Which parts fail
Components named in complaints (struts, shocks, control arms, ball joints, springs).
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).
Frame Failure, A licensed technician said my vehicle is dangerous to drive and cannot be fixed because of the advanced rusting of the frame. As I read the history of some Ford Trucks I find this is a continuing problem with no recalls and wonder why they can continue to manufacture faulty, dangerous products
There hasn't been any accidents but the rails underneath of the truck bed are rotting completely off the truck and I feel that would be a safety problem if it collapses and I don't understand why they're so rusty when the rest of the truck is not it this could be a problem!
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. …
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.
My vehicle has developed what I would refer to as a death wobble. At speeds from 40 to 55 mpg the front of the trick shakes as though it's going to rattle apart. This is clearly a Ford issue and is now getting a good share of attention on you tube. There are a lot of us out there who have inheritated this from Ford who is in constant denial of it's refusal to address and take corrective action to repair the buckleing of the front end. How many more accidents need to happen or Ford's diligence on preventitive measures May just save lives and customers. Please help in resolving this manufacturing issue.
Tl* the contact owns a 2004 Ford f-150. The contact stated that while driving at an unknown speed, the vehicle began to veer to the driver side. The failure recurred several times. The vehicle was taken an independent mechanic where it was diagnosed that the coil spring needed to be replaced. It was unknown if the vehicle was repaired. The manufacturer was made aware of the failure. The approximate failure mileage was 82,000.
Tl* the contact owns a 2004 Ford f-150. The contact noticed rust on the rear axle housing. The dealer diagnosed that the axle was nearly rusted all the way through and that the vehicle was unsafe to drive. The VIN was excluded from NHTSA campaign number: 15V608000 (suspension). The manufacturer was notified. The vehicle was not repaired. The failure mileage was approximately 76,000.
Original owner of 2004 Ford f150 fx4. From stop the rear end will vibrate as I accelerate. It's been doing it for quite a while. I believe it started around 40000 miles. I only have 54000 on it currently. So it has been like this for at least 3 or 4 years. It sounds like this is a pretty common issue. Does should definitely fix this known issue.
Hitch broke off due to ford common frame rot. Frame is rotted from leaf spring shackle and back
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. …
Suspension complaints in other F-150 years
Frequently asked questions
How common are suspension problems on the 2004 Ford F-150?
NHTSA has 118 complaints about the suspension of the 2004 Ford F-150, 6% of the model year's 2,029 complaints. The component named most often is front (20 mentions).
Is there a recall for 2004 Ford F-150 suspension problems?
No. NHTSA lists no suspension 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 suspension problems start?
Half of the complaints with a recorded mileage happened before about 16,000 miles, and 58% before 25,000 miles.
Is it dangerous?
Owners linked 2 crashes, 0 fires and 1 injury to suspension 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.