2004 Ford F-150 Service and Repair Manual

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Factory-Grade Data

The 2004 Ford F-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

  • Lariat Crew Cab Pickup 4-Door
  • STX Extended Cab Pickup 4-Door
  • XLT Crew Cab Pickup 4-Door
  • XLT Extended Cab Pickup 4-Door
  • XL Standard Cab Pickup 2-Door
  • Flotillera Standard Cab Pickup 2-Door
  • FX4 Extended Cab Pickup 4-Door
  • FX4 Crew Cab Pickup 4-Door
  • XLT Standard Cab Pickup 2-Door
  • STX Standard Cab Pickup 2-Door
  • FX4 Standard Cab Pickup 2-Door
  • Lariat Extended Cab Pickup 4-Door
  • XL Extended Cab Pickup 4-Door

Engines covered

  • 5.4L 330Cu. In. V8 GAS SOHC Naturally Aspirated
  • 4.6L 281Cu. In. V8 GAS SOHC Naturally Aspirated
  • 4.2L 256Cu. In. V6 GAS OHV 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 F-150 Recalls & Complaints

NHTSA #11V38500029/07/2011Component: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:MOUNTING

FORD IS RECALLING CERTAIN 1997 THROUGH 2003 MODEL YEAR FORD F-150, 2004 MODEL YEAR FORD F-150 HERITAGE, 1997 THROUGH 1999 MODEL YEAR F-250 LESS THAN 8,500 LBS. GROSS VEHICLE WEIGHT

Consequence

AS A RESULT OF THE CORROSION, ONE OR BOTH STRAPS MAY FAIL ALLOWING THE FUEL LINES TO SEPAR

Remedy

FORD WILL NOTIFY OWNERS AND INSTRUCT THEM TO TAKE THEIR VEHICLES TO A FORD OR LINCOLN DEAL

NHTSA #04V20000026/04/2004Component: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

CERTAIN PICKUP TRUCKS MAY HAVE A FUEL TANK WITH LOCALIZED DEPRESSIONS IN THE FUEL TANK WALL AT THE SEAM BETWEEN TOP AND BOTTOM HALVES OF THE TANK. IF A DEPRESSION IS LARGE ENOUGH,

Consequence

IF LEFT UNCORRECTED, A FUEL LEAK COULD EVENTUALLY DEVELOP.

Remedy

DEALERS WILL REPLACE THE FUEL TANK ON THESE VEHICLES. OWNER NOTIFICATION BEGAN ON MAY 6,

NHTSA #11V10700023/02/2011Component: AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE

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 WIT

Consequence

THE DRIVER SIDE FRONTAL AIR BAG COULD INADVERTENTLY DEPLOY INCREASING THE RISK OF INJURY O

Remedy

FORD WILL NOTIFY OWNERS AND INSTRUCT THEM TO TAKE THEIR VEHICLES TO A FORD OR LINCOLN/MERC

NHTSA #04V44300013/09/2004Component: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:MOUNTING

ON CERTAIN TRUCKS EQUIPPED WITH 4.2L, 4.6L AND 5.4L GASOLINE ENGINES, THE FUEL TANK MAY HAVE A DEPRESSION AT THE SEAM BETWEEN THE TOP AND BOTTOM HALVES OF THE TANK. IF A DEPRESSI

Consequence

FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.

Remedy

DEALERS WILL REPLACE THE FUEL TANK. THE RECALL BEGAN SEPTEMBER 17, 2004. OWNERS SHOULD C

NHTSA #06E02300013/03/2006Component: EXTERIOR LIGHTING:HEADLIGHTS

CERTAIN ANZO COMBINATION HEADLAMP ASSEMBLIES SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES. SOME COMBINATION LAMPS ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS WH

Consequence

WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING I

Remedy

ANZO WILL NOTIFY OWNERS AND REPLACE THE HEADLAMPS FREE OF CHARGE. THE RECALL BEGAN MAY 9,

NHTSA #09E02500011/05/2009Component: EXTERIOR LIGHTING:HEADLIGHTS

DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HE

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

DOPE, INC. WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAM

NHTSA #09E01200007/04/2009Component: EXTERIOR LIGHTING

SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HE

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAM

TSB #10235153

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 identification numbe

TSB #10205038

Safety recall 11S21 - Fuel tank strap fracture - requests for recall service action

TSB #10177863

This 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 and/or peeling paint wi

TSB #10172885

This SKU is an Oil Dipstick. The customer communication requested return of unsold inventory to inspect the dipstick tube. The dipstick tube inner diameter may be small enough that it prevents installation of the OE dipstick.

TSB #10165713

Some 2002-2008 F-Super Duty, F-150 and Mark LT vehicles may exhibit concern during or after programing the VSM. The programming may fail or vehicle symptoms such as inoperative door locks, dome lamps, door ajar indicators or auto lamps may

TSB #10156863

Some 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 replacement is recommended. Fo

TSB #10155551

Some 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 replacement is recommended. Fo

TSB #10143079

Various vehicles equipped with a 4.6L, 5.4L, 6.8L modular 3 valve engine built on or before 8-Jan-2016 may exhibit symptoms that may include upper end engine noise, rough running, misfire and/or engine damage. If diagnosis leads to only cam

Showing the 8 most recent of 149 technical service bulletins on file with NHTSA.

20110706Component: AIR BAGSCrash reportedFire reported1 injured

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT WAS DRIVING 50 MPH WHEN HE CRASHED INTO ANOTHER VEHICLE. THE AIR BAGS DID NOT DEPLOY AND THE SEAT BELTS FAILED TO RESTRAIN THE

20110706Component: SEAT BELTSCrash reportedFire reported1 injured

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT WAS DRIVING 50 MPH WHEN HE CRASHED INTO ANOTHER VEHICLE. THE AIR BAGS DID NOT DEPLOY AND THE SEAT BELTS FAILED TO RESTRAIN THE

20100907Component: AIR BAGS:FRONTALCrash reportedFire reported1 injured

2004 FORD F-150 FRONTALLY IMPACTED A TREE; PASSENGER'S AIR BAG DEPLOYED; DRIVER'S AIR BAG DID NOT DEPLOY UPDATED 09/16-10 *BF THE ENGINE COMPARTMENT CAUGHT ON FIRE. (LAWYER ON B

20051123Component: SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITEDCrash reportedFire reported1 injured

DT: THE CONTACT'S WIFE WAS DRIVING THE VEHICLE AND THE BRAKES WERE NOT WORKING PROPERLY. WHILE TRAVELING DOWN HILL THERE WHERE NO BRAKES. THIS, IN TURN, CAUSED THE CONTACT'S VEHIC

Showing the 4 most serious of 2429 complaints filed with NHTSA.

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