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. *dt 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. My truck has only 61,000 miles on it and from forums and posts I've read it seems to be a major issue for that year vehicle.
2004 Ford F-150 body complaints
Page 2 of 5: complaints 11 to 40 of 104, newest first, as owners wrote them.
Tl* the contact owns a 2004 ford f-150. While the vehicle was being serviced at jim trenary ford (located at 255 john deere dr, moscow mills, mo 63362, (636) 356-9000), the technician noticed that the frame was split completely in half and needed to be replaced. The technician informed the contact that the vehicle could not be driven. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure and did not assist. The approximate failure mileage was 200,000.
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.
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. - cannot be repaired and is unsafe. - cannot pass a state safety inspection. - cannot even be put on a lift because it has no structural strength.
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.
The truck was taken into mechanic. The mechanic put it up, and saw that entire frame was rusted. It is not fixable. Contacted john lance ford, where it was purchased. They advised to take truck to nearest ford dealer. We took it to ford in port clinton, ohio. The service manager took pictures and sent it to corporate office. It has been longer than 6 weeks, and have not heard back.
Tl* the contact owns a 2004 ford f-150. The contact looked underneath the vehicle and noticed that the entire bottom of the frame was rusted. The dealer (liberty ford, 9311 liberty rd, randallstown, md 21133, 410‑504‑2897) was contacted and stated that the frames were absolute. The vehicle was not repaired. The manufacturer was not notified. The failure mileage was approximately 78,000.
Tl* the contact owns a 2004 ford f-150. The vehicle was taken to an independent mechanic for repairs. Once the vehicle was placed on a lift, the mechanic noticed that the main rails that support the frame and the frame of the vehicle had extensive rust. The failure could cause the structure to potentially fracture or disintegrate. The independent mechanic diagnosed that the frame needed to be replaced. The dealer was not contacted. The manufacturer was notified of the failure. The VIN and failure mileage were not available.
My trucks frame has rusted out from the cab corners to the rear part of the frame rails. Ford motor company wont do anything about this problem. Numerous complaints have been filed, yet they wont do anything about it. Im not selling my truck because its a rare version of the 04 new style f-150. This is a very serious problem that people can die from and ford wont back them up on the 04-08 trucks.
The frame on my truck has split in half always been taken care of. Ive had it for 6 years and it been good. Until recently the bed has started to shake very violently. My dad and I have figured out that the frame on my truck has split in half! I did some research on this issue of frames failing. Most 11th gen owners like me have or had this kind of problem. Some frames have rotted out completely due to ford. This truck is very unsafe! And ive asked ford if they could do anything and they couldnt do anything. They wont back up their products.
Brought my 2004 f150 xlt to have some service work done, the truck needed a muffler and a new front upper control arm, I was advised by the service manager that I should have my frame looked at before going any further, both right and left sides of the frame in the middle of the truck have severe rust and I believe the structure is doomed to fail, I had planned on driving this truck for several more years as it is my daily driver. I am now left with a truck that cannot be certified for resale and has lost its value and further it is no longer safe. By the way the truck only has 190 thousand kms on it.
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. I feel that in this day and age a 13 year old truck should not experience this issue and the manufacturer should step up and take some responsibility for their product. Built ford tough. Yeah, right.
Tl* the contact owns a 2004 ford f-150. The contact stated that the rear driver side frame of the vehicle was rusted out near the fuel tank. The contact took the vehicle to the langley ford dealer who stated that the vehicle was not included in any recall regarding the frame. The vehicle was not officially diagnosed or repaired. The manufacturer was made aware of the failure and confirmed the dealer's information. The approximate failure mileage was 124,000. Updated 08/09/17*lj
Tl* the contact owns a 2004 ford f-150. While performing routine maintenance on the vehicle, the contact became aware of extreme corrosion to the subframe of the vehicle. The contact was concerned that the vehicle could fracture and separate at the center between the bed and the cabin. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The approximate failure mileage was 75,000.
Tl* the contact owns a 2004 ford f-150. The contact stated that the frame was fractured. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure. The failure mileage was 89,000.
My truck has 106,xxx miles on it. I have only owned it for 9 months. I took it to the shop for a repair and was told the frame was so rotten out they couldn't put it on the lift.
Within a couple years of manufacture noticed oxidation appearing on underside of hood, and some paint blistering on front edge of upper side of hood. These issues have worsened over time
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. People should be reimbursed by ford to get the problem fixed and for their lack of a quality product and service. Something needs to be done before someone loses their life.
Frame rusted in half,
Hood paint and roof paint peeling up for the last 7 years. It started with small blistering and what appeared to be just a few knicks on the hood. However it quickly spread and the entire hood as well as roof are in need of a paint job due to rust. I am the original owner and have apps 129000 miles on it.
The frame under my f150 is rusted through. I only have 81k miles on it and I don't understand why the frame is rusting so badly. It has already cost me 2,400 to have a certified welder replace some of the sections that were rusted out. I know just found another part of the frame that is rusted under the leaf spring. That is now going to cost me another $500.00.
Frame rusting out prematurely causing a safety hazard.
Both rear suicide doors will not open, the latch mechanism is broken and apparently cost over $700.00 to fix both. In addition I have replaced the wheel bearing on all wheels twice and now another one is going bad. It seems like I never have a period when all the bearings are good.
The frame of my 2004 f150 is almost completely rotten from the front of the leaf spring all the way up to the drivers door. The bed supports are also rotted completely off making the bed unsafe and unable to use.
During an oil change it was noticed that the left hand front differential mounting bracket appeared to have a crack pursuant with tsb 06-11-12. However upon closer examination it was shown that the damage was more extensive then the "concern of the left hand front differential mounting bracket separating from the frame rail." mention in the tsb. Instead of the aforementioned mount breaking, a section of the frame approximately 1/4 of an inch around the welds for the differential mount on all sides had separated from the rest of the frame leaving a hole in the frame approximately four inches across.
Tl* the contact owns a 2004 ford f-150. The contact stated that there was rust forming on the rear driver and passenger side tire wells. The failure recurred continuously. The vehicle was taken to an independent mechanic where it was diagnosed that the entire rear panel needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The approximate failure mileage was 84,800.
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.
2004 ford f-150. Consumer writes in regards to vehicle frame rust problems. *smd consumer sent additional correspondence. *smd the vehicle had to be towed to the repair shop, because the brakes went out. The rear brake lines, hoses, calipers, master cylinder and pads were replaced. Updated 03/09/15.
When it rains water comes in and drips on the passenger side rear seat. I have replace the third brake light lens twice and the rear window. I have read forums and it seems like this problem is common. I have a truck that smells like mildew. I have to drive it now with the interior pulled out.
The mirror(s) are full of corrosion and the drivers side mirror fell right off the car while driving.
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