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.

Hitch broke off due to ford common frame rot. Frame is rotted from leaf spring shackle and back

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.

Mileage: 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.

Mileage: 167,000

PAINT CRACKED ,COILS MALFUNCTION,SPRINGS FRONT

Mileage: 55

2004 F150 FX4. CONSUMER WRITES IN REGARDS TO DAMAGED FRAME. *LD *JS

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.

Mileage: 132,192

TL* THE CONTACT OWNS A 2004 FORD F-150. WHILE THE VEHICLE WAS UNDERGOING ROUTINE MAINTENANCE, THE INDEPENDENT MECHANIC DISCOVERED THAT THE FRAME AND CHASSIS OF THE VEHICLE WERE RUSTED AND CORRODED. FLAGSHIP FORD (850 FERN DR, BALDWIN, WI) AND THE MANUFACTURER WERE NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE MILEAGE WAS 138,000.

Mileage: 138,000

MY 2004 FORD F-150 HAS 61,000 MILES AND NO RUST ON THE OUTSIDE OF THE VEHICLE. I'VE KEPT THE TRUCK WELL MAINTAINED AND IT LOOKS ALMOST NEW. THE FRAME HOWEVER RIGHT WHERE THE REAR LEAF SPRING ATTACHES TO THE FRAME IS RUSTED RIGHT THROUGH. IT IS INCREDIBLE THAT THIS HAS NOT BEEN RECALLED AS OF YET. HOPEFULLY IT WILL BE RECALLED. WHILE DRIVING A PART OF THE EXHAUST HEAT SHIELD FELL ONTO THE DRIVESHAFT. WHEN I WENT TO INSPECT THE UNDERSIDE I FOUND A HOLE IN THE FRAME AND I WAS ABLE TO PUT MY FINGER RIGHT THROUGH IT. *DT CONSUMER STATED ONE IMPORTANT FACT THAT I FORGOT TO ADD TO MY COMPLAINT IS THE SECTION OF THE FRAME THAT RUSTED THROUGH HAS THE EXACT SAME ISSUE IN THE SAME SPOT ON BOTH THE PASSENGER FRAME RAIL AS WELL AS THE DRIVER'S SIDE FRAME RAIL. THE 2004 FORD ESCAPE WAS RECALLED FOR SIMILAR ISSUES THAT YEAR BUT IN THE FRONT OF THE VEHICLE. MY TRUCK HAS ONLY 61,000 MILES ON IT AND FROM FORUMS AND POSTS I'VE READ IT SEEMS TO BE A MAJOR ISSUE FOR THAT YEAR VEHICLE.*JB

Mileage: 61,000

TL* THE CONTACT OWNS A 2004 FORD F-150. WHILE THE VEHICLE WAS BEING SERVICED AT JIM TRENARY FORD (LOCATED AT 255 JOHN DEERE DR, MOSCOW MILLS, MO 63362, (636) 356-9000), THE TECHNICIAN NOTICED THAT THE FRAME WAS SPLIT COMPLETELY IN HALF AND NEEDED TO BE REPLACED. THE TECHNICIAN INFORMED THE CONTACT THAT THE VEHICLE COULD NOT BE DRIVEN. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND DID NOT ASSIST. THE APPROXIMATE FAILURE MILEAGE WAS 200,000.

Mileage: 200,000

THE MAIN FRAME RAILS( THAT RUN FROM FRONT BACK) HAVE AN EXTRA CLADDING THAT IS WELDED TO THE MAIN FRAME RAILS. THIS AREA I AM REFERRING TO IS WHERE A CROSS MEMBER( HOLDING THE WEIGHT OF THE REAR ENGINE AND TRANSMISSION) IS WELDED TO THE CLADDING AND THE TWO MAIN FRAME RAILS. THE CLADDING WAS NOT COMPLETELY WELDED SO WATER HAS GOTTEN BETWEEN THE CLADDING AND MAIN FRAME RAILS CAUSING SEVERE CORROSION AND FAILURE OF THAT CONNECTION POINT. EVEN THOUGH IT COULD BE SAID I TAKE EXTREMELY GOOD CARE OF MY VEHICLES THIS AREA SUDDENLY PRESENTED AS A BULGE AND SUBSEQUENT DISCOVERY OF AN EXTREME FAILURE. THIS CONSISTENT FAILURE HAPPENED ON BOTH FRAME RAIL CONNECTION POINTS. I FEEL THAT THIS FAILURE WILL BE OVERLOOKED AS IT WAS WITH ME ....AND COULD CAUSE FRAME FAILURE CAUSING PUBLIC HARM.

Mileage: 180,000

SAME DEAL AS EVERY OTHER MEMO I READ. MAJOR HIGHLIGHTING POINTS: - PREMATURE FRAME CORROSION AND RUST. - MECHANIC INFORMED ME THAT THE FRAME ON THE REAR HALF. - RUSTED AND CRACKED UNDER BED AND REAR WHEEL WELLS - FRAME WOULD NO LONGER SUPPORT WEIGHT OF VEHICLE - RUST THRU HOLES AND LONGITUDINAL CRACKS FORMED ON THE BOTTOM AND SIDE FRAME SURFACES AT THE STRESS POINT BEFORE THE REAR WHEEL BEND. - EXTREMELY UNUSUAL, TRUCK HAS BEEN GENERALLY BEEN GARAGE KEPT AND MAINTAINED IN GOOD MECHANICAL CONDITION. - THE EXTERIOR BODY DOES NOT EXHIBITS SPOTS OR SURFACE RUST ON VISIBLE BODY PANELS. - NO EVIDENT SIGNS OF RUST OR DEGRADATION OF STRUCTURE. - METICULOUSLY MAINTAINED VEHICLE OTHERWISE. (NEW TRANSMISSION, DRIVE SHAFT, ENGINE RETIMED, SPRAY BED LINER, ETC.) - CATASTROPHIC FAILURE OF THE FRAME STRUCTURE WAS IMMINENT AND THAT THE VEHICLE WAS NO LONGER SAFE TO DRIVE. - CANNOT BE REPAIRED AND IS UNSAFE. - CANNOT PASS A STATE SAFETY INSPECTION. - CANNOT EVEN BE PUT ON A LIFT BECAUSE IT HAS NO STRUCTURAL STRENGTH.

Mileage: 110,000

THIS A.M. AS I ENTERED MY DRIVEWAY, A NEIGHBOR STOPPED ME TO TALK. I STOPPED AND ROLLED DOWN MY WINDOW. HE WENT ON AND ON. SUDDENLY, MY TRUCK ACCELERATED AT FULL THROTTLE TOWARD MY GARAGE 70 FEET AWAY. MY FOOT WAS ON THE BRAKE TO NO AVAIL. I TURNED SLIGHTLY TO THE RIGHT AND HIT THE CORNER OF THE GARAGE. THE AIR BAGS DEPLOYED. MY GLASSES WENT FLYING. I WAS NOT HURT. A TREE HAD SOFTEN THE IMPACT. I WAS SEVERELY SHAKEN. MY BLOOD PRESSURE WAS ELEVATED. FORD MOTOR COMPANY IS NOT HELPFUL. MY INSURANCE COMPANY, GEICO, IS HANDLING THE ISSUE.

Mileage: 57,000

THE TRUCK WAS TAKEN INTO MECHANIC. THE MECHANIC PUT IT UP, AND SAW THAT ENTIRE FRAME WAS RUSTED. IT IS NOT FIXABLE. CONTACTED JOHN LANCE FORD, WHERE IT WAS PURCHASED. THEY ADVISED TO TAKE TRUCK TO NEAREST FORD DEALER. WE TOOK IT TO FORD IN PORT CLINTON, OHIO. THE SERVICE MANAGER TOOK PICTURES AND SENT IT TO CORPORATE OFFICE. IT HAS BEEN LONGER THAN 6 WEEKS, AND HAVE NOT HEARD BACK.

Mileage: 142,000

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT LOOKED UNDERNEATH THE VEHICLE AND NOTICED THAT THE ENTIRE BOTTOM OF THE FRAME WAS RUSTED. THE DEALER (LIBERTY FORD, 9311 LIBERTY RD, RANDALLSTOWN, MD 21133, 410-504-2897) WAS CONTACTED AND STATED THAT THE FRAMES WERE ABSOLUTE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILEAGE WAS APPROXIMATELY 78,000.

Mileage: 78,000

TL* THE CONTACT OWNS A 2004 FORD F-150. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR REPAIRS. ONCE THE VEHICLE WAS PLACED ON A LIFT, THE MECHANIC NOTICED THAT THE MAIN RAILS THAT SUPPORT THE FRAME AND THE FRAME OF THE VEHICLE HAD EXTENSIVE RUST. THE FAILURE COULD CAUSE THE STRUCTURE TO POTENTIALLY FRACTURE OR DISINTEGRATE. THE INDEPENDENT MECHANIC DIAGNOSED THAT THE FRAME NEEDED TO BE REPLACED. THE DEALER WAS NOT CONTACTED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VIN AND FAILURE MILEAGE WERE NOT AVAILABLE.

MY TRUCKS FRAME HAS RUSTED OUT FROM THE CAB CORNERS TO THE REAR PART OF THE FRAME RAILS. FORD MOTOR COMPANY WONT DO ANYTHING ABOUT THIS PROBLEM. NUMEROUS COMPLAINTS HAVE BEEN FILED, YET THEY WONT DO ANYTHING ABOUT IT. IM NOT SELLING MY TRUCK BECAUSE ITS A RARE VERSION OF THE 04 NEW STYLE F-150. THIS IS A VERY SERIOUS PROBLEM THAT PEOPLE CAN DIE FROM AND FORD WONT BACK THEM UP ON THE 04-08 TRUCKS.

Mileage: 172,070

THE FRAME ON MY TRUCK HAS SPLIT IN HALF ALWAYS BEEN TAKEN CARE OF. IVE HAD IT FOR 6 YEARS AND IT BEEN GOOD. UNTIL RECENTLY THE BED HAS STARTED TO SHAKE VERY VIOLENTLY. MY DAD AND I HAVE FIGURED OUT THAT THE FRAME ON MY TRUCK HAS SPLIT IN HALF! I DID SOME RESEARCH ON THIS ISSUE OF FRAMES FAILING. MOST 11TH GEN OWNERS LIKE ME HAVE OR HAD THIS KIND OF PROBLEM. SOME FRAMES HAVE ROTTED OUT COMPLETELY DUE TO FORD. THIS TRUCK IS VERY UNSAFE! AND IVE ASKED FORD IF THEY COULD DO ANYTHING AND THEY COULDNT DO ANYTHING. THEY WONT BACK UP THEIR PRODUCTS.

Mileage: 170,210

BROUGHT MY 2004 F150 XLT TO HAVE SOME SERVICE WORK DONE, THE TRUCK NEEDED A MUFFLER AND A NEW FRONT UPPER CONTROL ARM, I WAS ADVISED BY THE SERVICE MANAGER THAT I SHOULD HAVE MY FRAME LOOKED AT BEFORE GOING ANY FURTHER, BOTH RIGHT AND LEFT SIDES OF THE FRAME IN THE MIDDLE OF THE TRUCK HAVE SEVERE RUST AND I BELIEVE THE STRUCTURE IS DOOMED TO FAIL, I HAD PLANNED ON DRIVING THIS TRUCK FOR SEVERAL MORE YEARS AS IT IS MY DAILY DRIVER. I AM NOW LEFT WITH A TRUCK THAT CANNOT BE CERTIFIED FOR RESALE AND HAS LOST ITS VALUE AND FURTHER IT IS NO LONGER SAFE. BY THE WAY THE TRUCK ONLY HAS 190 THOUSAND KMS ON IT.

Mileage: 190,000

I HAVE A 2004 FORD F-150 XL EXTENDED CAB PICK UP WITH 140,000 MILES. I RECENTLY PURCHASED NEW TIRES AND AN EXHAUST . DROPPED OF THE TRUCK AT THE MECHANIC TO HAVE ITEMS INSTALLED. RECEIVED A CALL THE NEXT MORNING THAT THERE WAS A PROBLEM, SO WENT IN TO SEE WHAT THE ISSUE WAS. TURNS OUT THE FRAME OF THE TRUCK HAS ROTTED ON BOTH THE PASSENGER AND DRIVERS SIDE, WHERE THE BED MEETS THE CAB. WHEN THEY TRIED TO LIFT THE TRUCK TO INSTALL THE TIRES THE TRUCK DIDN'T MOVE, THE LIFT JUST STARTED CRUSHING THROUGH THE FRAME RAIL. QUITE DEVASTATING NEWS TO RECEIVE SINCE THE TRUCK RUNS AND DRIVES GREAT, BUT IS NOW A BIG HUNK OF SCRAP. WORRISOME ALSO AS I HAD JUST TAKEN MY FAMILY ON A 7 HOUR TRIP IN THE TRUCK A MONTH EARLIER AND HATE TO CONSIDER WHAT COULD HAVE HAPPENED IF WE HAD BEEN INVOLVED IN AN ACCIDENT. I FEEL THAT IN THIS DAY AND AGE A 13 YEAR OLD TRUCK SHOULD NOT EXPERIENCE THIS ISSUE AND THE MANUFACTURER SHOULD STEP UP AND TAKE SOME RESPONSIBILITY FOR THEIR PRODUCT. BUILT FORD TOUGH. YEAH, RIGHT.

Mileage: 140,000

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT THE REAR DRIVER SIDE FRAME OF THE VEHICLE WAS RUSTED OUT NEAR THE FUEL TANK. THE CONTACT TOOK THE VEHICLE TO THE LANGLEY FORD DEALER WHO STATED THAT THE VEHICLE WAS NOT INCLUDED IN ANY RECALL REGARDING THE FRAME. THE VEHICLE WAS NOT OFFICIALLY DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND CONFIRMED THE DEALER'S INFORMATION. THE APPROXIMATE FAILURE MILEAGE WAS 124,000. UPDATED 08/09/17*LJ *TR

Mileage: 124,000

TL* THE CONTACT OWNS A 2004 FORD F-150. WHILE PERFORMING ROUTINE MAINTENANCE ON THE VEHICLE, THE CONTACT BECAME AWARE OF EXTREME CORROSION TO THE SUBFRAME OF THE VEHICLE. THE CONTACT WAS CONCERNED THAT THE VEHICLE COULD FRACTURE AND SEPARATE AT THE CENTER BETWEEN THE BED AND THE CABIN. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 75,000.

Mileage: 75,000

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT THE FRAME WAS FRACTURED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 89,000.

Mileage: 89,000

MY TRUCK HAS 106,XXX MILES ON IT. I HAVE ONLY OWNED IT FOR 9 MONTHS. I TOOK IT TO THE SHOP FOR A REPAIR AND WAS TOLD THE FRAME WAS SO ROTTEN OUT THEY COULDN'T PUT IT ON THE LIFT.

MY TRUCK HAS ALWAYS BEEN WELL TAKEN CARE OF HAS 92, 000 MILES ON IT WHICH IS VERY LOW ON A 2004. IT WAS ALWAYS SERVICED AT THE DEALER WHERE WE PURCHASED THE TRUCK. I HAD 2 EXTENDED SERVICE WARRANTIES THROUGH THIS DEALER. THERE IS NO RUST ON THE BODY AT ALL. I TOOK IT TO ANOTHER GARAGE TO HAVE SOME WORK DONE ON IT AND WHEN THEY PUT IT ON THE LIFT THE BOX ON THE TRUCK STARTED TO PULL AWAY FROM THE CAB. WHEN IT WAS LOWERED, AND INSPECTED THE FRAME ON BOTH SIDES OF THE TRUCK WAS COMPLETELY ROTTED THRU. I HAD NO IDEA THAT IT WAS THIS BAD. THE FRAME MUST BE COMPLETELY RECONSTRUCTED AND OF COURSE FORD AND THE DEALER DON'T WANT TO TAKE ANY RESPONSIBILITY FOR IT. SOMEONE COULD HAVE BEEN KILLED NOT KNOWING THE SEVERITY OF THE FRAME. I DEPENDED ON FORD TO CONSTRUCT A SAFE VEHICLE AND FOR THE DEALER TO SERVICE MY TRUCK IN GOOD FAITH. PEOPLE SHOULD BE REIMBURSED BY FORD TO GET THE PROBLEM FIXED AND FOR THEIR LACK OF A QUALITY PRODUCT AND SERVICE. SOMETHING NEEDS TO BE DONE BEFORE SOMEONE LOSES THEIR LIFE.

Mileage: 92,000

WITHIN A COUPLE YEARS OF MANUFACTURE NOTICED OXIDATION APPEARING ON UNDERSIDE OF HOOD, AND SOME PAINT BLISTERING ON FRONT EDGE OF UPPER SIDE OF HOOD. THESE ISSUES HAVE WORSENED OVER TIME

Mileage: 15,000

FRAME RUSTED IN HALF,

Mileage: 90,000

HOOD PAINT AND ROOF PAINT PEELING UP FOR THE LAST 7 YEARS. IT STARTED WITH SMALL BLISTERING AND WHAT APPEARED TO BE JUST A FEW KNICKS ON THE HOOD. HOWEVER IT QUICKLY SPREAD AND THE ENTIRE HOOD AS WELL AS ROOF ARE IN NEED OF A PAINT JOB DUE TO RUST. I AM THE ORIGINAL OWNER AND HAVE APPS 129000 MILES ON IT.

Mileage: 40,000

THE FRAME UNDER MY F150 IS RUSTED THROUGH. I ONLY HAVE 81K MILES ON IT AND I DON'T UNDERSTAND WHY THE FRAME IS RUSTING SO BADLY. IT HAS ALREADY COST ME 2,400 TO HAVE A CERTIFIED WELDER REPLACE SOME OF THE SECTIONS THAT WERE RUSTED OUT. I KNOW JUST FOUND ANOTHER PART OF THE FRAME THAT IS RUSTED UNDER THE LEAF SPRING. THAT IS NOW GOING TO COST ME ANOTHER $500.00.

Mileage: 81,000

FRAME RUSTING OUT PREMATURELY CAUSING A SAFETY HAZARD.

Mileage: 62,000

BOTH REAR SUICIDE DOORS WILL NOT OPEN, THE LATCH MECHANISM IS BROKEN AND APPARENTLY COST OVER $700.00 TO FIX BOTH. IN ADDITION I HAVE REPLACED THE WHEEL BEARING ON ALL WHEELS TWICE AND NOW ANOTHER ONE IS GOING BAD. IT SEEMS LIKE I NEVER HAVE A PERIOD WHEN ALL THE BEARINGS ARE GOOD.

Mileage: 95,000

THE FRAME OF MY 2004 F150 IS ALMOST COMPLETELY ROTTEN FROM THE FRONT OF THE LEAF SPRING ALL THE WAY UP TO THE DRIVERS DOOR. THE BED SUPPORTS ARE ALSO ROTTED COMPLETELY OFF MAKING THE BED UNSAFE AND UNABLE TO USE.

Mileage: 150,000

DURING AN OIL CHANGE IT WAS NOTICED THAT THE LEFT HAND FRONT DIFFERENTIAL MOUNTING BRACKET APPEARED TO HAVE A CRACK PURSUANT WITH TSB 06-11-12. HOWEVER UPON CLOSER EXAMINATION IT WAS SHOWN THAT THE DAMAGE WAS MORE EXTENSIVE THEN THE "CONCERN OF THE LEFT HAND FRONT DIFFERENTIAL MOUNTING BRACKET SEPARATING FROM THE FRAME RAIL." MENTION IN THE TSB. INSTEAD OF THE AFOREMENTIONED MOUNT BREAKING, A SECTION OF THE FRAME APPROXIMATELY 1/4 OF AN INCH AROUND THE WELDS FOR THE DIFFERENTIAL MOUNT ON ALL SIDES HAD SEPARATED FROM THE REST OF THE FRAME LEAVING A HOLE IN THE FRAME APPROXIMATELY FOUR INCHES ACROSS.

Mileage: 58,414

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT THERE WAS RUST FORMING ON THE REAR DRIVER AND PASSENGER SIDE TIRE WELLS. THE FAILURE RECURRED CONTINUOUSLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE ENTIRE REAR PANEL NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 84,800.

Mileage: 84,800

I OWN A 2004 FORD HERITAGE 4X4 AND THE FRAME IS LITERALLY RUSTING AWAY ON OR ABOUT THE 10TH OF MARCH THE BRACKET THAT HOLDS THE REAR DRIVER SIDE LEAF SPRING ROTTED AWAY AND PUNCHED THROUGH THE BOTTOM OF MY BED. I WAS ONLY GOING 30 WHEN IT HAPPENED SO EVERYONE WAS SAFE. I ALSO HAD TO REPLACE THE TRAILER HITCH LAST YEAR BECAUSE THE FRAME WAS SO ROTTED AWAY. I STOPPED AT A STOP SIGN AND WHEN I WENT TO GO I SAW MY TRAILER JUST GO UP AND SLAM BACK DOWN ON THE GROUND. LUCKILY I WAS NOT GOING 65 MPH OTHERWISE I WOULD HAVE HAD A ACCIDENT. THE BACK OF THE FRAME NOW IS PAPER THIN. FORD SHOULD DO A RECALL ON THESE FRAMES. I HAVE OWNED MANY FORD AND NEVER HAD RUST THIS BAD. *TR

Mileage: 111,000

2004 FORD F-150. CONSUMER WRITES IN REGARDS TO VEHICLE FRAME RUST PROBLEMS. *SMD CONSUMER SENT ADDITIONAL CORRESPONDENCE. *SMD THE VEHICLE HAD TO BE TOWED TO THE REPAIR SHOP, BECAUSE THE BRAKES WENT OUT. THE REAR BRAKE LINES, HOSES, CALIPERS, MASTER CYLINDER AND PADS WERE REPLACED. UPDATED 03/09/15. *JB

WHEN IT RAINS WATER COMES IN AND DRIPS ON THE PASSENGER SIDE REAR SEAT. I HAVE REPLACE THE THIRD BRAKE LIGHT LENS TWICE AND THE REAR WINDOW. I HAVE READ FORUMS AND IT SEEMS LIKE THIS PROBLEM IS COMMON. I HAVE A TRUCK THAT SMELLS LIKE MILDEW. I HAVE TO DRIVE IT NOW WITH THE INTERIOR PULLED OUT. *TR

Mileage: 150,000

THE MIRROR(S) ARE FULL OF CORROSION AND THE DRIVERS SIDE MIRROR FELL RIGHT OFF THE CAR WHILE DRIVING. *TR

Mileage: 150,000

MY TRUCK IS ONLY 10 YEARS OLD AND THE FRAME IS ALL ROTTEN OUT I THINK IT IS A VERY SERIOUS THING IF YOU ARE DRIVING ALONG AND IT BREAKS. *TR

Mileage: 70,000

I TOOK MY TRUCK TO A GARAGE TO HAVE THE OIL CHANGED. WHILE UP ON THE RACK THE RUST WAS NOTICED BY MY MECHANIC WHO SAID IT WOULD NOT PASS INSPECTION BETTER HAVE IT FIXED. I CONTACTED A PROFESSIONAL WHO CAME TO MY HOUSE AND LOOKED AT IT WITH THE BED OFF. UPON HIS INSPECTION HE FOUND IT WAS UNREPAIRABLE THERE WAS NOT ENOUGH ORIGINAL METAL LEFT TO WELD TO. I HAVE CONTACTED FORD CUSTOMER RELATIONSHIP CENTER ONLY TO BE TOLD THERE IS NO WARRANTY, NO RECALL, SORRY FOR YOUR LUCK AND GOT HUNG UP ON. WHILE RESEARCHING ONLINE I HAVE DISCOVERED THAT FORD HAS A RECALL ON 2004 ESCAPES FOR THIS VERY SAME REASON "THE FRAMES ARE RUSTING OUT" IT WOULD MAKE SENSE TO ME THAT THERE MUST HAVE BEEN A BAD BATCH OF METAL USED IN THE BUILDING OF THESE FRAMES. I WOULD LIKE TO KNOW IF ANY MORE 2004 VEHICLES FROM FORD HAVE REPORTED SIMILAR PROBLEMS AND WHAT CAN WE DO ABOUT THIS? *TR

Mileage: 148,369

-REPAIR SHOP-2004 FORD F150 CREW CAB, FRAME COMPLETELY ROTTED THROUGH, FRAME REPLACEMENT REQUIRED. CUSTOMER WILL NOT HAVE REPAIRED. *TR

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT THE FRAME MEMBERS WERE EXTREMELY CORRODED. THE VEHICLE WAS NOT TAKEN TO A DEALER OR INDEPENDENT MECHANIC. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE AND CURRENT MILEAGE WAS 109,000.

Mileage: 109,000

VEHICLE'S BACK WINDOW LEAK NOTED WITHIN 60 DAYS AFTER PURCHASE, RESEALED BY DEALER X2-STILL LEAKS. WITHIN A PERIOD OF ONE YEAR AFTER PURCHASE, THREE OF THE FOUR WINDOW GEAR BOXES WERE REPLACED DUE TO FAILURE. I'VE NOTED SEVERAL COMPLAINTS ABOUT THESE ISSUES, MET OTHER OWNERS WHO HAVE HAD THESE ISSUES FIXED UNDER WARRANTY, YET WE WERE REQUIRED TO PAY FOR REPAIR. AT HIGHWAY SPEEDS, 65MPH, THE VEHICLE BEGINS TO SHIMMY, VIBRATE AND BECOMES DIFFICULT TO MAINTAIN CONTROL OF STEERING. VIBRATION MAKES RIDE UNPLEASANT AND NOISY. *TR

Mileage: 4,000

WHEN DRIVING AT RELATIVELY LOW SPEED, THE HOOD LIFTED VIOLENTLY. THE DRIVER WAS ABLE TO STOP THE TRUCK SAFELY. THE PORTION OF THE HOOD WHICH SECURES THE HOOD STRIKER GAVE WAY, ALLOWING THE HOOD TO OPEN SO VIOLENTLY THAT THE GRILLE FLEW OFF. THE HOOD WAS PROPERLY CLOSED/LATCHED BEFORE THE INCIDENT, AND THE STRIKER WAS STILL IN THE LATCH (COMPLETE WITH PIECES OF ALUMINUM TORN OFF OF THE HOOD) AFTER THE INCIDENT. IT APPEARS THAT GALVANIC CORROSION (STEEL STRIKER ON ALUMINUM HOOD) LIKELY CAUSED THE ISSUE. SINCE THIS TRUCK IS IN A FLEET, THE REMAINDER OF THE F-150S OF THE SAME BODY STYLE (MY2008 AND OLDER) WERE CHECKED, 65 OF 580 TRUCKS HAD EITHER CRACKING OR CORROSION AROUND THE STRIKER BAR WHICH MAY LEAD TO THIS ISSUE. NOTE - THIS IS AN ONTARIO, CANADA FLEET BUT THESE ISSUES LIKELY AFFECT US-SOLD VEHICLES. *TR

Mileage: 135,025

WHILE ATTEMPTING TO ACCELERATE ONTO A HIGHWAY MY VEHICLE SPUTTERED AND I WAS UNABLE TO GET UP TO SPEED IN A REASONABLE AMOUNT OF TIME. FORTUNATELY I WAS ON A 4 LANE HIGHWAY AND THE APPROACHING VEHICLES WERE ABLE TO AVOID ME BY PULLING INTO THE PASSING LANE. I BROUGHT MY VEHICLE IN FOR SERVICE AND A CORRODED FUEL PUMP CONTROL MODULE WAS RESPONSIBLE FOR THE HESITATION. ACCORDING TO MY MECHANIC, HE CATEGORIZED THE PROBLEM AS DEFECTIVE DESIGN. THE MODULE IS MOUNTED IN A AREA SUSCEPTIBLE TO CORROSION. THIS IS A RELATIVELY EASY FIX HOWEVER IN MY CASE THE SPARE TIRE CARRIER HAD TO CUT OFF TO ACCESS THE MODULE. *TR

Mileage: 125,948

REAR PASSENGER SIDE QUARTER PANEL RUST DUE TO RUBBER PANEL BEING IMPROPERLY INSTALLED AT FACTORY. FULL RUST THROUGH IN THE MIDDLE OF THE PANEL, FROM THE INSIDE OUT. *TR

Mileage: 115,000

RUST IN THE REAR PASSENGER QUARTER PANEL DUE TO A KNOW FACTORY DEFECT OF A RUBBER PAD BEING INSTALLED IMPROPERLY, CONTACTED FORD ABOUT THE PROBLEM, THEY REFUSE TO REPAIR OR ASSIST IN ANY WAY. *TR

Mileage: 115,000

WAS DRIVING DOWN THE ROAD AT APPROXIMATELY 55 MPH AND THE LEFT DRIVER'S SIDE WINDOW CAME CRASHING DOWN. I THOUGHT A ROCK WAS COMING THROUGH THE WINDOW AND ALMOST WENT OFF THE ROAD. *TR

Mileage: 45,349

IN LATE-JUNE 2012 A LOUD CLUNK/THUD/POP/SMALL EXPLOSION OCCURRED IN THE PASSENGER-SIDE DOOR OF MY 2004 FORD F-150 REGULAR CAB TRUCK, WHILE THE VEHICLE WAS STOPPED AND IDLING, AND THE WINDOW DROPPED INTO THE DOOR FRAME. WHEN I RETURNED HOME I REMOVED THE DOOR PANEL AND DISCOVERED THAT A SMALL PIECE OF MOLDED PLASTIC, 1 1/8" X 1 7/8" (PROBABLE COST TO FORD ABOUT 39 CENTS) ON THE WINDOW REGULATOR HAD DISINTEGRATED/FAILED, ALLOWING THE REGULATOR CABLE TO RELEASE THE WINDOW. I HAVE FOUND A REPLACEMENT WINDOW REGULATOR ON THE INTERNET FOR $70 (FORD CHARGES $175 FOR THE PART) AND WILL REPAIR THE DEFECTIVE ITEM MYSELF. I NOTIFIED FORD OF THE FAILURE OF A LESS-THAN-QUALITY PLASTIC PIECE ON THE REGULATOR AND ASKED FOR REIMBURSEMENT. FORD RESPONDED: "THERE ARE NO FACTORY WARRANTIES OR PROGRAMS IN EFFECT ON YOUR VEHICLE THAT WOULD PROVIDE FINANCIAL ASSISTANCE FOR YOUR CURRENT VEHICLE CONCERN." HOWEVER, THEY DID ADD: "RECOMMEND THAT YOU KEEP YOUR REPAIR RECEIPTS IN CASE FORD INITIATES A RECALL OR CUSTOMER SATISFACTION PROGRAM IN THE FUTURE BASED ON CUSTOMER FEEDBACK OR FURTHER ENGINEERING REVIEW OF SIMILAR COMPLAINTS." I SEE FROM THE LARGE NUMBER OF COMPLAINTS ON THIS WEBSITE BY FORD TRUCK OWNERS THAT I AM BUT ONE OF HUNDREDS WHO HAVE BEEN AFFECTED, AND OBVIOUSLY, THERE WILL BE HUNDREDS MORE; THE ODDS ARE VERY HIGH THAT THE MAJORITY OF THE PLASTIC PIECES ON FORD TRUCK WINDOW REGULATORS WILL FAIL SOONER OR LATER, AND I SERIOUSLY DOUBT THAT THE 2004 FORD F-150 TRUCK IS THE ONLY MODEL YEAR THAT CONTAINS PLASTIC PARTS IN THE WINDOW REGULATORS. $70 TO REPLACE A FAILED PIECE OF PLASTIC THAT INITIALLY PROBABLY COST FORD ABOUT 39 CENTS TO PRODUCE IS A SAD COMMENTARY ON QUALITY. *TR

Mileage: 54,360

ON 25 MARCH 2011, I ENCOUNTERED A LOUD POP IN THE DOOR ON THE DRIVER-SIDE OF MY 2004 FORD F-150 REGULAR CAB TRUCK, AND THE WINDOW DISAPPEARED INTO THE DOOR FRAME. I REMOVED THE DOOR PANEL AND DISCOVERED THAT THE CABLE MECHANISM WITHIN THE WINDOW REGULATOR HAD FAILED. WITHOUT FURTHER DELAY I TURNED THE TRUCK INTO MY FORD DEALER TO HAVE THE WINDOW REGULATOR REPAIRED, AND RECEIVED A REPAIR BILL OF $301.86 (THE REGULATOR ALONE COST $159.36); THE FORD ADVISOR STATED THAT THEY HAD THE PART IN STOCK SINCE THE WINDOW REGULATOR FAILURE WAS A COMMON OCCURRENCE. I DID NOT INSPECT THE REGULATOR TO DETERMINE WHY THE CABLE MECHANISM HAD FAILED. AFTER THIS INCIDENT I VISITED WWW.NHTSA.GOV TO DETERMINE THE EXTENT OF THE PROBLEM, AND LEARNED THAT MORE THAN 240 OTHER 2004 FORD TRUCK OWNERS HAD EXPERIENCED THE EXACT SAME PROBLEM IN ONE DOOR OR THE OTHER IN THEIR TRUCKS. AS MIGHT BE EXPECTED WHEN INFERIOR PARTS ARE INSTALLED IN A VEHICLE, SUCH AS THE WINDOW REGULATORS IN THE 2004 FORD TRUCKS, THE PASSENGER-SIDE WINDOW REGULATOR ALSO FAILED. IN THE SECOND INSTANCE I DETERMINED THAT A SMALL, CHEAP PIECE OF MOLDED PLASTIC ON THE WINDOW REGULATOR HAD FAILED BECAUSE OF THE IMMENSE PRESSURE APPLIED TO IT WHEN THE WINDOW WAS BEING RAISED. DETAILS OF THAT FAILURE ARE LISTED ELSEWHERE ON THIS WEBSITE. *TR

Mileage: 51,320

IS ANYBODY DOING ANYTHING ABOUT THE FORD WINDOW REGULATOR PROBLEM. OVER THE YEARS ALL OF MY SONS WINDOWS HAVE ALL FALLEN DOWN. AT TIMES LEAVING THE KIDS WITH EXPOSURE TO WHOEVER PASSES BY...THIS IS NOT SAFE. TWO WINDOWS FAILED ON THE SAME DAY. TRIED TO CALL FORD AND GOT NO REASONABLE RESPONSE... *JS

Mileage: 100,000

I HAVE OWNED THIS TRUCK SINCE 2004, NO SERIOUS ISSUES. THIS PAST FRIDAY I NOTICED POWER WAS STILL GOING TO MY TRUCK WHEN IT WAS TURNED OFF. THE POWER ACCESSORY RELAY WAS CLICKING VIGOROUSLY THEN STOPPED, NO POWER INSIDE MY VEHICLE. I STARTED THE TRUCK AND EVERYTHING WORKED EXCEPT FOR THE RADIO. I WENT FOR A DRIVE THAN AND THEN THE REVERSE LIGHTS CAME ON THE DOOR BUZZER WAS GOING OFF, AS I WENT TO STOP I HEARD A GRINDING NOISE OCCUR THAN STOPPED. WAS ABLE TO GET IT HOME. I HAVE 30 YEARS OF MECHANIC EXPERIENCE AND TRIED TO FIND A POSSIBLE SHORT. WHEN I REMOVED THE PASSENGER SIDE ROCKER PANEL I FOUND THE HARNESS COVERED IN RUSTY WATER. NOW DOING RESEARCH ON THE INTERNET, I HAVE SEEN HUNDREDS OF PEOPLE COMPLAINING ABOUT THIS ISSUE, THAT FORD WONT COVER. IT TURNS OUT MANY PEOPLE HAD TO HAVE WIRING HARNESS REPLACED COSTING THOUSANDS. WHILE CONDUCTING MY RESEARCH I HAVE FOUND OUT WATER IS LEAKING THROUGH THE WINDSHIELD THE REAR WINDOW AND WIRING HARNESS THAT TRAVELS THROUGH THE FIREWALL. PLEASE HELP, FORD WILL NOT ADMIT TO THEIR MISTAKE. *TR

I AM THE OWNER OF A 2004 F-150. THIS IS MY FIFTH FORD PRODUCT ON A ROW, TWO OF THEM PURCHASED NEW. RECENTLY THE PASSENGER SIDE REAR WINDOW REGULATOR FAILED, CAUSING THE WINDOW TO SLIDE DOWN INTO THE DOOR. IN DECEMBER. I PURCHASED A REPLACEMENT REGULATOR/MOTOR ASSEMBLY AND JUST FINISHED THE INSTALLATION. WHEN I EXAMINED THE OLD UNIT I FOUND THE OPERATING CABLE INCORRECTLY SPOOLED ONTO THE PRIMARY PULLEY. WHEN THE CABLE OVERLAPPED ITSELF THE END PULLED OUT OF THE LIFTING BLOCK. WHEN I WAS SEARCHING FOR INFORMATION ABOUT THE REPLACEMENT PROCEDURE, I CAME ACROSS NUMEROUS WEBSITES DETAILING COMPLAINTS ABOUT THE FAILURE OF F150 WINDOW REGULATORS. THIS LEADS ME TO BELIEVE THAT THE PROBLEM IS DUE TO A FAULTY DESIGN AND SHOULD BE ADDRESSED BY FORD WITH A REDESIGNED PART AND A RECALL TO REPLACE EXISTING UNITS. I WILL BE CONTACTING MY CONGRESSMAN, ABOUT THIS EXPENSIVE AND ANNOYING DEFECT.WEBSITES DETAILING THE ISSUE ARE LISTED BELOW: HTTP://WWW.JEREBEASLEYREPORT.COM/2011/08/PROBLEMS-WITH-FORD-F-150-WINDOW-REGULATORS/ HTTP://WWW.CARCOMPLAINTS.COM/FORD/F-150/2005/WINDOWS_WINDSHIELD/POWER_WINDOW_REGULATOR_FAILURE.SHTML INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6) *TT

Mileage: 63,000

I WAS TRAVELING ON A MAIN BOULEVARD WHEN ALL OF A SUDDEN THE DRIVERS SIDE WINDOW SLID DOWN WITH A LOUD SOUNDING BANG. THE WINDOW DID NOT BREAK. HOWEVER, WHAT SEEMS TO BE A SPRING LOADED MECHANISM, MUST HAVE BROKEN CAUSING THE WINDOW TO COLLAPSE DOWN INSIDE THE DOOR. THE SOUND WAS SO LOUD, IT CAUSED A NERVOUS REACTION IN ME WHICH RESULTED IN PULLING ON THE STEERING WHEEL TO ONE SIDE. THANKFULLY, THERE WERE NO VEHICLES TO THAT SIDE AND I WAS ABLE TO CORRECT MY STEERING TO GET BACK INTO MY LANE. AS IF ONE EXPERIENCE WAS NOT SUFFICIENT, IT HAPPENED AGAIN 9/1/11. THIS TIME ON THE PASSENGER SIDE DOOR. THE SAME EXACT EXPERIENCE REPEATED EXCEPT THAT THIS TIME I WAS DRIVING AT 75MPH ON I-25. I EXPECTED TO FIND A RECALL TO THIS DIS-FUNCTIONAL MECHANISM. WHAT ARE THE CHANCES OF THIS HAPPENING ALMOST BACK TO BACK WITHIN A 6 WEEK PERIOD? *TR

Mileage: 70,000

WINDOW REGULATOR ON 2004 F 150 LARIAT DRIVERS DOOR BROKE ALLOWING THE WINDOW TO DROP SCARING ME SO BAD THAT I WENT OFF THE ROAD JUST MISSING CRASHING INTO SEVERAL TREES. IT SOUNDED LIKE SOMEONE HAD SHOT OUT MY WINDOW, WHILE I WAS DRIVING IN A THUNDER STORM. THE ROADS WERE WET, BUT THERE WAS KNOW WARNING WHEN THE WINDOWBROKE, THEN I WAS GETTING HIT IN THE FACE WITH RAIN IT FELT LIKE GLASS HITTING ME IN THE FACE. THIS SHOULD BE A RECALL BY FORD, I HAVE RESEARCH THIS PROBLEM AND HAVE FOUND IT TO BE MASSIVE IN NUMBERS WITH A BIG EXPENSE TO FORD CUSTOMERS. THIS MANY CASES SEEMS MORE THAN JUST A FLUKE INCIDENT. THIS SHOULD BE LOOKED INTO, I'M SO LUCKY TO BE HERE NOW I JUST MISSED THOSE TREES AND MY WIFE IS NOW SCARED THAT IT MAY HAPPEN TO ONE OF MY OTHER REMAINING WINDOWS AND DOES NOT WANT TO RIDE WITH ME ANYMORE.. *TR

Mileage: 136,500

2004 FORD F150 SUPERCREW STARTS SHAKING HORRIBLY AT HIGHWAY SPEEDS WHEN PULLING A TRAVEL TRAILER. IT DOESN'T MATTER IF YOU SLOW DOWN, SPEED UP, OR TAKE OUT OF GEAR THE ONLY WAY TO MAKE IT QUIT IS TO COME TO A COMPLETE STOP. THIS HAS HAPPENED 3 TIMES TO ME SO FAR AND IT FEELS AS IF ALL THE WHEELS ARE ABOUT TO FALL OFF. I CALLED MY DEALER AND THEY SAID THAT THEY HAVEN'T HEARD OF THIS PROBLEM, BUT IF YOU DO A SEARCH ON IT THERE IS A LOT OF PEOPLE CONCERNED OF THIS DANGEROUS ISSUE. LUCKILY I HAVEN'T BEEN ON AN INTERSTATE WITH MY TRAVEL TRAILER BECAUSE I WOULD BELIEVE THAT THIS COULD CAUSE ME TO POSSIBLY LOSE CONTROL AT THOSE KIND OF SPEEDS. *TR

Mileage: 44,000

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT THE VEHICLE FRAME WAS NOT PROPERLY ALIGNED WITH THE BODY OF THE VEHICLE. THE CONTACT DISCOVERED THE FAILURE WHEN HE NOTICED THAT THE REAR TIRES WERE PROTRUDING OUTWARD ABNORMALLY. THE VEHICLE WAS TAKEN TO THE DEALER WHO DID NOT DIAGNOSE THE FAILURE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE AND THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 83,000 AND CURRENT MILEAGE 99,000.

Mileage: 83,000

DOOR POWER WINDOW REGULATOR FAILS (BROKEN PLASTIC PIECE) AND DOOR WINDOW GLASS FALLS INTO THE DOOR. THIS USUALLY OCCURS WHILE DRIVING - SEE THOUSANDS OF INTERNET REPORTS. THIS IS A DANGEROUS DEFECT IN THE REGULATOR THAT FORD KNOWS ABOUT AND REFUSES TO RECALL. REPAIR PART AND LABOR COST APPROX $400 PER WINDOW. I HAVE HAD 2 WINDOW REGULATORS FAIL SO FAR! FORD SHOULD BE RESPONSIBLE FOR THIS. *TR

Mileage: 90,370

3RD POWER WINDOW REGULATOR FAILURE IN 1.5 YRS ON 2004 FORD F-150 SUPERCREW TRUCK. WHEN REGULATOR FAILS, IT SOUNDS AS THOUGH SOMEONE STRUCK OR SHOT THE WINDOW CAUSING ME TO JUMP AND TAKE MY EYES OFF THE ROAD TO SEE WHAT HAD HAPPENED AND IF ANY PASSENGERS WERE INJURED ALMOST CAUSING ME TO COLLIDE WITH AN ON-COMING VEHICLE. I HAVE HAD TWO OF THE REGULATORS REPLACED BY A LOCAL PAINT AND BODY SHOP WHERE I WAS TOLD THAT IT IS A KNOWN PROBLEM WITH THE REGULATORS. MY COST TO DATE HAS BEEN IN EXCESS OF $350 AND I NOW HAVE TWO SUCTION CUPS HOLDING ONE WINDOW UP UNTIL I CAN AFFORD TO HAVE IT REPAIRED. *TR

Mileage: 108,000

2004 FORD F150 WINDOW REGULATOR FAILURES...MULTIPLE TIMES..SEVERAL MONTHS APART. THE WINDOW COMES CRASHING DOWN AND IS TOTALLY OPEN. I HAVE DOGS THAT RIDE WITH ME. THIS HAS GOT TO BE FIXED BY FORD. *TR

Mileage: 66,020

WHILE DRIVING AT HIGHWAY SPEED THE REAR PASSENGER WINDOW DROPED, AT THAT TIME MY GRANDSON (3) TAUGHT IT WOULD BE OK TO THROW HIS SOCKER BALL OUT. THE BALL BOUNCED OF A CAR BEHIND ME BUT NO DAMAGE BUT SCARED THE DRIVER ALMOST CAUSING AN ACCIDENT. THIS IS A BIG PROBLEM, WINDOWS SHOULD NOT DROP LIKE THAT GOOD THING WEATHER WAS GOOD, I CAN ONLY IMAGINE IF IT HAD BEEN RAINING THE OTHER CAR WOULD HAVE NOT BEEN ABLE TO STOP CAUSING A MAJOR ACCIDENT AND I WOULD BE GETTING SEUD. THIS ISSUE NEEDS FIXING BY FORD BECAUSE IS NOT AN ISOLETED PROBLEM THOUSANDS ARE HAVING THE SAME PROBLEM. WINDOW NOT FIXED YET STILL RESEARCHING FOR PARTS. *TR

Mileage: 106,755

FRONT PASSENGER SIDE WINDOW SUDDENLY DROPPED FOR NO REASON. *TR

Mileage: 49,651

I PURCHASED A USED 2004 FORD XL F 150 4 X 4 WHCIH WAS MANUFACTURED IN THE U.S. BUT SOLD IN CANADA SER # [XXX]. THE TRUCK HAS A CONSTANT VIBRATION AT 50 MPH AND I HAVE SPENT $2,500 TRYING TO FIX IT WITH OUT SUCCESS. WHAT REALLY SCARED ME WAS THAT ON ONE OCCASSION THE VIBRATION INSTANTLY BECAME SO SEVERE, THAT I ALMOST LOST CONTROL OF THE TRUCK AND HAD TO PULL OFF THE ROAD.. ARE THERE OTHER COMPLAINTS WITH THIS SAME PROBLEM? ARE YOU AWARE OF WHAT CAUSES THIS PROBLEM? MY INVESTIGATION LEADS ME TO BE CONVINCED THAT IT IA AN INHERENT FORD MANUFACTURING DEFECT. ANYTHING THAT YOU HAVE THAT WOULD SUPPORT MY BELIEF WOULD BE OF GREAT ASSISTANCE, OR ANY INFO AT ALL WOULD HELP. I HAVE SUED FORD AND THE TRIAL IS JUNE 12 A FEW WEEKS FROM NOW SO IF YOU HAVE ANYTHING PLEASE FORWARD IT ASAP [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

Mileage: 90,000

I WAS HAVING A RATTLING NOISE UNDER MY TRUCK FOR THE PAST SEVERAL MONTHS. MY NEIGHBOR WHO USED TO WORK FOR FORD THINKS ITS THE CABLES FOR THE SPARE TIRE UNDER MY TRUCK. HE BELIEVES THE SPARE TIRE CABLES ARE LOOSE AND NEED TO BE TIGHTENED. I LOOKED IN THE OWNERS MANUAL TO FIGURE OUT HOW TO GET THE SPARE TIRE OUT. I HAVE TO USE MY IGNITION KEY TO OPEN THE LOCK TO GET TO THE TIRE. MY KEY ONLY FITS HALF WAY IN AND WONT OPEN THE LOCK. I USED WD40 TO MAYBE GET IT LOOSE. TRIED AGAIN AND NOTHING. I RESEARCHED ONLINE AND MANY PEOPLE HAVE THE SAME PROBLEM. I CALLED THE DEALER AND THEY WONT FIX IT FOR FREE SINCE ITS NOT UNDER WARRANTY. WHAT HAPPENS IF I GET A FLAT TIRE? I WONT BE ABLE TO GET TO MY SPARE. THIS ALSO HAPPENED ON MY OTHER FORD TRUCK. *TR

Mileage: 50,000

THERE ARE FACTORY MADE SQUARE HOLES UNDER THE SIDES OF THE TRUCK. WHEN IT RAINS, THE WHEELS SPLASH WATER INTO THESE HOLES. THE WATER COMES UP INTO THE FLOOR OF THE TRUCK. INSIDE THE TRUCK THERE IS A PLASTIC PANEL ALONG THE EDGES OF THE DOOR THAT POPS OUT. IT IS THE SQUARE HOLES THAT IT POPS OUT OF THAT THE WATER COMES IN THROUGH. I CAN STICK MY FINGER FROM THE UNDER OUTSIDE IF THE TRUCK AND SEE THEM THRU THE HOLES THAT HOLD THE PLASTIC PANELING ON THE INSIDE. THE WATER COLLECTS ALONG WHERE ALL THE ELECTRICAL WIRES ARE RUNNING AND SOAKS UP INTO THE CARPET. *TR

2004 FORD F-150 SUPERCREW WINDOW REGULATOR FAILURE. DRIVING SAFETY HAZARD, DISTRACTIONS DURING DRIVING AT HIGHWAY SPEEDS. COULD LEAD TO POSSIBLE SEVERE INJURY OR DEATHS. SECOND TIME IN 10,000 MILES. POOR DESIGN AND FLIMSY PARTS USED BY FORD. EXPENSIVE REPAIR. *TR

Mileage: 80,000

I OWN A FORD F150 V8 5.4 TRITAN ABOUT A MONTH AGO MY PASSENGERS SIDE WINDOW FELL DOWN IN THE DOOR WHILE I WAS DRIVING DOWN THE ROAD. IT SCARED ME AND CAUSED ME TO SWERVE WHILE DRIVING. THIS IS DEFINITELY AN ISSUE. ABOUT A WEEK AGO MY DRIVERS SIDE E WINDOW DID THE SAME THING WHILE DRIVING ON A TWO LANE WINDING ROAD. IT CRASHED DOWN INTO THE DOOR SCARING ME AND ALMOST CAUSING AN ACCIDENT. AFTER DOING SOME RESEARCH I REALIZED THAT THIS IS PROBLEM MANY OTHER FORD OWNERS ARE HAVING AND NOT JUST A FLUKE. SOMETHING NEEDS TO BE DONE ABOUT THIS BEFORE IT CAUSES AN ACCIDENT RESULTING IN SOMEONE'S DEATH. *TR

Mileage: 70,000

SECOND WINDOW DRIVE FAILURE IN 6 WEEKS. VERY LOUD BANG FROM DOOR (SOUNDS LIKE TRUCK IS HIT BY LARGE ROCK/HARD OBJECT) WHICH IS VERY STARTLING, THEN WINDOW GLASS SLIDES DOWN INTO DOOR. ON THE FREEWAY THIS IS EXTREMELY DISTRACTING AND DANGEROUS. THE FIRST WINDOW FAILURE (ONE MONTH AGO) COST ME $430.00 AT FORD DEALER TO REPAIR. I WAS NEVER INFORMED THAT THIS WAS A FREQUENT PROBLEM. AFTER SECOND FAILURE IN 4 WEEKS, I WENT ON THE WEB AND DISCOVERED THAT THIS IS HAPPENING TO THOUSANDS OF 2004-2005 F-150'S, AND FORD REFUSES TO ADDRESS IT! I'M WAITING TO TALK TO DEALERS SERVICE MANAGER ABOUT SECOND FAILURE TO TRY AND GET FORD TO PAY FOR THE REPAIRS, AS WELL AS INSPECT THE OTHER WINDOWS AND REPAIR THEM AS NECESSARY. IT'S ONLY A MATTER OF TIME BEFORE THEY FAIL AS WELL. - THIS IS A WELL-KNOWN DESIGN DEFECT!!! FORD HAS ALREADY CHANGED THE DESIGN/PART # FOR THE FAULTY PART (REGULATOR/CABLE ASSY) THREE TIMES- AND IT STILL FAILS WITHOUT WARNING! THESE TRUCKS SHOULD BE RECALLED AND FIXED AT FORD'S EXPENSE!!!! *TR

Mileage: 46,375

THE PAINT ON MY 2004 FORD F150 IS BUBBLING AND RUSTING ON THE REAR QUARTER PANEL AND FORD REFUSES TO FIX IT DESPITE THE FACT THAT ITS A KNOWN ISSUE. *TR

Mileage: 60,000

I WAS DRIVING DOWN I-35 IN THE RAIN WHEN A LOUD BANG STARTLED ME. I NOTICED RIGHT AWAY THAT MY 2 YEAR OLD GIRL WAS CRYING AND HER WINDOW WAS DOWN WITH RAIN POURING IN. I HAD TO PULL OVER IN TRAFFIC ON THE INTERSTATE IN THE RAIN TO TRY AND FIX THE PROBLEM. THE BANG HAD SCARED HER AND SHE WAS GETTING WET. WE MOVED THE CARSEAT OVER TO THE OTHER SIDE AND I WAS ABLE TO PULL THE WINDOW UP. MY WIFE HAD TO HOLD IT UP WITH HER HAND ALL THE WAY HOME. FROM THE SOUND OF THAT BANG I AM SUPRISED THE WINDOW DIDN'T SHATTER. IF IT WOULD HAVE MY LITTLE GIRL COULD HAVE LOST AN EYE OR BEEN CUT BADLY. I WAS ABLE TO LOOK AT IT TODAY AND IT SEEMS THAT THE LITTLE CABLE THAT PULLS THE WINDOW UP HAS BROKEN LOOSE FROM THE PLASTIC PULLEY IT WINDS UP ON. I HAVE DONE A BIT OF RESEARCH TONIGHT AND THIS IS A VERY COMMON PROBLEM. FORD KNOWS ABOUT THE PROBLEM SINCE THEY TEND TO KEEP PLENTY OF THESE WINDOW REGULATORS IN STOCK. MANY OF THE PEOPLE ON THESE WEBSITES HAVE HAD MULTIPLE FAILURES. ONE HAD REPLACED ALL FOUR WINDOW REGULATORS ON HIS F-150. THE PROBLEMS STARTED WHEN THEY CHANGED FROM A SOLID METAL SCISSORS TYPE TO THIS MOUSE TRAP LOOKING THING WITH PLASTIC PULLEYS. THE ENGINEER THAT DESIGNED THIS THING SHOULD HAVE HIS P.E. LICENSE REVOKED. IT IS A TERRIBLE PIECE OF ENGINEERING. FORD SHOULD FIX THIS PROBLEM AND DO A RECALL ON THIS PROBLEM BEFORE ONE OF THESE WINDOWS SHATTERS AT HIGHWAY SPEED AND THROWS GLASS INTO THE FACE OF A SMALL CHILD. *TR

Mileage: 96,000

OWN A FORD F-150 YEAR 2004 AND A WINDOW IN ONE OF THE DOORS HAS FALLEN. THIS TIME IT WAS THE BACK PASSENGER WINDOW THAT SCARED MY WIFE WHILE DRIVING WHEN IT FELL TO THE BOTTOM OF THE INSIDE DOOR. I HAVE ALREADY HAD EVERY WINDOW REPLACED ONCE AND THE DRIVER WINDOW TWICE, AND THIS WILL BE TWICE FOR THIS DOOR, IN TOTAL IT HAS BEEN 6 TIMES WINDOWS HAVE FELL. THIS REQUIRES A RECALL. WHEN DRIVING THIS CAN BE A SAFETY HAZARD WHEN YOU THINK SOMEONE HAS SHOT YOUR WINDOW OR SOMETHING HAS CRASHED BEHIND YOU AND IT HAPPENS THAT YOUR WINDOW HAS FELL DOWN MAKING LIKE A CRASHING SOUND. IT CAN BE VERY FRIGHTENING WHILE DRIVING AND COULD CAUSE A SAFETY PROBLEM. AND BEING THE 6TH TIME, NEEDS REDESIGNED PROPERLY. *TR

Mileage: 51,500

A RUST AND PANEL PERFORATION ON THE RIGHT BOX OUTER OF 2004 FORD F-150'S. RUST DEVELOPS UNDER THE PAINT ON THE RIGHT BOX OUTER PANEL BEHIND THE RIGHT REAR WHEEL OPENING AND ABOUT AT THE CENTER FOR HEIGHT OF THE PANEL. THIS HAS HAPPENED ON SEVERAL TRUCKS OF FRIENDS AS WELL AS MY TRUCK. THE DEALERS ARE SAYING IT IS BECAUSE THERE IS A BRACE WELDED TO THE PANEL DURING PRODUCTION AND THE WELD ID THE ROOT OF THE RUST. FORD IS SAYING THAT THEY HAVE NO RESPONSIBILITY AND WON'T HELP TO COVER THE COST OF REPAIR. AS A RETIRED ENGINEER FROM ANOTHER MANUFACTURER AND ALSO HAVING WORKED FOR THE OTHER OF THE BIG THREE, I KNOW THAT WELDING DESTROYS THE RUST PREVENTABLE ON THE SHEET METAL. THE WELD PROCESS FLOWS GALVANIZE AWAY FROM THE WELD AREA AND THEN HELPS TO PRECIPITATE THE RUST TO FORM. THE TRUCKS HAVE ALL HAD NO PAINT DAMAGE OR ACCIDENTS IN THE AREA OF THE RUST FORMING. BUBBLES APPEAR UNDER WHAT LOOKS LIKE GOOD SOLID PAINT AND THEN BREAKS THROUGH AND SHOWS RUSTED METAL. WITH THE NUMBER OF TRUCKS HAVING THE SAME ISSUE IT LOOKS TO BE A SYSTEMIC ISSUE FROM THE MANUFACTURING PROCESS. THE OTHER TWO DOMESTIC MANUFACTURERS WILL NOT WELD ON WHAT IS KNOWN AS A CLASS A OUTER PANEL SURFACE. A CUSTOMER?S LINE OF SIGHT WALKING UP TO A VEHICLE IS CONSIDERED TO BE CLASS A SURFACE. THERE SHOULD NOT ANY BE WELDS ON IT AND LITTLE OR NO METAL FINISH. THAT, METAL FINISHING, ALSO WOULD REMOVE THE RUST PROTECTING GALVANIZE. ANOTHER CONCERN IS THAT SOME STATES HAVE ANNUAL INSPECTIONS THAT WOULD CAUSE THIS TO HAVE TO BE REPAIRED. THE OWNER WOULD BE STUCK WITH THIS COST THROUGH NO FAULT OF HIS OR HER OWN. *TR

NOTED THAT DRIVERS DOOR DID NOT LINE UP CORRECTLY AS BEFORE. BODY SHOP NOTED THAT DOOR HAD EVIDENCE OF A WELD FAILING IN AREA WHERE THE HINGES INSERT INTO THE DOOR. THAT WAS 2/27/06 AND TRUCK HAD APPROX. 62,000 MILES ON IT. THEN THIS SPRING (2008) I BEGAN TO NOTICE THAT THE DOOR BEGAN TO FIT EVEN WORSE THAN BEFORE AND PUT MY CAMERA BETWEEN DOOR AND DOOR POST TO TAKE PHOTOS AS MY HEAD WOULD NOT FIT IN THAT AREA TO GET A GOOD VIEW. PHOTOS SHOWED NUMEROUS CRACKS HAD DEVELOPED IN AREA OF HINGE INSERTIONS ON THE DOOR AND THE ENTIRE DOOR END HAD WARPED OUT OF SHAPE IN AREA OF HINGE ATTACHMENTS. NOW TRUCK HAS 113,000 MILES AND WHEN MY DEALER SPOKE TO CORPORATE FORD, THEY WERE TOLD THAT THE WARRANTY FOR BODY DEFECTS HAD EXPIRED AT 36,000 MILES. I SPOKE TO CUSTOMER ASSISTANCE AND WAS TOLD THEY WOULD DO NOTHING AS THERE WAS NO RECALL ISSUED. THAT WAS SOMETIME IN MAY 2008. MY CONTENTION IS THAT THIS IS A SAFETY ISSUE NOT A BODY DEFECT AND PUTS ME IN DANGER SHOULD THERE BE A CRASH. THIS DOOR WILL NOT PROTECT ME IN A SIDE IMPACT AS IT IS NOT PROPERLY ATTACHED TO THE VEHICLE. *TR

Mileage: 62,000

I PURCHASED A 2004 FORD F150 SUPERCREW FX4 IN DECEMBER OF 2007. SINCE OWNING THE VEHICLE I HAVE FOUND THAT THE HOOD SHAKES VIOLENTLY ON THE FREEWAY AT SPEEDS OF OVER 50 MPH, OFTEN SCARING EACH INDIVIDUAL IN THE TRUCK. I HAVE NOTICED A LOUD IRRITATING NOISE COMING FROM THE WINDSHIELD AREA, UNABLE TO PIN POINT EXACTLY WHAT IS CAUSING IT., ALSO CAUSING ME TO BE A LITTLE NERVOUS THAT ONE DAY IT WILL COME FLYING IN AT ME. THESE ARE THE TWO MAJOR PROBLEMS WITH THE VEHICLE, THE MINOR ISSUE IS THE 12V OUTLET NOT WORKING AT ALL. I HAVE TAKEN THE VEHICLE BACK TO THE DEALERSHIP SEVERAL TIMES IN AN ATTEMPT TO HAVE THESE ISSUES LOOKED INTO. MY LAST VISIT TO THE DEALERSHIP RESULTED IN THEM KEEPING THE TRUCK AND SUPPLYING US WITH A RENTAL WHILE THEY LOOKED INTO THE ISSUES AND RESOLVED THEM. SINCE HAVING THE TRUCK BACK THE WINDSHIELD OR WHATEVER IS CAUSING THE IRRITATING NOISE HAS ONLY GOTTEN LOUDER, THERE IS NO DIFFERENCE CONCERNING THE HOODS VIOLENT SHAKING, AND THE 12V OUTLET STILL DOES NOT WORK. I'VE COME TO THE CONCLUSION THAT GOING TO THE DEALERSHIP IS A WASTE OF TIME AND ENERGY ONLY CAUSING MORE STRESS TO MY LIFE WITH HIGHER INSECURITIES CONCERNING MY TRUCK. I REALLY WOULD LIKE TO FIND AS MUCH INFORMATION CONCERNING THE HOOD AND WINDSHIELD ISSUES SO I CAN ENSURE MY SAFETY AND THOSE OF WHOM ARE RIDING WITH ME. THIS TRUCK IS A NICE TRUCK, MY DREAM TRUCK, AND ALL I WANT IS TO MAKE SURE THAT I'M SAFE WHILE I'M DRIVING IT. *TR

FINGER CRUSHED UNDER DRIVERS DOOR HANDLE. THE LEVER THAT OPENS THE REAR DOOR OF THE 2004 - F150 WHILE TRYING TO OPEN IT FROM THE INSIDE PASSENGER SEAT. SURGERY NEEDED TO PLACE TIP OF FINGER BONE BACK INTO PLACE. *TR

I WAS DRIVING A 2004 FORD 150 PICKUP SOUTH ON INTERSTATE 29 NEAR GLENWOOD IOWA WHEN THE STEERING WHEEL BEGAN TO VIBRATE. I TRIED TO PULL TO THE RIGHT TO SEE WHAT WAS CAUSING IT WHEN THE RIGHT FRONT TIRE SEEMED TO EXPLODE. I WAS ABLE TO PULL OFF THE HIGHWAY TO THE RIGHT WITHOUT LOSING CONTROL OF THE TRUCK AND GOT OUT TO SEE WHAT HAD HAPPENED. I FOUND THE RIGHT FRONT PASSENGER TIRE STILL INFLATED BUT WITHOUT ANY TREAD ON THE TIRE. I ALSO FOUND HALF THE RUNNING BOARD WAS MISSING, AND A SMALL DENT IN THE DOOR JUST ABOVE WHERE THE RUNNING BOARD USED TO BE. I CALLED A TOW TRUCK AND HAD THE VEHICLE TOWED TO TINCHER FORD IN GLENWOOD IOWA AND HAD THE TIRE REPLACED. THIS COST WA S$157.00. I STILL DID NOT KNOW WHAT IT WAS GOING TO COST TO REPLACE THE RUNNING BOARD. THE MECHANIC MENTIONED HE HAD NEVER SEEN THE TREAD ON A TIRE SEPARATE THE WAY THIS ONE DID. I KEPT THE OLD TIRE AND REPLACED IT WITH THE EXACT SAME BRAND, A GENERAL AMERITRAC TR P255/70 R17. I AM NERVOUS ABOUT DRIVING ON THESE TIRES NOW WITH THE FEAR OF THIS REOCCURING. I JUST HEARD THERE HAS BEEN A SERIES OF ACCIDENTS AND EVEN DEATHS CAUSED BY THIS TIRE. I WOULD ALSO LIKE TO RECOVER THE COST OF THE REPAIRS TO MY PICKUP AND TIRES.*AK

Mileage: 55,000

NOTICING WATER LEAK FROM EITHER THE 3RD BRAKE LIGHT OR THE TOP OF THE REAR WINDOW INTO THE CAB OF THE TRUCK. REAR WINDOW IS NOT THE STYLE THAT OPENS. *JB

DT*: THE CONTACT STATED THAT THE SPEEDOMETER AND GAUGES FROM THE DASHBOARD PANEL ARE UNREADABLE DURING THE DAY. THE DASHBOARD BACKGROUND IS BLACK WITH RED NEEDLES AND NUMBERS. THE DEALER DETERMINED THAT THE PANEL COULD NOT BE CHANGED.*AK THE CONSUMER STATED HE MUST USE A FLASH LIGHT TO SEE HOW FAST HE IS GOING, OR TO READ ANY OTHER GAUGES. UPDATED 07/25/06. *JB

Mileage: 75

2004 F150 RIGHT FOG LIGHT REPLACED, FRONT KICK PANEL CRACKED AND LOOSE. *TS ***NAR*** THE FLOOR TRIM ON THE PASSENGER SIDE CAME APART. THE VEHICLE WOULD NOT START. THE CHECK ENGINE LIGHT ILLUMINATED. THE OIL PRESSURE READ ZERO. THE TEMPERATURE GAUGE FAILED. *NM

DEAR SIR/MADAM I OWN A 2004 F150 SUPER CAB PICKUP TRUCK WITH 4 DOORS, I AM HAVING A PROBLEM WITH THE DOOR AJAR LIGHT. WHEN THE REAR DOOR IS AJAR THE FRONT DOOR WILL LATCH TO THE REAR DOOR, WHICH SATISFIES THE DOOR AJAR SAFETY LIGHT, BUT THE FRONT AND REAR DOOR ARE NOT SAFELY LATCHED. I AM A LARGE MAN SO MY SEAT IS AS FAR BACK AS IT COULD GO AND THE BACK IS SLIGHTLY RECLINED, WHEN I GET IN AND OUT OF THE VEHICLE MY SHOULDER HITS THE REAR DOOR HANDLE THAT PROTRUDES INTO THE DRIVERS SEAT AND AT TIMES WILL SLIGHTLY OPEN THE DOOR. I WON'T REALIZE THAT I AM DRIVING WITH THE DOOR UNSAFELY LATCHED AND HAVE NO IDEA THAT THE DOOR IS AJAR UNTIL I HIT A BUMP LARGE ENOUGH TO RATTLE THE DOOR. MY QUESTION IS, IS IT SAFE TO DRIVE THE VEHICLE WITH THE FRONT AND REAR DOORS AJAR AND IN AN AHEAD ON COLLISION WILL THIS AREA BE COMPROMISED, THUS WOULD THE CRUMPLE ZONE BE AFFECTED DRASTICALLY AND WOULD THE STABILITY OF THE VEHICLE BE COMPROMISED? ALSO IS IT SAFE IN A SIDE COLLISION? I FEEL THAT THIS IS A MAJOR SAFETY CONCERN AND SHOULD BE ADDRESSED IMMEDIATELY. I TOOK THE TRUCK IN FOR SERVICE AT FULLERTON FORD IN SOMERVILLE NJ THE SAID THAT FORD SAID THAT THIS IS NORMAL AND I CALLED FORD COMPANY THEY SAID THIS IS NORMAL AND THAT I HAD NO RECOURSE WITH THEM. IF I WOULD HAVE KNOWN THAT THIS WAS INHERENT TO THE F150 SUPER CAB I WOULD NOT HAVE PURCHASED THIS MODEL, I WAS TOLD THE F150 CREW CAB HAS THIS SAFETY DEVICE INSTALLED THUS THE SAFETY PROBLEM WAS ADDRESSED IN THIS MODEL BUT NOT THE SUPER CAB. WAS THIS SAFETY CONCERN OVERLOOKED OR KNOWINGLY OMITTED FROM THE DESIGN? *JB

REAR WINDOW SEAL IS LOOSE AND WINDOW RATTLES INSIDE OF MOUNTING AREA INDICATING AN INSUFFICIENT MOUNT TO RETAIN WINDOW IN MOUNTING AREA. *NM

Mileage: 2,500

POOR PAINT FROM FACTORY, RUNS IN CLEAR COAT. THEY ONLY WANTED TO REPAINT IT AND THE SHOP THEY WANTD TO USE WAS NOT EVEN A FORD SHOP. 2004 F-150. JOPLIN FORD LINCOLN MERCURY WAS THE DEALER.

2004 FORD F150 PROBLEMS WITH UPPER BALL JOINT ASSEMBLY AS WELL AS TIRE WEAR.*MR THE UPPER JOINT WAS THE CAUSE OF THE TIRE WEAR ON ONE TIRE. THE CONSUMER STATED SINCE HE PURCHASED THE VEHICLE IT EXHIBITED A RATTLE NOISE, THE SIDE VIEW MIRROR HAD TO BE REPLACED BECAUSE IT WAS VIBRATING SO BADLY, THE HOOD HAD TO BE REINFORCED SO IT WOULD NOT FLUTTER AT HIGHWAY SPEEDS. THE VEHICLE NEEDED A NEW TRANSMISSION. *JB

Mileage: 12,700

MY TRUCK HAS A PROBLEM WITH THE BED JUMPING UP AND DOWN AS IT GOES DOWN THE ROAD. THIS IS VERY DANGEROUS WHEN YOU GOING AROUND A CORNER. I HAVE BROUGHT THIS PROBLEM UP TO THE DEALER SEVERAL TIMES, AND THEY TOLD ME THAT THE WAS THE WAY THE VEHICLE WAS SUPPOSE TO PERFORM. NO, IT WAS NOT RIGHT FOR A VEHICLE TO PERFORM THIS WAY. *AK

HAD HORRIBLE VIBRATION AT HIGHWAY SPEEDS,AFTER 6 OR SO VISITS THEY REPLACED THE DRIVESHAFT. NOW AT IDLE WARM OR COLD I HAVE A CONSTANT SHUTTER,AND NOW A STEERING WHEEL NIBBLE HAS DEVELOPED. COMPLETELY DISSAPPOINTED IN THIS TRUCK.THIS WAS MY FIRST NEW VEHICLE,A SHAME IT TURNED OUT LIKE THIS!*AK

Mileage: 1,000

HOOD APPEARS TO BE LOOSE ENOUGH TO FLY OFF VEHICLE AT HIGHWAY SPEEDS. WEAK HINGES. STEERING WHEEL VIBRATION/NIBBLE AT ANY SPEED. *JB

Mileage: 25

I BOUGHT MY FORD F150 4X4 FLARESIDE 2004 LAST NOVEMBER 30,2004. DROVE IT HOME,NOTICE A STRONG VIBRATION IN THE STEERING WHEEL AND SHAKING OF THE WHOLE TRUCK AT SPEED BETWEEN 35-65 MILES. I TOLD THE SERVICE MANAGER ABOUT THE PROBLEM WHO TOLD ME THAT THEY CANNOT DO ANYTHING ABOUT IT UNTIL THEY HEAR ANYTHING FROM FORD HEADQUARTERS. AT 1800 MILES, MY TRUCK SHAKES SO BAD THAT I FELT LIKE SOMETHING MASSAGING MY CALF MUSCLES AND MY BACK, WORSE AT SPEED OF 55-65 MPH. I HAVE TO EITHER SLOW DOWN OR SPEED UP TO 70-75 MPH TO REMEDIED THE SHAKING. I HAVE CALLED FORD CUSTOMER SERVICE 3X AND ALSO BEEN TO THE DEALERSHIP FOR TIRE ROTATION AND BALANCE, THEN ROAD FORCE TIRE BALANCE AND THEN INSTALLATION OF A DAMPNER. IT DID NOT WORKED! I CALLED THE DEALERSHIP AGAIN 1/11/05. THEY CANNOT GAVE ME A GOOD WAY TO FIX THE SAID PROBLEM. THIS IS CAUSING A LOT OF DISCOMFORT ON MY DAILY HOUR DRIVE TO WORK AND ANXIETY OF HOW SAFE AM I ON CONTINUING TO DRIVE THIS BUILD TOUGH VEHICLE AS ADVERTISED. I AM PLANNING TO FILE A LEMON TO GET MY MONEY BACK. DISPUTE SETTLEMENT BOARD IS OUT OF THE OPTION. *JB

Mileage: 1,800

I CURRENTLY OWN A 2004 F150 FX4 SUPERCREW. THE TRUCK HAS A BAD VIBRATION BETWEEN (60-65 MPH) WHICH IN TURN CAUSES THE BED TO SHAKE. THE DEALERSHIP BALANCED THE TIRES AND REPLACED THE DRIVESHAFT, AND NOW THEY ARE ORDERING A COUNTER BALANCE WHICH WILL BE INSTALLED UNDER THE RIGHT REAR OF THE TRUCK. THE DEALER IS ALSO LOOKING INTO THE POSSIBILITY OF A PROBLEM WITH THE GOODYEAR WRANGLER TIRES WHICH HAVE 1 PLY OF NYLON IN THE TREAD--THE TIRES SEEM TO BE REAL BAD IN COLD WEATHER. I VOICED MY CONCERNS ABOUT THE BED SHAKING AND HOW YOU CAN TAKE YOUR FIST AND HIT THE REAR BUMPER OF THE TRUCK AND THE BED WILL SHAKE REPEATEDLY. ACCORDING TO A FORD TECHNICIAN--"THIS IS A CHARACTERISTIC OF THIS TRUCK". THIS "CHARACTERISTIC" MAKES THIS VEHICLE UNSTABLE ON ROUGH ROADS. PERSONALLY I BELIEVE FORD SHOULD SAVE ITS NAME AND CORRECT THE PROBLEM. I AM STILL WORKING WITH MY DEALER, BUT THINGS ARE NOT LOOKING GOOD. *JB

Mileage: 15

PURCHASED 04 FORD F150 FX4 4X4 12/18/04. SINCE PURCHASE, ALONG WITH TWO OTHER NEW TEST DRIVEN EQUIVALENTS, NOTICED EXCESSIVE WIND NOISE AT 40 MPH. BEST WAY TO DESCRIBE THIS IS IT SOUNDS SIMILAR TO THE HEAT/COOL FAN AT HIGH (E.G. SETTING 4) SPEED. IT IS LOUD AND VERY IRRETATING. FOR THE PROBLEM TO BE RESOLVED, IT WOULD BE THE SAME AS WHEN YOU TURN OFF THE HEAT/COOL FAN AT HIGH. NOTE: THE HEAT/COOL ANALOGY IS FOR COMPARISON PURPOSES ONLY, IT HAS NOTHING TO DO WITH IT. NUMEROUS OTHER 'COMPLAINTS' HAVE BEEN LOGGED ON FORD TRUCK ENTHUSIASTS WEB SITE SO I AM NOT ALONE. IT DOESN'T SOUND LIKE ENGINE NOISE, MORE LIKE WIND/AIR ENTERING THE ENGINE AND MAKING IT'S WAY INTO THE CAB SOMEWHERE IN THE FRONT/BOTTOM OF THE DASH IS MY BEST GUESS. IT DOESN'T APPEAR TO BE A LEAK IN THE WINDSHIELD ANYWHERE, BUT THEN AGAIN, BASED ON ONE PERSON ON THE FORD TRUCK ENTHUSIASTS THREAD HAD THE PROBLEM FIXED AT A DEALER VIA A THIRD PARTY AUTO GLASS PERSON SEALING UP THE TOP OF THE WINDOW. THE EXACT SOLUTION IS SKETCHY BUT IT'S THE ONLY RESOLUTION I'VE SEEN. IN FACT, THAT PERSON GAVE THE DEALER CONTACT INFORMATION IF ONE HAS QUESTIONS: LEN - THE SERVICE MANAGERAT AT WOODY SANDER FORD, CINCINNATI, OH (513)541-5586. I ABSOLUTE HATE WIND NOISE AND IT IS SIGNIFICANT AND THUS A SOLUTION TO THIS PROBLEM MUST BE MADE BY FORD! I'LL BE DOING MUCH MORE INVESTIGATION... AT THIS TIME, I FELT IT NECESSARY TO FILE A COMPLAINT SINCE ONE DOES NOT YET EXIST. I DECIDED TO PURCHASE THE VEHICLE NONE-THE-LESS FIGURING THE FIX CANNOT BE THAT DIFFICULT AND I LIKED THE TRUCK OUTSIDE OF THAT ONE PROBLEM.*AK

Mileage: 50

TAILGATE CABLES DO NOT SUPPORT EVENLY, ONE CABLE APPEARS LONGER THAN THE OTHER BUT IT IS NOT. *BF *TC

2004 FORD F150 2X4 REGULAR CAB FLAIRSIDE EVERE VIBRATION AT SPEEDS BETWEEN 45 AND 55 MPH. SEEMS TO BE IN REAR END OF VEHICLE. DEALERSHIP (MARSHAL MIZE FORD CHATTANOOGA, TN) STATES THEY CANNOT FIND PROBLEM BUT THERE IS A PROBLEM ACCORDING TO FORD ENGINEERING TSB 40303. SERVICE MANAGER STATED HE HEARD OF SOME VIBRATION ISSUES. FORD NEEDS A RECALL.*AK

Mileage: 200

WHILE DRIVING MY 2004 FORD F-150 CREW CAB WITH THE TAILGATE DOWN @ 10MPH I WENT OVER A SMALL SPEED BUMP. THE TAILGATE SEPERATED FROM THE TRUCK. WHEN I WENT TO FORD DEALER THEY SAID, "YEAH, IT SHOULDN'T COME OFF THAT EASY" BUT THEY REFUSE TO REPAIR THE VEHICLE. THE DEALER SAID TO HOLD ON BECAUSE HE FELT HE WOULD SEE ALOT OF THIS. THE GATE IS SPRING LOADED MAKING IT "BOUNCE" WHEN IT IS DOWN. *AK

Mileage: 7,500

THE BUMPER RUSTED FROM THE INSIDE. CONSUMER WAS CONCERNED THAT THIS COULD BE SERIOUS PROBLEM. TOOK VEHICLE TO THE DEALER, AND WAS TOLD THIS WAS A NORMAL THING, THE BUMPER RUSTING THROUGH FROM THE INSIDE.*AK

I HAVE OWNED MY 2004 F-150 SUPERCAB 4X4 LARIAT FOR APPROXIMATELY 5 WEEKS. THE VEHICLE HAD A VERY BAD SHAKE IN THE REAR END AT APPROXIMATELY 59 MILES AN HOUR. DEALER INSTALLED A "DAMPNER", WHICH WAS SUPPOSED TO CORRECT THE PROBLEM. INSTALLATION OF THE DAMPNER ONLY RELOCATED THE VIBRATION TO 54-55 MILES AN HOUR. AT TIMES, THE VIBRATION IS SO BAD, I MUST SLOW DOWN OR SPEED UP SO I CAN SEE OUT OF THE REAR VIEW MIRROR. THE DEALERSHIP AND THE FORD REGIONAL SERVICE TECHNICIAN HAVE TOLD ME THAT THE NEW MODEL OF F-150 HAS A MUCH STIFFER FRAME AND THAT IS THE CAUSE OF THE VIBRATION. THEY GO ON TO SAY THAT THIS RIDE VIBRATION IS NORMAL THROUGHOUT THE ENTIRE LINE OF THE F-150S. WHEN IT RAINS AND THE VEHICLE IS HOPPING UP AND DOWN IN THE REAR, I AM HONESTLY AFRAID THAT IF I HYDROPLANE THE LEAST AMOUNT, I WILL LOSE CONTROL OF THE TRUCK AND HAVE AN ACCIDENT. I HAVE ASKED REPEATEDLY FOR THIS PROBLEM TO BE RESOLVED, BUT THEY SAY THEY HAVE DONE ALL THEY CAN AND THAT THIS IS THE NORMAL RIDE OG THE VEHICLE. I JUST DON'T BELIEVE IT.*AK

Mileage: 70

THE EMISSION LIGHT CAME ON. THE VEHICLE WAS TAKEN TO THE DEALER, AND CONSUMER WAS TOLD THAT FUEL PUMP WAS DEFECTIVE. THE GAUGE WENT OUT OF CONTROL. AFTER FILLING THE TANK, THE GAUGE READ EMPTY. *AK THE BRAKE LIGHT WIRING WAS INOPERATIVE, ALIGNMENT WAS OUT, THE VEHICLE HAD STUCK IN PARK, THE RIGHT PASSENGER DOOR WAS INOPERATIVE, THE SPEEDOMETER READ WRONG, AND THE VEHICLE WOULD DIE OUT. *SC

Mileage: 5,000

TAILGATE STRAPS ARE THE SAME LENGTH, BUT WHEN YOU PUT PRESSURE ON THE TAILGATE, ONLY THE LH TAILGATE STRAP SUPPORTS THE TAILGATE. THE TRUCK HAS VIBRATION AND STEERING WHEEL NIBBLE PROBLEMS. THEY HAVE BALANCED THE TIRES 4 TIMES, REPLACED THE TIRES. THE FSE FROM FORD TOOK THE VEHICLE FOR A RIDE AND SAID IT NEEDS A NEW DRIVESHAFT. THE BRAKE DUST IS A BIG PROBLEM. YOU NEED TO WASH THE WHEELS DAILY. FORD NOW HAS UPDATED PADS. I HOPE THEY REPLACE THEM UNDER WARRANTY. TWO OF THE ROTORS ARE ALSO GROOVED. THE TRUCK HAS 3000 MILES ON IT. IT HAS BEEN IN 5+ TIMES NOW! THE AC UNIT ONLY HAD 22 OUNCES OF FLIUD IN IT. IT IS SUPPOSED TO HAVE 30+. MY AIR WAS VERIFIED TO BE 8-10 DEGREES WARMER THAN SPEC. THE GAS DOOR (SPRING) BROKE. THE PAINT ON THE HOOD IS FLAWED. IT DIDN'T GET FULLY SPRAYED ON THE RIGHT FRONT OF THE HOOD. BOTH SIDES OF THE REAR DIFF. ARE WET. SOMETHING IS LEAKING. THE SEATBELT STITCHING IS COMING APART.*AK

Mileage: 1

PURCHASED '04 F-150 IN OCTOBER OR '03. AT SPEEDS, THE VIBRATION WAS SO BAD THAT MY HANDS SHOOK ON THE WHEEL, AND I COULD SEE THE HOOD MOVING. TWO TRIPS TO THE DEALER TO CHANGE TIRES AND BALANCE, ETC. DID NOTHING, THEN A PARTICULAR MECHANIC GOT ON IT AND FOUND OUT ABOUT THE DAMPER FIX. HE INSTALLED IT AND THERE IS GREAT IMPROVEMENT. I AM AMAZED THAT THE TRUCK CONTINUES TO BE SOLD WITH NO EFFORT TO CORRECT THE VIBRATION PROBLEMS, PARTICULARLY WHEN THE ADVERTISING CONTINUES TO SAY THAT IT IS SUCH A REMARKABLE VEHICLE. I ALSO HAD A SIDEWALL BLOW OUT AND IT WAS TOUGH TO FIND REPLACEMENT GENERAL TIRE IN THE CORRECT SIZE. MY COMPLAINT ISN'T THE DEALER, ITS THE DESIGNERS. I'LL BE INTERESTED TO SEE IF CHANGES ARE MADE IN THE 2005.*AK

THE CONSUMER OWNS A NEW 2004 FORD F-150. THE CONSUMER NOTICED THAT THE ODOMETER, TRIPOMETER, OUTSIDE TEMPERATURE GAUGE AND COMPASS WERE MOVED TO A SMALL PANEL INSIDE THE SPEEDOMETER WINDOW. ON THE PREVIOUS MODEL THE GAUGES WERE VISIBLE. ON THIS MODEL THE GAUGES CAN ONLY BE SEEN AT NIGHT OR ON DARK DAYS. ON BRIGHT DAYS IT'S VERY DIFFICULT TO READ THE DISPLAYS. DEALERSHIP WAS NOTIFIED, BUT DID NOT RESOLVE THE PROBLEM. *AK *NM

TEST DROVE NEW F-150 SUPER-CREW-CAB 4X2, AT 60 MPH EXPERIENCED A TERRILBE SHIMMY IN STEERING WHEEL AND BAD VIBRATION FROM LEFT REAR OF TRUCK. RETURNED TRUCK TO LOT AND TEST DROVE NEW F-150 SUPER-CREW-CAB 4X4, EXPERIENCED THE SAME PROBLEM AT 30 MPH AND 60 MPH. BOUGHT 4X4, SALESMAN SAID THE TRUCK MOST LIKELY NEEDED WHEEL BALLANCING, OR IT WAS OUT OF ROUND. WE MADE AN APPOINTMENT FOR TWO DAYS LATER TO ADDRESS THE SHIMMY/VIBRATION PROBLEM.THE MECHANIC HAD THE TRUCK ON LIFT FOR TWENTY MINUTES. RESULT, DEALER HAS TO ORDER A PART FOR A SERVICE BULLETIN THAT REQUIRES A VIBRATION DAMPENING DEVICE TO BE INSTALLED. THIS IS INTERESTING, THER IS A WHOLE LOT OF NEW F-150 TRUCKS AT THIS DEALERSHIP. I DROVE TWO AND BOTH HAD SAME PROBLEM. THEY (FORD), HAVE A KNOWN SERVICE BULLETIN FOR THIS PROBLEM AND YET AS PLENTIFUL AS THIS PROBLEM IS ON THE LOT THEY HAVE TO ORDER THE PART, AGAIN FOR A KNOW PROBLEM DOCUMENTD BY THEIR BULLETIN THAT THIS PART IS REQUIRED AND THEY DON'T HAVE IT IN STOCK TO FIX MY TRUCK OR THE OTHER ONE I TEST DROVE ON THEIR LOT OR THE NEXT ONE AND SO-ON AND SO-ON.....AFTER READING ALL OF THESE COMPLAINTS THERE HAD BETTER BE A FIX FOR THIS OR I WILL SURELY DELIVER MY $40,000 WORTH OF INQUIRIES AND ADVERTISEMENTS. MOTOR TREND TRUCK OF THE YEAR...OR NOT!!! *AK

Mileage: 15

WHILE LOADING THE VEHICLE TAILGATE FELL OFF. *AK

Mileage: 7,491

THE CONSUMER STATED THE MANUFACTURER INSTALLED A THIN METAL COOLING COIL ON THE FRONT FRAME MEMBER, WHICH WAS 13 INCHES FROM THE GROUND. THIS COIL COULD BE DAMAGED IF THE TRUCK GOES THROW A PUDDLE,WHICH WOULD RESULT IN STEERING FAILURE. *JB

WHILE DRIVING WITH THE REAR WINDOW OPEN, THE VEHICLE VIBRATED. THE DRIVER TOOK THE VEHICLE TO THE DEALER FOR ANALYSIS. *PH EXTREME VIBRATION OF THE CAB WAS ENCOUNTERED UPON LEAVING EITHER OR BOTH REAR DOOR WINDOWS BELOW 30%WHILE DRIVING ABOVE 35 MPH. THE VIBRATION INCREASED WHEN THE SPEED INCREASED AND WAS MOST PREVALENT ABOVE 50 MPH. THE VIBRATION SEEMD TO BE CAUSED BY AIR PRESSURE ENTERING THE VEHICLE. *CB *JB

Mileage: 324