2004 Ford E-150 problems
The Ford E-Series (also known as the Ford Econoline, Ford Econovan or Ford Club Wagon) is a range of full-size vans manufactured and marketed by the Ford Motor Company. Introduced for 1961 as the replacement of the Ford F-Series panel van, four generations of the model line have been produced. Marketed for both cargo and passenger transport configurations, the E-Series has been designed with multiple design variations for both retail and commercial sale, including vans, and commercial-grade cutaway van chassis and stripped chassis (a chassis without bodywork).
With over 8.2 million units sold since 1961, the Ford E-Series is the third-best selling van line in history (outranked only by the Ford Transit and Volkswagen Transporter). Ford retired the E-Series passenger and cargo vans after 2014, replacing them with the Ford Transit. As of current production, the E-Series remains offered exclusively in cutaway and stripped-chassis configurations. In 2021, the model line entered its 60th year of production (becoming the second current Ford line to do so).
The E-Series (cutaway/stripped chassis) is assembled by Ford at its Ohio Assembly facility (Avon Lake, Ohio), which has produced the model line since 1975. Prior to its closure, Lorain Assembly (Lorain, Ohio) assembled the model line from 1961 to 2005.
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Common 2004 Ford E-150 problems
The Ford E-150 2004, like any vehicle, has some common problems based on complaints from its owners. The most frequently reported issue is related to the engine and engine cooling, with 110 problems reported. This issue can manifest in various ways, such as rough running engines, misfires, and engine oil leaks from the cylinder head area.
Rough running engines and misfires can be caused by faulty ignition coils or ignition coil boots. When the rubber boot that insulates the coil dries and cracks, it can allow arcing, leading to engine misfires. Replacing the ignition coil mechanism can cost between $140-$200, depending on the E-Series Model and Year.
Engine oil leaks from the cylinder head area can be caused by a faulty cylinder head gasket. If the gasket is damaged, it is recommended to replace it, along with the mating surfaces on the cylinder head and block. In extreme cases, the cylinder head may need to be replaced. The average cost for replacing a head gasket is between $1100-$1400.
Another common problem is the front end making a rattle noise over bumps. This issue can be caused by excessive play in the upper and lower ball joints due to moisture entry and lack of lubrication. Replacing one ball joint can cost around $250, while replacing both is about $550.
Loud popping noises and misfires can be caused by a spark plug that has been dislodged from the cylinder head, causing the threads on the spark plugs to be stripped. If the vehicle is still under warranty, it is recommended that the cylinder head be replaced. If it is not under warranty, using "Lock-N-Stitch" aluminum inserts to replace threads in the cylinder can be a solution, starting at around $500 just for the tool kit.
Coolant leakage from the heater core can be caused by electrolysis that runs through the coolant, leading to corrosion and deterioration of heater core and radiator parts. Replacing the heater core is a $200-$300 fix. Adding ground straps can help prevent future corrosion of components.
These common problems with the Ford E-150 2004 can lead to increased repair costs, making an extended vehicle protection plan a valuable investment. Through Zubie Perks, you can get $100 off an extended warranty package from CARCHEX, the leading auto warranty insurer.
What is the transmission problem on a 2004 Ford f150?
The transmission of the 2004 F-150 tends to overheat frequently. This may have been because the transmission cooling assembly wasn't good enough to provide the necessary cooling. The overheating resulted in abnormal expansion of the gears. The gears would grind against each other and would produce metal shavings.
Why does my Ford e150 shut off while driving?
The most common reasons a Ford E-150 engine stalling are the fuel system, the air intake system, or the ignition system.
What years did Ford have bad transmissions?
The Ford Focus transmission problems hit the vehicles marketed between 2010 and 2016. All the affected cars belonged to Focus, Fiesta, and EcoSport models equipped with a Powershift automatic transmission.
Is there any recalls on a 2004 Ford F-150?
FORD IS RECALLING CERTAIN MODEL YEAR 2004-2006 F-150 PICK UP TRUCKS AS WELL AS CERTAIN MODEL YEAR 2006 LINCOLN MARK LT VEHICLES. IF THE CLOCKSPRING JUMPER WIRE COMES IN CONTACT WITH THE DRIVER SIDE FRONTAL AIR BAG LOWER HORN PLATE, THE WIRE INSULATION MAY BECOME CHAFED, CREATING A POTENTIAL FOR A SHORT CIRCUIT.
What is the transmission problem on a 2004 Ford f150?
The transmission of the 2004 F-150 tends to overheat frequently. This may have been because the transmission cooling assembly wasn't good enough to provide the necessary cooling. The overheating resulted in abnormal expansion of the gears. The gears would grind against each other and would produce metal shavings.
Why does my Ford e150 shut off while driving?
The most common reasons a Ford E-150 engine stalling are the fuel system, the air intake system, or the ignition system.
What are 3 common signs of transmission trouble?
SIGNS OF TRANSMISSION TROUBLE
- GEARS WON'T SWITCH. If your automatic transmission vehicle won't shift gears or it struggles to shift, it could be a sign of low or contaminated transmission fluid. ...
- CHECK ENGINE LIGHT. ...
- SLIPPERY GEARS. ...
- SHAKING AND KICKING. ...
- BURNING SMELL. ...
- NOISY IN NEUTRAL. ...
- LEAKY FLUID. ...
- TRICKY TRANSITIONS.
What are the warning signs of transmission problems?
Here are seven signs to look for if you suspect your transmission has a problem.
- Clunking. Have you noticed that your car is making some new sounds that you have never heard before? ...
- Burning Smell. ...
- Gears Are Grinding. ...
- No Response or Slow Response. ...
- Fluids Are Leaking. ...
- There's a Light On. ...
- Neutral Is Noisy.
2004 Ford E-150 complaints
The NHTSA has received 0 complaints about various vehicle components related to the 2004 Ford E-150.
You can leave your car complaint via the special form below.
2004 Ford E-150 recalls
The National Highway Traffic Safety Administration (NHTSA) has issued 6 recalls for different components of the 2004 Ford E-150.
- Manufacturer: FORD MOTOR COMPANY
- Components: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY
- Summary: 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.
- Consequence: A FUEL LEAK IN THE PRESENCE OF AN IGNITION SOURCE MAY RESULT IN A FIRE.
- Remedy: 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.
- Manufacturer: VAN CONVERSIONS OF LEHIGH VALLEY INC.
- Components: EQUIPMENT ADAPTIVE/MOBILITY
- Summary: 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.
- Consequence: THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE UNINTENTIONALLY.
- Remedy: 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.
- Manufacturer: VAN CONVERSIONS OF LEHIGH VALLEY INC.
- Components: EQUIPMENT ADAPTIVE/MOBILITY
- Summary: 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.
- Consequence: A LIFT OCCUPANT CAN BE INJURED SHOULD THE LIFT BEGIN TO STOW UNINTENTIONALLY.
- Remedy: 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.
- Manufacturer: UFI FILTERS USA
- Components: FUEL SYSTEM, GASOLINE
- Summary: 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.
- Consequence: FAILURE OF THIS CONNECTION COULD LEAD TO FUEL SPILLAGE AND, IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.
- Remedy: 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.
- Manufacturer: FORD MOTOR COMPANY
- Components: ENGINE AND ENGINE COOLING
- Summary: 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.
- Consequence: THESE HOT PARTICLES MAY IGNITE THE AIR FILTER ELEMENT WITH THE POTENTIAL FOR AIR INDUCTION SYSTEM DAMAGE OR UNDERHOOD FIRE.
- Remedy: 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.
- Manufacturer: FORD MOTOR COMPANY
- Components: ELECTRICAL SYSTEM:WIRING
- Summary: ON CERTAIN VANS, A DIODE IN THE ANTI-LOCK BRAKING SYSTEM (ABS) MODULE MAY EXPERIENCE AN ELECTRICAL SHORT.
- Consequence: 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.
- Remedy: 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.
Additional sources
More sources of information about 2004 Ford E-150 problems:
Ford E150 2004: Troubleshooting Misfire Issues | JustAnswer
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