Which parts fail
Components named in complaints (doors, hood, frame, rust, paint and trim).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Ford F-150 owners, lightly cleaned up (personal details are redacted by NHTSA).
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.
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.
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. …
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. …
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. …
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. …
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. 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. …
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.
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.
Body complaints in other F-150 years
Frequently asked questions
How common are body problems on the 2004 Ford F-150?
NHTSA has 104 complaints about the body & structure of the 2004 Ford F-150, 5% of the model year's 2,029 complaints. The component named most often is body (58 mentions).
Is there a recall for 2004 Ford F-150 body problems?
No. NHTSA lists no body & structure recall for the 2004 Ford F-150, though it has 5 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Ford F-150 body problems start?
Half of the complaints with a recorded mileage happened before about 75,000 miles, and 24% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 0 fires and 3 injuries to body & structure problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.