2004 Ford E-150 Problems
- Complaints
- 33filed with NHTSA
- Median mileage
- 65,000miles, 22 complaints with mileage
- Recalls
- 5campaigns on record
- Trend
- RisingComplaints filed in the last 3 full calendar years are at least 25% higher than in the 3 years before.
- NHTSA crash rating
- —overall rating starts with 2011 models
- EPA fuel economy
- 15 mpgcombined, 4.6L 8-cyl RWD · 14 city / 18 hwy
Sources: NHTSA records for the 2004 Ford E-150 (complaints, recalls, investigations), EPA fuel economy. Report an error
NHTSA recorded 33 consumer complaints for the 2004 Ford E-150. The part named most often is brakes, with 8 complaints (24% of the total), followed by transmission and drivetrain (4) and vehicle speed control (4). 22 of the complaints include a mileage, and 41% of those were filed for vehicles with under 50,000 miles; the median is 65,000 miles. Of all complaints, 2 involved a crash, 2 an injury, according to the filers. NHTSA lists 5 recall campaigns and 41 technical service bulletins for this model year. Brakes complaints overlap with 1 technical service bulletin filed under the same part. Transmission and drivetrain complaints overlap with 6 technical service bulletins filed under the same part.
Not compared (before 2008). Model years 2008–2023 of the same vehicle that have at least 25 complaints are compared, and a model needs at least 3 of them.
Which parts are reported most
Complaints can name more than one part, so the counts add up to more than the total. Select a part to see its complaints, recalls and bulletins.
- Brakes8 24%
- Engine2 6.1%
- Wheels2 6.1%
- Electrical system1 3.0%
- Engine cooling1 3.0%
- Exterior lighting1 3.0%
Also reported: Fuel system (1), Seat belts (1), Seats (1), Body and structure (1), Suspension (1).
Example complaints
Brakes: “First application of brakes after backing out of my drive way rattling noise in brake lines at the ABS control manifold, it is hyd. Press. Bleeding off, brake pedal starts to go down, I have exp. With hyd. And know that, the vibration in the line will cause fittings to fail at the valve under the (b) nut,,#2 (leds) in mirror are falling back in to the body of the mirror assy, barely visible from driver seat.”
NHTSA complaint #10091098, filed 2004-09, 2,000 milesTransmission and drivetrain: “Today was driving normally on the side road not towing & in overdrive when around 40mph the overdrive disengaged & starts revving like it's in neutral. I pull over & put it into park & then back into overdrive & start driving once again & same thing happened three times. Luckily there was a service shop close. I took the truck in & they said take it to a transmission shop. He also said it was fine to take it out of overdrive & that wouldn't cause it to do that. So, I took it out of overdrive & it didn't miss a beat. …”
NHTSA complaint #10526410, filed 2013-07, 79,964 milesVehicle speed control: “When driving on a highway with the vehicle speed cruise control on, the component will shut off without warning. I have brought the auto back to the dealer twice with this complaint, both times I was told that the problem was fixed. Both times the component failed again while in use. I will be bringing the auto in to the dealer again in two days for the same repair. I see that Ford motors has been aware of this problem publicly since oct. 01, 2004.”
NHTSA complaint #10143820, filed 2005-11, 19,800 milesVisibility (wipers, defrost, mirrors): “My 2004 f-150 has a window regulator go out for the second time this is a real issue it is a hazard to my children and a real big cost to me being 300 dollar both times I had to replace it need to be recalled what a big disappointment can you help me in this matter thank you.”
NHTSA complaint #10327234, filed 2010-04, 49,000 milesMileage when problems were reported
41% of the 22 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 19,800 and 93,000 miles.
Complaints by year filed
Trend: rising. Complaints filed in the last 3 full calendar years are at least 25% higher than in the 3 years before.
Fuel economy and running cost
EPA ratings for each 2004 Ford E-150 version. Annual fuel cost is the EPA's estimate at its current fuel prices for 15,000 miles a year (55% city driving).
| Version | Engine | Transmission | City | Hwy | Comb. | Fuel / yr |
|---|---|---|---|---|---|---|
| E150 Club Wagon RWD | 4.6L 8-cyl | 4-speed automatic | 14 | 18 | 15 | $4,450 |
| E150 Club Wagon RWD | 5.4L 8-cyl | 4-speed automatic | 12 | 16 | 14 | $4,800 |
| E150 Econoline 2WD | 4.6L 8-cyl | 4-speed automatic | 13 | 18 | 15 | $4,450 |
| E150 Econoline 2WD | 5.4L 8-cyl | 4-speed automatic | 13 | 16 | 14 | $4,800 |
Source: U.S. EPA and Department of Energy, fueleconomy.gov. Ratings are for comparing vehicles; real-world mileage varies with driving and conditions.
Recalls and investigations
- 09V100000Mar 27, 2009Equipment adaptive/mobilityCovers: Ford E-150 2004–2007, E-350 2004–2007, E-250 2004–2007
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…
- 09V102000Mar 27, 2009Equipment adaptive/mobilityCovers: Ford E-150 2004–2007, E-350 2004–2007, E-250 2004–2007
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…
- 04V562000Nov 26, 2004Equipment adaptive/mobilityCovers: Ford E-150 1997–2000, 2004, E-350 1997–2000, 2004, E-250 1997–2000, 2004 +8 more
On certain vans equipped with sure-lok wheelchair securement systems, the sprocket teeth of the retractor assembly is out of alignment.
- 04V444000Sep 13, 2004Electrical system › WiringCovers: Ford E-150 2003–2004, E550 2003–2004, E-350 2003–2004 +2 more
On certain vans, a diode in the anti-lock braking system (abs) module may experience an electrical short.
- 04V445000Sep 13, 2004Engine and engine coolingCovers: Ford E-150 2003–2004, E550 2003–2004, E-350 2003–2004 +2 more
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…
Recall details for the 2004 Ford E-150 → · Check a VIN at nhtsa.gov/recalls
Technical service bulletins
TSBs are manufacturer notes to dealers about known repair procedures. They are not recalls and do not by themselves mean a vehicle has a fault. 41 on record; the latest 10 are shown.
- 10243490Sep 7, 2023Transmission and drivetrain. When performing any transmission fluid changes or topoffs involving MERCON SP, MERCON LV has replaced all versions of MERCON SP and can be used going forward. Mixing MERCON LV and MERCON SP in the…
- 10056196May 1, 2014Transmission and drivetrain. Ford: when shifting between park, reverse and/or during 2-3 shift, an intermittent clunk occurs with a torqshift transmission. Model 2003-2014 f-super duty, e series, excursion, f-53 motorhome…
- 10055629Feb 1, 2014Engine cooling, Transmission and drivetrain. Ford: on some trucks, there is a no crank situation and if voltage on transmission range sensor at pin 21, is less than 5 volts, disconnect the engine cooling fan clutch, electronically, and recheck…
- 10022675Sep 19, 2007Brakes. Brake booster system may exhibit a brake pedal kickback and/or grabbing condition when applying the brakes.
- 10022243Apr 1, 2007Engine cooling. Lack of power due to low fuel pressure - fuel tank liner seperation.
- 10021621Feb 1, 2007Fuel system. Lack of power due to low fuel pressure, fuel tank liner seperation.
- 10020671Dec 20, 2006Fuel system. Slow fuel fill on vehicles with a 4.6l or 5.4l engine and mid-ship fuel tank.
- 10022232Dec 1, 2006Exterior lighting. Headlight adjustment needed.
- 10021229Sep 1, 2006Engine cooling. Watch for oil flow from the base engine oil pump. Vehicles equipped with a 6.0l diesel engine.
- 10021173Jun 1, 2006Engine cooling. Oil flow from the base engine oil pump.
Other model years of the Ford E-150
| Year | Complaints | Median mi | Recalls | Crash ★ | MPG | Score (50 = typical) | Trend |
|---|---|---|---|---|---|---|---|
| 2016 | 8 | 6,500 | 1 | — | — | — | Not enough data |
| 2015 | 8 | 18,000 | 1 | — | — | — | Not enough data |
| 2014 | 6 | 16,738 | 6 | — | 14 | — | Not enough data |
| 2013 | 19 | 82,800 | 6 | — | 14 | — | Stable |
| 2012 | 12 | 60,000 | 8 | — | 14 | — | Not enough data |
| 2011 | 23 | 37,500 | 11 | — | 14 | — | Falling |
| 2010 | 10 | 42,500 | 7 | — | — | — | Not enough data |
| 2009 | 7 | 83,000 | 12 | — | — | — | Not enough data |
| 2008 | 11 | 66,325 | 17 | — | — | — | Not enough data |
| 2007 | 12 | 49,000 | 18 | — | — | — | Not enough data |
| 2006 | 17 | 44,373 | 14 | — | 15 | — | Stable |
| 2005 | 16 | 52,879 | 2 | — | 15 | — | Rising |
| 2004 | 33 | 65,000 | 5 | — | 15 | Not compared (before 2008) | Rising |
| 2003 | 21 | 16,354 | 5 | — | 14 | — | Stable |
| 2002 | 28 | 86,000 | 3 | — | 14 | Not compared (before 2008) | Rising |
| 2001 | 37 | 73,000 | 4 | — | 15 | Not compared (before 2008) | Stable |
| 2000 | 50 | 104,602 | 6 | — | 15 | Not compared (before 2008) | Rising |
| 1999 | 83 | 96,000 | 6 | — | 14 | Not compared (before 2008) | Falling |
| 1998 | 60 | 89,146 | 5 | — | 14 | Not compared (before 2008) | Stable |
| 1997 | 102 | 103,000 | 6 | — | 14 | Not compared (before 2008) | Stable |
| 1996 | 59 | 120,000 | 3 | — | 13 | Not compared (before 2008) | Stable |
| 1995 | 71 | 95,000 | 3 | — | 14 | Not compared (before 2008) | Falling |
| 1994 | 121 | 129,500 | 7 | — | 14 | Not compared (before 2008) | Rising |
| 1993 | 71 | 135,000 | 4 | — | 14 | Not compared (before 2008) | Falling |
| 1992 | 64 | 100,000 | 4 | — | 14 | Not compared (before 2008) | Stable |
| 1991 | 15 | 75,000 | 1 | — | 13 | — | Stable |
| 1990 | 17 | 126,000 | 3 | — | 13 | — | Falling |
| 1989 | 31 | 94,000 | 2 | — | 13 | Not compared (before 2008) | Rising |
| 1988 | 14 | — | 0 | — | 13 | — | Not enough data |
| 1987 | 17 | 70,000 | 0 | — | 14 | — | Stable |
| 1986 | 9 | — | 0 | — | 14 | — | Not enough data |
All Ford E-150 model years · Best and worst years by complaints
Frequently asked questions
How many NHTSA complaints does the 2004 Ford E-150 have?
NHTSA recorded 33 consumer complaints for the 2004 Ford E-150 as of Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
What part of the 2004 Ford E-150 is reported most often?
Brakes is named most often, in 8 complaints (24% of the total), followed by transmission and drivetrain with 4.
Has the 2004 Ford E-150 been recalled?
NHTSA lists 5 recall campaigns for this model year. To check a specific vehicle, enter its VIN at nhtsa.gov/recalls.
What gas mileage does the 2004 Ford E-150 get?
The EPA rates the 2004 Ford E-150 (E150 Club Wagon, 4.6L 8-cyl) at 15 mpg combined, 14 city and 18 highway, with an estimated annual fuel cost of $4,450 at 15,000 miles a year. Other engine and drive versions are rated differently.
At what mileage are problems with the 2004 Ford E-150 reported?
Among the 22 complaints that include a mileage, the median is 65,000 miles and the middle half falls between 19,800 and 93,000 miles; 41% were filed for vehicles with under 50,000 miles.
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate. Fuel economy is from the EPA and DOE (fueleconomy.gov).
Complaint counts come from NHTSA’s public complaint database; we count each complaint once. The source records for this vehicle are on nhtsa.gov. Scores and trends are our own summaries of that data, described in the methodology. This page is not legal, safety or repair advice: for a specific vehicle, check its VIN at nhtsa.gov/recalls and ask a qualified mechanic. See an error? Tell us.