2004 Ford F-150 structure problems
104 owner complaints filed with NHTSA name the structure on the 2004 Ford F-150 — 5% of all complaints for this model year.
What owners report
“The underbody frame is 95% rusted out, this vehicle is available for inspection upon request. I could have been fatally injured, not knowing the under frame was gone, until vehicle was taken in for new tires. The vehicle was inspected by Firestone tire and Gene Butman Ford. There were no warning…”
filed Jul 7, 2023
“The truck has had a complete body frame failure. The entire frame is rusted through with large holes. I am unable to put it on a jack to change the tires. It has failed inspections and has not been inspected since 2019. I have a 1992 ford truck that has NO rust issue on the frame. This year is a…”
filed Apr 20, 2022
Verbatim excerpts from complaints filed with NHTSA. Reports are not independently verified.
Related service bulletins
For 2000-2024 Ford and Lincoln vehicles, swapping a module from a vehicle for diagnosis purposes is likely to cause errors and is not recommended. It is also not recommended to order a replacement module using a vehicle…
SSM 51536 · Service Bulletin/Repair Instructions · issued Apr 4, 2023This 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 corrosion concerns appearing as bubbled…
TSB 20-2233 · Service Bulletin/Repair Instructions · issued Jul 13, 2020Some 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 accompanying white dust. Panel…
TSB 19-2026 · Service Bulletin/Repair Instructions · issued Feb 7, 2019
Structure problems in other F-150 years
| Year | Reports | Share |
|---|---|---|
| 2025 F-150 | 3 | 3% |
| 2024 F-150 | 2 | 1% |
| 2023 F-150 | 21 | 5% |
| 2022 F-150 | 14 | 2% |
| 2021 F-150 | 35 | 4% |
| 2020 F-150 | 22 | 3% |
| 2019 F-150 | 31 | 2% |
| 2018 F-150 | 191 | 8% |
| 2017 F-150 | 109 | 8% |
| 2016 F-150 | 199 | 10% |
| 2015 F-150 | 147 | 9% |
| 2014 F-150 | 31 | 2% |
Other reported problem areas on the 2004 Ford F-150
Counts are unique NHTSA complaints naming this component group. Complaints are unverified owner reports; mileage is computed only from complaints that included a usable odometer reading.