Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
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 undisclosed speeds, the vehicle shuddered and failed to accelerate while the accelerator pedal was depressed. The check engine warning light was illuminated. The contact pulled over to the shoulder of the roadway and was able to restart the vehicle. The contact scanned the vehicle with a scanner and retrieved an unknown camshaft phaser error code. The local dealer was not contacted. The vehicle was not repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 100,000.
The contact owns a 2004 Ford F-150. The contact stated that while driving at an undisclosed speed, the contact observed the spark plug being ejected from the fuel compartment. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic, who was unable to diagnose the failure. The vehicle was repaired, but the failure reoccurred. The manufacturer was notified of the failure but referred the contact to the NHTSA Hotline for assistance. The failure mileage was 150,000.
Truck died, lost all power while driving down the road. This has happened 5 - 6 times through the years starting around 2010. Sometimes driving down freeway sometimes driving slowly into driveway. Battery was checked, it was okay and connected fine. Various other engine problems later include a rattle noise and low RPM. Running hot, chugging along like running out of gas, etc. Having to pull over till it could go again. Currently just a little over 100,000 miles.
I am now a victim of the 2004-2008 5.4l cam phaser problem. It started out when I came to a stop light and the truck started shacking really bad and making a loud knocking sound. As soon as I accelerated it went away so I thought it was a fluke. Nope!! It stated doing it more and more but I was not getting a check engine light. Finally the light came on and gave me the code p0012-intake camshaft position timing over retarded on bank 1. The only place to take it was Ford because they have the most up to date and complete diagnostics tool. It is still in the shop right now but to look at the phasers to see if I need both it is running me $600 just for them to remove the valve covers to look. He said it was going to cost me close to $1500 just to fix the issue! …
I bought this vehicle used with 139000 miles on Saturday 05/16/15. Now I was not expecting a new vehicle but not one with so many problems either. First of all it has a very rough idle, I found that there is a serious problem with this engine and removal of the spark plugs. The repair shop will not even give an estimate for changing the spark plugs as there are very well known problems with them breaking off in the engine. Ford knows about this and has put out a notice about this known problem. I had to take it for a lower steering arm replacement on Monday 05/18/15 as the wheel was not returning to the straight position without assistance. Now there is a humming noise from the rear differential that the repair guy said is the pinion barring and that it needs to be fixed. …
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. …
Within a few weeks of purchasing my vehicle in February after pulling into a parking lot the check engine light came on. I also noticed it was making a ticking noise like a diesel engine but it's not a diesel. I went to get the codes and found it was a retarded variable valve timing issue code p0022. I looked online and went to multiple shops and mechanics to figure out the problem. After paying to replace the vct solenoids it was apparent that that was not the issue causing the timing problem. For weeks I noticed the truck shaking and at one point it actually stalled as I was pulling out of a parking lot into a busy road and it stalled as I was going into the road which caused the on coming traffic to slow and stop to avoid hitting me in the middle of the road. …
My truck felt like it was driving really well, I was driving from a to b which was about 6 miles. Im almost home & I stop at a light,when it turned green I accelerated &when I did I heard a knocking sound&so I pulled over& I couldn't pin point exactly where it was coming from,just it was coming from the back of the engine on the right side. Im guessing maybe the 3rd or 4th spark plug. I checked my oil I was maybe 1quart low. So hoping that was it, I bought a quart&some oil repair to go in with it. The guy at autozone thought the same. As u could guess that didn't work.it sound almost like a lawn mower.which is baffling cuz there was no warning, no check engine light,no prior noise.I'm lost.I've been reading about spiting spark plugs&a lot of the same stuff happening in these trucks.I'm wondering if there was a recall? If not why? …
I have 2004 f-150 with 92,000 miles on it , I bought it 3 years ago with 70,000 on it making a slight tapping noise . I talked with many people and and the dealer saying that this is the way the engine is designed and should be fine.yesterday driving down a major highway in northern virginia traveling at 65 MPH my truck started making a noise from the engine and shut off , I had good oil pressure ,water temp was fine I pulled it off the highway, never to start again. I had it towed to a locale Ford dealer in fairfax va.after reading from Ford forum web site and hearing the horror stories I feel I am in for a hugh repair bill.I also see there is a class action suit against the Ford motor company for not standing behind their vehicles when there seems to be a major flaw in the engines design. Aprox. …
2004 f150 4.6ltr engine. Spark plug blow out #3 cylinder 64865 miles. Original factory parts. Spoke directly to Ford motors they act as if this is my fault. The parts have never been changed. Ford told me it is not covered under warrenty because this is a maintanence part. The dealer told me that this has been a big problem for Ford. But they wont honor to fix the problem even though it is a mechanical failure due to bad design. It cost 600.00 to fix and I beleive this should be covered by Ford due to the number of instences. There were two trucks fixed the same day for the same problem and again the service department said this has been a big issue. I would like this to be resolved. The consumer should not have to worrie about a spark plug blowing out while driving. …
NHTSA investigations
Spark plug ejection from cylinder head
On September 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 Ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or…
Engine complaints in other F-150 years
Frequently asked questions
How common are engine problems on the 2004 Ford F-150?
NHTSA has 257 complaints about the engine & cooling of the 2004 Ford F-150, 13% of the model year's 2,029 complaints. The component named most often is engine (46 mentions).
Is there a recall for 2004 Ford F-150 engine problems?
No. NHTSA lists no engine & cooling 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 engine problems start?
Half of the complaints with a recorded mileage happened before about 89,000 miles, and 15% before 25,000 miles.
Is it dangerous?
Owners linked 5 crashes, 14 fires and 2 injuries to engine & cooling 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.