Which parts fail
Components named in complaints (battery, alternator, wiring, ignition, instrument cluster, infotainment).
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 contact owns a 2004 Ford F-150. The contact stated that while driving at an undisclosed speed, the vehicle made an abnormal popping sound and then lost motive power. The contact was able to drive to the residence. The vehicle was taken to an independent mechanic, who determined that the spark plug had blown out of the cylinder and determined that the spark plug needed to be replaced. The manufacturer was made aware of the failure and advised the contact to file a complaint with the NHTSA Hotline. The failure mileage was approximately 364,000. The VIN was unavailable.
I get a warning message which indicates the the Crash Sensor is not working on my Ford truck - this component inflates the Air Bag in the event of a crash. The part number for the Crash Sensor is Motorcraft 6L3Z-14B004-AA. I attempted to purchase a replacement Crash Sensor from a local Ford dealer. I was told that Ford no longer makes this part. The parts manager suggested that I check with local aftermarket parts stores; Advance Auto Parts, AutoZone, Fisher and NAPA. Nobody makes an aftermarket Crash Sensor for my vehicle. I also searched Amazon without success. I am therefore driving a vehicle with Air Bags which will not deploy - possibly causing a fatality. It seems like the manufacturer, Ford, should be required to sell replacement Crash Sensors until they become available as an Aftermarket Product.
Electrical malfunction with fuses , problems with brake light, engine light and air bag light . Some fuses blown out after brake light fuse popped wipers don't work at all air bog turns on and off every day not sure why
Tl* the contact owned a 2004 Ford f-150. While the vehicle was parked in the driveway, a neighbor alerted the contact that the vehicle was on fire. There were no warning indicators illuminated prior to the fire. The fire department arrived and extinguished the fire. A fire report was filed. There were no injuries. The vehicle was totaled. The dealer and the manufacturer were not contacted. The failure mileage was approximately 150,000.
On my way home from the lake, my vehicle starting idling rough. Pulled over to check things out, couldn't find any noticable issues. Retarted vehicle and engine started smoking. I raised the hood and smoke was billowing out from the coil atop the number 2 spark plug, drivers side, looking from front to rear of engine. Had thevehicle towed to bill collins Ford of louisville,ky.they informed me that the spark plugs needed changing. Upon removal, 4 of the eight spark plugs broke off in the engine head. This cost me $857.00 to change 8 spark plugs that normally I could do myself. The breaking of spark plugs in this type engine, 5.4l triton, is a well known issue, that Ford motor company knew about. Yet they have yet to do a recall. Instead, they developed a tool to take these broken sprk plugs out, yet the consumer still has to pay sometimes upwards of $2,000.00 for the repair. …
I saw your report on the news about fords new fire problem. I have a 2004 f-150 xlt lariat p/u truck with 3000 miles on it , only 3 months old, catch fire on me as I was driving down the road.it was a severe electrical fire. Before it happened , the radio would stay on after I locked and left the vehicle.I have been with out my vehicle since 10/04 . Ford , and the dealer keeps giving me the run around. Ford leagal dept told me to call my insurance co!they are telling me they are sending a field engineer 2-08-05 to check it out. They have been very evasive and not co-operative at all , and I think they are comming in just to cover things up! The vehicle was involved in a minor accident on 10-04 ($3000) damage.and Ford is trying to make me believe its accident related and they wont cover it. But now I see the news , I can see clearley now ! …
My husband was driving home this past Sunday and was starting to turn into the drive when the left passenger window fell down into the door. He had not put it down or up - it just fell down. This is now the 4th window we have replaced in this truck. The other three have been replaced, to the tune of $350.00 each. When I brought this to the attention of the service manager at the local Ford dealership, he said there was nothing that he could do - the window regulators just break. I contacted the Ford 800 number and was told the same thing - nothing to be done - just a broken part - even though it happens a lot. He said there was no recall on it so there was no help they could give. So, I guess I'll be paying another $350.00 and pray they don't start dropping again since Ford won't admit they have a problem.
Refer to NHTSA campaign 11V107000. Ford recall number 11s18. Vehicle was manufactured at norfolk, va plant. My VIN was not included in the original or expanded recall; however, it is now exhibiting the same problem; airbag warning light flashes twice x five times, then remains on. Possible clockspring jumper wire chafing. Wear could cause electrical short and unexpected airbag inflation while driving. This first occurred about ten days ago, but then the vehicle sat in the driveway for eight days. Current mileage is 115544. Today I called Ford customer service and was informed there was no warranty action or active recall that would cover this investigation and repair. I believe the recall should be further expanded to cover this incident. It began with vehicles made at the norfolk va plant.
Tl* the contact owns a 2004 Ford f-150. The contact stated that the vehicle stalled and the accelerator pedal hesitated when depressed. As a result, the vehicle made an abnormal puttering sound while in drive. In addition, the electrical system failed. The spark plugs were changed multiple times. The vehicle was taken to an independent mechanic who stated that the spark plugs should not be touched because they were Ford certified spark plugs and tear easily. A special onsite Ford mechanic repaired the spark plugs. The accelerator pedal and stalling failures were not repaired. The manufacturer and dealer were not made aware of the failures. The failure mileage was 233,000.
I leave my windows up on the truck. It is cold (winter time) truck was in the garage. I went to the garage and the window on the passenger side was down. I cranked the truck, pushed the button and the window would not come up. I took the truck to the dealer they said the front door window regulator had to be replaced. This cost $344.66 to replace the regulator. Since the first replacement, the two back windows have done the same thing. I assume if my truck is having this problem others are also. This appears to be a defect and the company should pay for the repairs.
Electrical complaints in other F-150 years
Frequently asked questions
How common are electrical problems on the 2004 Ford F-150?
NHTSA has 99 complaints about the electrical system of the 2004 Ford F-150, 5% of the model year's 2,029 complaints. The component named most often is wiring (4 mentions).
Is there a recall for 2004 Ford F-150 electrical problems?
No. NHTSA lists no electrical system 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 electrical problems start?
Half of the complaints with a recorded mileage happened before about 55,000 miles, and 35% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 12 fires and 0 injuries to electrical system 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.