Model year record

2004 Ford E-150 recalls & problems

The 2004 Ford E-150 has 7 safety recalls and 33 owner complaints on file with NHTSA. The most-reported problem area is service brakes, hydraulic (9 complaints).

Recalls7safety recalls

Complaints33filed by owners

Crashes · fires2 · 0reported in complaints

Injuries · deaths2 · 0reported in complaints

Safety recalls

Fuel system, gasolineNov 8, 2011

Storage › Tank assembly

Recall 11E04700017 vehicles

Problem: FORD IS RECALLING CERTAIN REPLACEMENT FUEL TANKS THAT COULD BE INSTALLED INTO MODEL YEAR 2004 THROUGH 2008 E-150, E-250, AND E-350 VANS AND WAGONS. THE AFFECTED FUEL TANKS HAVE AN EXTRA OBDII SENSOR HOLE ON THE TOP OF THE TANK THAT MAY NOT BE PROPERLY SEALED AND MAY LEAK FUEL.
Risk: A FUEL LEAK IN THE PRESENCE OF AN IGNITION SOURCE MAY RESULT IN A FIRE.
Fix: FORD WILL NOTIFY OWNERS, AND DEALERS WILL REPLACE THE FUEL TANKS FREE OF CHARGE. THE SAFETY RECALL BEGAN ON NOVEMBER 28, 2011. OWNERS MAY CONTACT FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-800-232-5952.

Equipment adaptive/mobilityMar 27, 2009

Equipment adaptive/mobility

Recall 09V10000052 vehiclesopened after NHTSA action (ODI)

Problem: VAN CONVERSIONS IS RECALLING 52 MY 2004-2007 FORD E-150, E-250 E-350 AND MY 2006 GM SAVANNA 3500 VANS BUILT ON FORD AND GM CHASSIS AND EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE LIFTS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 403, "PLATFORM LIFT SYSTEM ACCESSIBLE FOR MOTOR VEHICLES," THE ANTI-STOW INTERLOCK MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER. THE PRESSURE SENSING SWITCH THAT DETECTS THE PRESENCE OF WEIGHT ON THE PLATFORM WAS NOT ADJUSTED TO THE NECESSARY SENSITIVITY LEVEL. THE LIFT COULD STOW EVEN THOUGH SOMEONE OR SOMETHING IS STILL ON THE LIFT.
Risk: A LIFT OCCUPANT CAN BE INJURED SHOULD THE LIFT BEGIN TO STOW UNINTENTIONALLY.
Fix: VAN CONVERSIONS IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEASE SEE 07E097). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR VAN CONVERSIONS AT 610-837-0707.

Equipment adaptive/mobilityMar 27, 2009

Equipment adaptive/mobility

Recall 09V10200074 vehiclesopened after NHTSA action (ODI)

Problem: VAN CONVERSIONS IS RECALLING 74 MY 2004-2007 FORD E-150, E-250 E-350 AND MY 2006 GM SAVANNA 3500 VANS BUILT ON FORD AND GM CHASSIS AND EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 404, "PLATFORM LIFT INSTALLATIONS IN MOTOR VEHICLES." THE THRESHOLD WARNING SYSTEM MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER IN A CERTAIN SPOT WITHIN THE DEFINED THRESHOLD AREA.
Risk: THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE UNINTENTIONALLY.
Fix: VAN CONVERSIONS IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEASE SEE 07E095). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR VAN CONVERSIONS AT 610-837-0707.

Fuel system, gasolineJun 13, 2006

Fuel system, gasoline

Recall 06E05600058,640 vehicles

Problem: CERTAIN AFTERMARKET FUEL FILTERS SOLD UNDER THE PUROLATOR BRAND NAME, P/N F65277, SHIPPED FROM JANUARY 16 THROUGH JUNE 2, 2006, FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. DUE TO INCORRECT DESIGN, THE QUICK CONNECTORS MAY NOT FULLY SEAT WITH THE TUBE INTERFACE, EVEN THOUGH THE PERSON MAKING THE CONNECTION MAY BELIEVE THAT THE QUICK CONNECTOR IS FULLY ATTACHED.
Risk: FAILURE OF THIS CONNECTION COULD LEAD TO FUEL SPILLAGE AND, IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.
Fix: UFI WILL NOTIFY OWNERS AND REPLACE THE FILTERS FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 4, 2006. OWNERS MAY CONTACT UFI FILTERS USA AT 800-230-5876.

Equipment adaptive/mobilityNov 26, 2004

Equipment adaptive/mobility

Recall 04V5620001,660 vehiclesopened after NHTSA action (ODI)

Problem: ON CERTAIN VANS EQUIPPED WITH SURE-LOK WHEELCHAIR SECUREMENT SYSTEMS, THE SPROCKET TEETH OF THE RETRACTOR ASSEMBLY IS OUT OF ALIGNMENT.
Risk: IN THE EVENT OF A VEHICLE CRASH, THE WHEELCHAIR MAY NOT BE ADEQUATELY SECURED POSSIBLY RESULTING IN INJURIES TO A WHEELCHAIR OCCUPANT.
Fix: DEALERS WILL INSPECT AND REPLACE THE WHEELCHAIR SECUREMENT RETRACTORS AS NECESSARY. SURE-LOK WILL HANDLE THE REPAIRS FOR THIS CAMPAIGN. OWNERS SHOULD CONTACT SURE-LOCK AT 1-908-231-1804 OR MOBILITYWORKS AT 1-800-769-8267.

Electrical systemSep 13, 2004

Wiring

Recall 04V444000214,849 vehicles

Problem: ON CERTAIN VANS, A DIODE IN THE ANTI-LOCK BRAKING SYSTEM (ABS) MODULE MAY EXPERIENCE AN ELECTRICAL SHORT.
Risk: THE ELECTRICAL SHORT MAY CAUSE AN ABS MALFUNCTION THAT WOULD ILLUMINATE THE ABS WARNING LIGHT, OR THE MODULE MAY OVERHEAT RESULTING IN A BURNING ODOR, SMOKE, AND/OR FIRE. THIS CONDITION MAY OCCUR WHILE THE VEHICLE IS BEING DRIVEN OR UNATTENDED.
Fix: DEALERS WILL INSTALL A NEW FUSE IN THE ABS CIRCUIT AND INSTALL A HEAT SHIELD OVER THE ABS MODULE. THE RECALL BEGAN ON OCTOBER 15, 2004. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673. ALSO FORD IS EXTENDING THE LIMITED WARRANTY (FOR A ONE TIME REPLACEMENT) OF THE ABS MODULE FOR A TOTAL OF 10 YEARS OR 150,000 MILES FROM THE WARRANTY START DATE, WHICHEVER OCCURS FIRST. IF YOUR VEHICLE HAS ALREADY ACCUMULATED MORE THAN 150,000 MILES, THIS COVERAGE WILL LAST UNTIL SEPTEMBER 30, 2005.

Engine and engine coolingSep 13, 2004

Engine and engine cooling

Recall 04V445000253,076 vehicles

Problem: ON CERTAIN VANS, THE AIR FILTER ELEMENT MATERIAL PROCESS RESULTED IN AN AIR FILTER PAPER ELEMENT THAT CAN SMOLDER OR BURN. THIS CHANGE IN FILTER PAPER COMPOSITION COMBINED WITH THE CONFIGURATION OF THE AIR INDUCTION SYSTEM, MAY ALLOW HOT CARBON PARTICLES TO CONTACT THE AIR FILTER ELEMENT DURING CERTAIN DRIVING CONDITIONS THAT CREATE HOT PARTICLES.
Risk: THESE HOT PARTICLES MAY IGNITE THE AIR FILTER ELEMENT WITH THE POTENTIAL FOR AIR INDUCTION SYSTEM DAMAGE OR UNDERHOOD FIRE.
Fix: DEALERS WILL INSPECT AND REPLACE THE AIR FILTER ELEMENT. THE RECALL BEGAN SEPTEMBER 27, 2004. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673. ALSO FORD IS EXTENDING THE LIMITED WARRANTY (FOR A ONE TIME REPLACEMENT) OF THE ABS MODULE FOR A TOTAL OF 10 YEARS OR 150,000 MILES FROM THE WARRANTY START DATE, WHICHEVER OCCURS FIRST. IF YOUR VEHICLE HAS ALREADY ACCUMULATED MORE THAN 150,000 MILES, THIS COVERAGE WILL LAST UNTIL SEPTEMBER 30, 2005.

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

Fuel economy

E150 Econoline 2WD

15mpg combined

City / highway	13 / 18 mpg
Fuel	Regular Gasoline

4.6 L · 8 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,450/year to fuel

E150 Club Wagon

15mpg combined

City / highway	14 / 18 mpg
Fuel	Regular Gasoline

4.6 L · 8 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,450/year to fuel

E150 Econoline 2WD

14mpg combined

City / highway	13 / 16 mpg
Fuel	Regular Gasoline

5.4 L · 8 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,800/year to fuel

E150 Club Wagon

14mpg combined

City / highway	12 / 16 mpg
Fuel	Regular Gasoline

5.4 L · 8 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,800/year to fuel

EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.

What owners report

Problem area	Complaints	Crashes	Injuries	Typical mileage*
Service brakes, hydraulicFoundation components › Hoses, lines/piping, and fittings; Foundation components › Disc › Pads	9	0	0	10,131 mi
Vehicle speed controlAccelerator pedal; Cruise control	4	1	0	—
Power train	4	0	1	105,920 mi
Latches/locks/linkagesDoors › Latch	2	0	0	—
WheelsLugs/nuts/bolts/studs	2	0	0	—
Seat beltsFront › Warning light/devices	2	0	0	—
VisibilityPower window devices and controls	2	0	0	—
Engine	2	0	0	—
Engine and engine cooling	1	0	0	—
Fuel system, gasolineDelivery › Fuel pump	1	0	0	—
Electrical system	1	0	0	—
Service brakes, airAntilock	1	1	1	—

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Power train1 injury
The contact owns a 2004 Ford F-150. The contact stated that while parked when the vehicle suddenly rolled backwards downhill the contact's son attempted to get into the vehicle to make it stop. The trailer's jackknife stopped the vehicle from going onto the road. The contact manually moved the vehicle back into their garage. The contact stated their son did receive injuries to their head, left or right leg (the contact was unsure of the exact leg), and their left or right arm (the contact was unsure of the exact arm). Medical attention was needed. The dealer was not contacted. The manufacturer was informed of the failure and opened a case. The manufacturer referred the contact to the NHTSA…
Jul 10, 2025 · 74,000 miles
Power train
VIBERATION IN REAR AND CLUNKING NOISR IN REAR WHEN STOPPING AT LIGHT THEN TAKING OF WHILE MAKING A RIGHT TURN
Feb 10, 2016 · 176,000 miles
Engine
2004 FORD 4.6L ENGINE: #2 SPARK PLUG EJECTED FROM CYLINDER HEAD. ~$700 TO REPAIR!!!
Jul 13, 2015 · 117,000 miles
Exterior lighting
THERE ARE TONS OF DRIVERS ON PUBLIC ROADS USING OFF ROAD LED LIGHT BARS AND USING AMPLIFIED HID HEADLIGHTS. THEY ARE SO BRIGHT I HAVE TO BLOCK THE LIGHT WITH MY HANDS WHEN THEY DRIVE BY. I KNOW THIS IS ILLEGAL. IT IS TERRIBLY UNSAFE. WHY ARE THERE NOT LAWS BEING ENFORCED TO PREVENT THEIR USE ON THE STREET?
Jun 2, 2015 · 50,000 miles
Power train
AT THE POINT I REACH 40 MPH TRUCK SHIFTS TO NEUTRAL, HAVE TO PULL OVER SAFELY AND TAKE TRUCK OUT OF OVERDRIVE TO GET HOME. VERY DANGEROUS WHEN TRAVELING AT THAT RATE OF SPEED. DID SOME OF MY OWN INVESTIGATING AND FOUND MANY WEBSITE HAVE ANGRY PEOPLE WHO ALSO OWN SAME VEHICLES WITH VERY LOW MILEAGE. I SAW THE RANGE OF MILES BETWEEN 44,000 MILES TO 150,000 MILES. PLEASE REFER TO WWW.CARCOMPLAINTS.COM JUST TO START WITH, THERE ARE MANY OTHER WEBSITES FOR THIS MODEL YOU CAN SEE. PLEASE HELP. *TR
Apr 3, 2015 · 131,876 miles
Suspension
TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT THE LOWER BALL JOINTS WERE CAUSING PREMATURE WEARING OF THE TIRES. THE CONTACT INSPECTED THE VEHICLE AND NOTICED THAT THE FRONT END SPRINGS WERE COMPLETELY FRACTURED. THE DEALER AND MANUFACTURER WERE MADE AWARE OF THE FAILURE. THE MANUFACTURER STATED THAT THERE WERE NO ACTIVE RECALLS REGARDING THE FAILURE AND DECLINED TO PROVIDE A REMEDY TO RESOLVE THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 93,000. UPDATED 05/05/14*JB
Apr 12, 2014 · 93,000 miles
Visibility/wiper
TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THE FRONT PASSENGER'S SIDE WINDOW INDEPENDENTLY OPENED. THE FAILURE RECURRED SEVERAL MONTHS LATER ON THE REAR PASSENGER WINDOW. THE VEHICLE WAS TAKEN TO THE DEALER, WHO STATED THAT BOTH WINDOW REGULATOR ASSEMBLIES WOULD NEED TO BE REPAIRED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURE WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 60,000.
Oct 16, 2013 · 60,000 miles
Engine
TL* THE CONTACT OWNS A 2004 FORD E-150. THE CONTACT STATED THAT A PRIVATE MECHANIC ATTEMPTED TO REMOVE THE SPARK PLUGS BUT THEY WERE FUSED TO THE ENGINE. THE VEHICLE WAS EVENTUALLY REPAIRED. THE MANUFACTURER WAS CONTACTED ABOUT THE FAILURE. THE FAILURE MILEAGE WAS 118,000. THE VIN WAS UNAVAILABLE.
Sep 1, 2013 · 118,000 miles

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.

NHTSA defect investigations

SPARK PLUG EJECTION FROM CYLINDER HEADClosed
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 EJECTED FROM THE ENGINE.AS OF DECEMBER 8, 2005, ODI IS NOT AWARE OF ANY ALLEGATIONS WHERE THE ALLEGED DEFECT RESULTED IN A LOSS OF VEHICLE CONTROL, A CRASH, AN INJURY, OR A FATALITY IN ANY OF THE 10,319,810 SUBJECT VEHICLES.IN ADDITION, ODI IS AWARE OF ONLY TWO INCIDENTS WHERE THE VEHICLE STALLED WITHOUT RESTART.INFORMATION CONTAINED IN THE ODI CONSUMER COMPLAINTS AND OBTAINED FROM 72 TELEPHONE INTERVIEWS WITH COMPLAINANTS SHOWED THE FOLLOWING:(1) 99% OF THE COMPLAINTS WERE ON MY…
DP05005 · opened Sep 22, 2005 · closed Jan 4, 2006