2004 Ford E-150 Service and Repair Manual

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Factory-Grade Data

The 2004 Ford E-150 service and repair manual is a detailed, OEM-style reference for diagnostics, maintenance, and repair work. Use it to verify procedures, specifications, and system information before you start a job.

You'll find coverage across key vehicle systems with clear section structure, including wiring diagrams and powertrain, braking, steering, suspension, HVAC, and electrical topics. Digital format makes it easy to search while you work.

Trims covered

  • XL Standard Passenger Van 3-Door
  • Base Standard Cargo Van 2-Door

Engines covered

  • 4.6L 281Cu. In. V8 GAS SOHC Naturally Aspirated
  • 5.4L 330Cu. In. V8 GAS SOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2004 Ford E-150 Recalls & Complaints

NHTSA #09V10000027/03/2009Component: EQUIPMENT ADAPTIVE/MOBILITY

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

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 (PLEA

NHTSA #09V10200027/03/2009Component: EQUIPMENT ADAPTIVE/MOBILITY

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

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 (PLEA

NHTSA #04V44500013/09/2004Component: ENGINE AND ENGINE COOLING

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 TH

Consequence

THESE HOT PARTICLES MAY IGNITE THE AIR FILTER ELEMENT WITH THE POTENTIAL FOR AIR INDUCTION

Remedy

DEALERS WILL INSPECT AND REPLACE THE AIR FILTER ELEMENT. THE RECALL BEGAN SEPTEMBER 27, 2

NHTSA #04V44400013/09/2004Component: ELECTRICAL SYSTEM:WIRING

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 LI

Remedy

DEALERS WILL INSTALL A NEW FUSE IN THE ABS CIRCUIT AND INSTALL A HEAT SHIELD OVER THE ABS

NHTSA #11E04700008/11/2011Component: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

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 A

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 SAFE

TSB #10243490

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 same transmission is acceptable. After 30-J

TSB #10056196

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 CHASSIS, LOW CAB FORWARD. *PE

TSB #10055629

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 VOLTAGE. MODEL 2003-2007 F SUPER DUTY, 20

TSB #10022675

BRAKE BOOSTER SYSTEM MAY EXHIBIT A BRAKE PEDAL KICKBACK AND/OR GRABBING CONDITION WHEN APPLYING THE BRAKES. *NJ

TSB #10022243

LACK OF POWER DUE TO LOW FUEL PRESSURE - FUEL TANK LINER SEPERATION. *KB

TSB #10022232

HEADLIGHT ADJUSTMENT NEEDED. *KB

TSB #10021621

LACK OF POWER DUE TO LOW FUEL PRESSURE, FUEL TANK LINER SEPERATION. *KB

TSB #10021229

WATCH FOR OIL FLOW FROM THE BASE ENGINE OIL PUMP. VEHICLES EQUIPPED WITH A 6.0L DIESEL ENGINE. *KB

Showing the 8 most recent of 60 technical service bulletins on file with NHTSA.

20050531Component: SERVICE BRAKES, AIR:ANTILOCKCrash reported1 injured

WE PURCHASED OUR 2004 FORD EXPEDITION IN JULY, TOOK IT TO FLORIDA ON VACATION AND WHILE DRIVING ON THE INTERSTATE IT STARTED SHUDDERING. WHEN WE FINALLY GOT IT STOPPED (THE BRAKES

20050819Component: VEHICLE SPEED CONTROL:ACCELERATOR PEDALCrash reported

ON JULY 25, 2005 AT @ 10:00AM [XXX] WAS OPERATING MY 2004 FORD EXPLORER XLT (4 DOOR) VIN NO.: [XXX]. SHE WAS INTENDING TO BACK OUT OF THE STONE DRIVEWAY OF HER RESIDENCE LOCATED A

20250724Component: POWER TRAIN1 injured

The contact owns a 2004 Ford F-150. The contact stated that while parked when the vehicle suddenly rolled backwards downhill the contact's son attempted to get into the vehicle to

20160504Component: POWER TRAIN

VIBERATION IN REAR AND CLUNKING NOISR IN REAR WHEN STOPPING AT LIGHT THEN TAKING OF WHILE MAKING A RIGHT TURN

Showing the 4 most serious of 36 complaints filed with NHTSA.

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