2004 Ford F-150 Body and structure Problems
- Complaints
- 104about this part
- Share
- 5%of 2,029 total for the year
- Median mileage
- 72,500miles
- Trend
- FallingComplaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.
NHTSA recorded 104 complaints about the body and structure of the 2004 Ford F-150, 5% of the 2,029 complaints for this model year. Where a mileage was given, the median is 72,500 miles. 1 of these say a crash was involved, according to the filers.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“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.”
NHTSA complaint #10892272, filed 2016-08, 81,000 miles“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.”
NHTSA complaint #11072320, filed 2018-02, 172,070 miles“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.”
NHTSA complaint #10682143, filed 2015-02, 150,000 miles“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.”
NHTSA complaint #10787975, filed 2015-11, 95,000 miles“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. …”
NHTSA complaint #11205939, filed 2019-05, 61,000 milesRelated service bulletins
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- 10177863Jul 13, 2020This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/Mercury vehicles equipped with aluminum body panels may exhibit…
- 10156863Feb 7, 2019Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without…
- 10155551Feb 7, 2019Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without…
- 10012943Dec 7, 2005An aluminum-backed butyl pad may have been added to the inside surface of the right hand side box outer panel in front of the tail lamp. Customer satisfaction program 04b23…
- 10014165Dec 27, 2004Aluminum corrosion - service tip.
- 10013421Nov 1, 2004Paint bubbling on passenger side of pickup bed.
- 10013392Nov 1, 2004Water leak at passenger side lower a pillar.
- 10011338Sep 1, 2004Water leak from high mount stop lamp.
- 10013111Jan 1, 2004Hood flutter at highway speeds.
Body and structure: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2026 | 1 | 8% |
| 2025 | 3 | 3% |
| 2024 | 3 | 2% |
| 2023 | 24 | 6% |
| 2022 | 14 | 2% |
| 2021 | 36 | 3% |
| 2020 | 22 | 3% |
| 2019 | 32 | 2% |
| 2018 | 193 | 8% |
| 2017 | 112 | 8% |
| 2016 | 199 | 10% |
| 2015 | 148 | 8% |
| 2014 | 31 | 2% |
| 2013 | 48 | 2% |
| 2012 | 24 | 1% |
| 2011 | 33 | 2% |
| 2010 | 92 | 11% |
| 2009 | 34 | 10% |
| 2008 | 23 | 6% |
| 2007 | 31 | 6% |
| 2006 | 44 | 8% |
| 2005 | 77 | 7% |
| 2004 | 104 | 5% |
| 2003 | 32 | 8% |
| 2002 | 45 | 5% |
| 2001 | 65 | 5% |
| 2000 | 66 | 6% |
| 1999 | 95 | 9% |
| 1998 | 138 | 10% |
| 1997 | 226 | 8% |
| 1996 | 7 | 2% |
| 1995 | 18 | 3% |
| 1994 | 33 | 5% |
| 1993 | 13 | 2% |
| 1992 | 8 | 2% |
| 1991 | 8 | 3% |
| 1990 | 4 | 1% |
| 1989 | 8 | 4% |
| 1988 | 9 | 6% |
| 1987 | 5 | 5% |
| 1986 | 9 | 15% |
| 1985 | 3 | 11% |
Other parts of the 2004 Ford F-150
863 complaintsTransmission and drivetrain
232 complaintsEngine cooling
167 complaintsBrakes
139 complaintsSuspension
118 complaintsElectrical system
99 complaintsEngine
92 complaintsOther or unknown
86 complaintsAir bags
85 complaintsSteering
75 complaintsFuel system
74 complaintsVehicle speed control
70 complaints
← All problems reported for the 2004 Ford F-150
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.
To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology