and the problem was first noticed in 2019 and was told the vehicle was unsafe to drive, a hazard and should not be driven.”

“The truck has had a complete body frame failure. The entire frame is rusted through with large holes. I am unable to put it on a jack to change the tires. It has failed inspections and has not been inspected since 2019. I have a 1992 ford truck that has NO rust issue on the frame. This year is a complete design failure where they used substandard steel or other garbage. It is a safety hazard.”

“TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT WHILE THE VEHICLE WAS AT AN INDEPENDENT MECHANIC FOR ROUTINE MAINTENANCE, THE TECHNICIAN NOTICED THAT THE SUBFRAME WAS SEVERELY RUSTED THROUGH. THE VEHICLE WAS LATER TAKEN TO TONY BETTEN & SONS FORD, INC (3839 PLAINFIELD AVE NE, GRAND RAPIDS, MI 49525) WHERE THE CONTACT WAS INFORMED THAT THE DRIVER'S AND PASSENGER'S SIDE SUBFRAME WERE SEVERELY RUSTED, AND THAT THE SUBFRAME NEEDED TO BE REPLACED. THE SUBFRAME WAS NOT REPLACED NOR WAS THE VEHICLE REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 167,000.”

“THE FRAME IS ROTTED COMPLETELY. IT IS A SAFETY ISSUE THAT WHEN DISCOVERED AND SEARCHED SEEMS TO A HUGE ISSUE. I WAS ADVISED NOT TO DRIVE THE VEHICLE AS IT NOT SAFE TO DRIVE. I BOUGHT THIS TWO DAYS AGO.”

“TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED WHILE ROUTINE MAINTENANCE WAS BEING PERFORMED ON THE VEHICLE, THE CONTACT DISCOVERED THAT THE SUBFRAME WAS EXTREMELY CORRODED. THE VEHICLE WAS NOT TAKEN TO BE DIAGNOSED NOR REPAIRED. NEITHER THE DEALER NOR THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 167,000.”

“THIS VEHICLE IS OTHERWISE IN GOOD CONDITION WITH VERY LITTLE BODY RUST LIMITED TO THE BACK CORNER OF THE PASSENGER CABIN. HOWEVER THE LEFT FRAME RAIL STARTING 14 INCHES AHEAD OF THE FRONT ATTACHMENT POINT OF THE LEAF SPRING. THE RUST HOLE EXTENDS THE WIDTH OF THE FRAME RAIL FOR A DISTANCE OF 17 INCHES. ONE FINGER SIZE HOLE WAS OBSERVED. THE FRAME BOTTOM STEEL WAS EASILY STRIPPED AWAY WITH TWO FINGERS AND A THUMB TO THE LENGTH AND WIDTH DESCRIBED. THE REMAINDER OF THE FRAME HAS EXTENSIVE SURFACE RUST BUT NO HOLE AND OTHERWISE FAIR CONDITION. THE LICENSED STATE VEHICLE INSPECTION SHOP FAILED THE VEHICLE DUE TO THE FRAME RUST AT THIS LOCATION. OTHERWISE, WITH SOME MINOR MECHANICAL ISSUES, THE TRUCK IS IN GOOD CONDITION AND COULD BE SAFELY USED FOR A NUMBER OF MORE YEARS. ONLINE THIS RUST PROBLEM AT THIS POINT HAS A LARGE NUMBER OF COMPLAINTS IN FORD F-150 TRUCKS IN 2004 AND 2005. OBVIOUSLY THERE WAS A MANUFACTURING ISSUE FRAME FORMING TO CAUSE THIS RUST THROUGH IN SO MANY TRUCKS AT THIS FRAME LOCATION AND NOT ELSEWHERE.”