The 2004 Ford F-150 has 8 recalls, the most serious being a fuel tank seam defect that can allow fuel to leak and create a fire risk, and a clockspring wire that can chafe against the driver airbag horn plate and cause the airbag to deploy unexpectedly.
The fuel tank issue appears across several filings but describes the same problem: a depression at the seam between the top and bottom halves of the tank allows fuel to seep through the tank wall. Early signs include a fuel smell or the "Service Engine Soon" light coming on. A separate but related fuel system concern involves corroded fuel tank mounting straps that can fail, allowing the fuel lines to separate from the tank or the tank itself to drop and contact the ground. On the lighting side, certain Eagle Eyes replacement headlamps do not meet federal photometric standards and can reduce road visibility at night, raising the risk of a crash.