2004 Ford E-150 problems, complaints & recalls
Most-reported problem areas: Service Brakes, Hydraulic (4) · Power Train (4) · Wheels:lugs/Nuts/Bolts/Studs (2)
🧭 Reliability snapshot
Compared against other Ford E-150 model years — complaint volume vs the model's median year, recalls and severity. How we score →
🛣️ Complaints by mileage
22 NHTSA complaints that reported an odometer reading.
Safety recalls (1)
Fuel System, Gasoline:storage:tank Assembly 2011-11-08 · campaign 11E047000 · 17 vehicles
Defect: FORD IS RECALLING CERTAIN REPLACEMENT FUEL TANKS THAT COULD BE INSTALLED INTO MODEL YEAR 2004 THROUGH 2008 E-150, E-250, AND E-350 VANS AND WAGONS. THE AFFECTED FUEL TANKS HAVE AN EXTRA OBDII SENSOR HOLE ON THE TOP OF THE TANK THAT MAY NOT BE PROPERLY SEALED AND MAY LEAK FUEL.
Risk: A FUEL LEAK IN THE PRESENCE OF AN IGNITION SOURCE MAY RESULT IN A FIRE.
Fix: FORD WILL NOTIFY OWNERS, AND DEALERS WILL REPLACE THE FUEL TANKS FREE OF CHARGE. THE SAFETY RECALL BEGAN ON NOVEMBER 28, 2011. OWNERS MAY CONTACT FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-800-232-5952.
Service bulletins (60)
Technical service bulletins are repair instructions manufacturers send dealers for known issues. Unlike recalls, the fix is not automatically free — but naming the bulletin at the service desk can save diagnosis time and support goodwill repairs.
Power Train:automatic Transmission 2023-09-07 · SSM 51909 · Service Bulletin/Repair Instructions
when performing any transmission fluid changes or topoffs involving mercon sp, mercon lv has replaced all versions of mercon sp and can be used going forward. mixing mercon lv and mercon sp in the same transmission is acceptable. after 30-jun-2023, mercon sp atf will no longer be manufactured and wi
Power Train:automatic Transmission 2014-05-01 · ASI-44534 · Service Bulletin/Repair Instructions
ford: when shifting between park, reverse and/or during 2-3 shift, an intermittent clunk occurs with a torqshift transmission. model 2003-2014 f-super duty, e series, excursion, f-53 motorhome chassis, low cab forward. *pe
Power Train:automatic Transmission:torque Converter 2014-02-01 · ASI-44404 · Service Bulletin/Repair Instructions
ford: on some trucks, there is a no crank situation and if voltage on transmission range sensor at pin 21, is less than 5 volts, disconnect the engine cooling fan clutch, electronically, and recheck voltage. model 2003-2007 f super duty, 2004-2010 e series, 2003-2005 excursion.
Service Brakes, Air 2007-09-19 · 071110 · Service Bulletin/Repair Instructions
brake booster system may exhibit a brake pedal kickback and/or grabbing condition when applying the brakes. *nj
Engine And Engine Cooling:engine:diesel 2007-04-01 · 19728 · Service Bulletin/Repair Instructions
lack of power due to low fuel pressure - fuel tank liner seperation. *kb
Fuel System, Gasoline 2007-02-01 · 19621 · Service Bulletin/Repair Instructions
lack of power due to low fuel pressure, fuel tank liner seperation. *kb
Showing the 6 most recent of 60 bulletins. Search all of them free at nhtsa.gov.
What owners report
2025-07-24 · Power Train · 74,000 mi“the contact owns a 2004 ford f-150. the contact stated that while parked when the vehicle suddenly rolled backwards downhill the contact's son attempted to get into the vehicle to make it stop. the trailer's jackknife stopped the vehicle from going onto the road. the contact manually moved the vehicle back into their garage. the contact stated thei…”
2016-05-04 · Power Train · 176,000 mi“viberation in rear and clunking noisr in rear when stopping at light then taking of while making a right turn…”
2015-08-17 · Engine · 117,000 mi“2004 ford 4.6l engine: #2 spark plug ejected from cylinder head. ~$700 to repair!!!…”
2015-06-08 · Exterior Lighting · 50,000 mi“there are tons of drivers on public roads using off road led light bars and using amplified hid headlights. they are so bright i have to block the light with my hands when they drive by. i know this is illegal. it is terribly unsafe. why are there not laws being enforced to prevent their use on the street?…”
2015-04-26 · Power Train · 131,876 mi“at the point i reach 40 mph truck shifts to neutral, have to pull over safely and take truck out of overdrive to get home. very dangerous when traveling at that rate of speed. did some of my own investigating and found many website have angry people who also own same vehicles with very low mileage. i saw the range of miles between 44,000 miles to…”
2014-04-14 · Suspension · 93,000 mi“tl* the contact owns a 2004 ford f-150. the contact stated that the lower ball joints were causing premature wearing of the tires. the contact inspected the vehicle and noticed that the front end springs were completely fractured. the dealer and manufacturer were made aware of the failure. the manufacturer stated that there were no active recalls r…”
2014-03-05 · Visibility/Wiper · 60,000 mi“tl* the contact owns a 2004 ford f-150. the contact stated the front passenger's side window independently opened. the failure recurred several months later on the rear passenger window. the vehicle was taken to the dealer, who stated that both window regulator assemblies would need to be repaired. the vehicle was not repaired. the manufacture was …”
2013-09-10 · Engine · 118,000 mi“tl* the contact owns a 2004 ford e-150. the contact stated that a private mechanic attempted to remove the spark plugs but they were fused to the engine. the vehicle was eventually repaired. the manufacturer was contacted about the failure. the failure mileage was 118,000. the vin was unavailable. …”
2013-07-23 · Power Train · 79,964 mi“today was driving normally on the side road not towing & in overdrive when around 40mph the overdrive disengaged & starts revving like it's in neutral. i pull over & put it into park & then back into overdrive & start driving once again & same thing happened three times. luckily there was a service shop close. i took the truck in & they said take …”
2011-03-13 · Service Brakes, Hydraulic · 85,000 mi“during the winter months our 2004, ford, e150, van has had occasional yet complete brake failure several times. typically, it has happened when it was very cold -10f and typically slower speeds 10-15mph but today it was 30 f and speeds were 45-50 mph as we were coming down a mountain pass in colorado. we almost rear ended a semi and almost took a…”
Excerpts of consumer complaints filed with NHTSA, lightly truncated. They are owner statements, not verified findings.