While driving, the vacuum solenoid for the 4 wheel drive tries to engage the 4 wheel drive - even at highway speeds- resulting in a horrible sound. The sound was "like I had run over a shopping cart or hit something in the road and was dragging it under the truck". this happened 5 times in two days in less than 30 miles of total driving. The noise is so loud and alarming that it made me immediately apply the brakes and pull to the side of the road because I thought I had hit something/someone. At first I wondered if my muffler or drive shaft or some other part had fallen off of the truck. This "false engagement" of the 4 wheel drive happens without any warning in all kids of driving conditions (slow, fast, breaking or accelerating). A new, redesigned (now has a cover on it to keep moisture out- which was causing the failure) vacuum solenoid was installed on truck - a $27 part. Dealership kept old part. Tech. At dealer told me that this part will go bad at some point and need replacing on all the trucks with the part. He said "not if but when". Ford knew about the problem - hence the redesigned part. Ford has not notified owners of this part and it's impending failure.

- Delmar, MD, USA

Engine shut down while driving 30 mph this happened twice dealer scanned for code and found code P2104 idle air control valve stuck closed replaced body and motor assembly 6036 WP94 no charge under warranty recall replace switch 6306 WP94 and vacuum tebe 6L3Z*9W431.

- Conway, SC, USA

5.4L, supercrew-- engine was replaced by Ford at 38,000 miles (after complaint to Ford cust svc) due to injector failure and cylinder hydra-lock. Now at 46,000 miles, complete transmission failure. Only used for daily driver, no towing, never off-road. Transmission failed on initial start on 60 degree morning, no pre-failure indicators. Paid $2800 for transmission rebuild. I have noticed a fairly large number of problems reported on sub-standard factory transmission and engine parts on Ford trucks.

- Andrews Afb, MD, USA

The contact owns a 2005 Ford F-150. While driving 55 mph, the vehicle stalled when the brake pedal was depressed. When the failure occurred, the check engine indicator illuminated on the instrument panel. The dealer repaired the failure and they stated that the sensors failed; however, the failure still persists. The vehicle was taken to the dealer approximately two times. The Ford manufacturer issued a recall for the power booster line. The vehicle has not been taken in to have the recall repaired. The failure mileage was 18,000 and current mileage was 35,820.

- Perris, CA, USA

Slowing to a stop at light. Was gong about 25. Almost at complete stop, when engine went to almost full throttle. I pushed brake harder but still drove into the parked car in front of me. No damage done, just a very hard bump. Turned key off, put in park. Car in front of me drove ahead and parked to side of road. I started the engine and it immediately went to very high throttle. Turned key off, waited 20 seconds, tried again. And it was ok. I pulled ahead and off to side to talk to other person involved. After 15 mins I calmed down and went home.

- Thompson, OH, USA

The contact owns a 2005 Ford F-150. On two separate occasions, the vehicle misfires and loses power, but does not have to be restarted. The dealer stated that the spark plugs may need to be changed; however, they may break off in the process. The current mileage was 52,838 and failure mileage was 52,700.

- Ft. Rucker, AL, USA

I bought a truck at selinsgrove Ford about a month ago. The night I got it home I noticed it sounded like a diesel.. that was fine then when you get up to about 55mph its has a bad shimmy and I had it back a couple of different time and they say they don't know what to do about it now. It had to be wrecked or something because there was a crease on the bumper and the drivers side door needed adjusted.

- New Berlin, PA, USA

I have a 2005 Ford with the 5.4 lt. Engine. At the 63,000 mile mark I decided to replace the spark plugs due to slight idle problem. After spending $102 on a new set of spark plugs I ran into the problem of the spark plug's lower half breaking inside the cylinder head, it took me two days to complete the replacement due to a faulty design of the spark plugs. The spark plug steel shell is made of two parts a top half that has the threads made onto it and the lower half that has the hood were the gap is made between the electrode and itself allowing for a spark to happen. The problem being in that these two parts are only crimped together, the crimping is not strong enough and the lower half due to the carbon build up maintains itself jammed in the cylinder head while the top part slips at the crimping area turns and is threaded out causing the separation, I was going to weld the two parts together so that the next time I had to change the spark plugs the lower half would turn with the top half of allowing it to break itself free from the carbon build up and not break in the cylinder head but decided not to go with it too much trouble I'll get rid of the truck before the spark plug need replacing. Well what I hope to get out of this is that Ford revamps it's spark plug design by either welding these two parts together or making the spark plug shell a 1 piece so that I don't have this problem again if I do decide to buy another Ford product after the hell I had to go though changing these spark plugs.

- San Ysidro, CA, USA

2004-2007 F-150 truck say to change the spark plugs out at 100K. The dealers say $300 to change but if they snap of it could cost more" they almost always snap!!! Ford has a spark plug that snaps in half when trying to change out do to carbon build up. Bad design and then is about $88 hr for a tech to fix. Almost all dealerships break them and cost the owner $1000 to $1800 for a spark plug change do to poor design" everyone is breaking and Ford is making a ton of money on a problem that should be recalled!!!!! if you research this on the web need I say no more....I bought a $32,000 truck that I cant change the spark plugs.. something really needs to happen. Thank you ken belk

- Waterford, MI, USA

My truck has 56K on it bought it used with 35K on it when it starts runs with high idle and the top end ticks really bad the ticking does not go away at all speeds at a stop light it sounds like a diesel tic tic tic sounds like a lifter is stuck. I put "lucas" in it to try to make it go away then I changed the oil ran about two weeks with no difference and changed it again and no change called Ford dealer they couldn't help they said I would have take it in and get charged $165. Then I changed the spark plugs maybe a fouled plug that wasn't it there goes 120 bucks a couple of weeks ago my wife was driving on the freeway and the drivers side window falls the window regulator broke $140 replaced that already. The passenger seat belt locks up sometimes now to the front the steering wheel shakes really bad when you apply the brakes turned the rotors at Napa $20 new brake pads $90 at kragens balanced tires free I work at a tire shop shaking went away for about three days 350 miles later the shaking is back with a vengeance checked the balancing on the tires they were good rotors are out of shape again still on there now and the shaking is getting worse I cant afford them right now so they will stay there hooked up the snap on ehtos computer to it and registers that two sensors have an open circuit but no explanation for top end noise injectors might be bad.

- Fresno , CA, USA

At 2:.00 am the morning of April 24, 2008 we were awakened by our seriously agitated dog, to find our 2005 Ford F150 engulfed by flames and to soon see our other two vehicles and our home destroyed by fire. A total of four investigators have concluded that the cause of the fire is the Ford F150. The truck is presently under lock and key and the investigation continues to find the exact component.

- Waynesboro, VA, USA

The contact owns a 2005 Ford F150. While driving, the vehicle lost some power and the engine light illuminated which read engine failed soft mode. The consumer took the vehicle to the dealer, but the could not duplicate the problem. The dealer told the consumer the vehicle was safe to drive, however once the consumer approached a light, the vehicle stalled, the fail safe light came on and the brakes locked up. Smoke emitted from under the hood and then there was a fire. The vehicle was destroyed.

- Mililani, HI, USA

The contact owns a 2005 Ford F-150. When slowing down for a turn or approaching a stop, the accelerator pedal does not retract. On April 16, 2008, the vehicle completely shut off. On January 7, 2008, the dealer replaced the throttle position sensor, but the failure recurred two additional times. The contact has an appointment with the dealer on April 21, 2008 to take another look at the vehicle and attempt to identify the failure. The speed was unknown. The failure mileage was 35,000 and current mileage was 38,300. The consumer stated the problem occurred 5 times prior to January 7th 2008 and 2 times between January 7th and April 16th. Updated 05/05/08

- Downingtown, PA, USA

The truck started cutting out and acting like it was not getting any fuel. We continued to drive the truck home and turned the truck off. The next day went out to start truck did not want to start had it towed to Ford dealer. They said due to fuel injection malfunction the motor had to be replaced.

- Hale Center , TX, USA

Needed tuneup, 75,549 miles, took F-150 truck to local auto service facility for a tuneup. 2 plugs broke off in head due to plug failure plug motorcraft # pzt1F. Thus the head had to be removed to take out the broken plug. This was very expensive. We have one of the spark plugs used in this vehicle.

- Trevor, WI, USA

The contact owns a 2005 Ford F-150. The contact stated that the vehicle will shut off and the steering wheel will lock while driving. The failures occur without warning. The service engine light illuminated on the dashboard and displayed that the engine has malfunctioned. The dealer repaired the failure three times by replacing the spark plugs and the chassel body. The speed was unknown. The current mileage was 70,000 and failure mileage was 50,000.

- New Orleans, LA, USA

Experienced sudden loss of power steering and power brakes while normal and routine driving on highway. No warning of any kind that failure was about to occur. Engine ran rough, engine light warning came on after brake and steering failure and then engine shut off. Narrowly avoided rear end collision and driving off the highway and into steep ravine. Was able to bring vehicle under control with a lot of effort to steer and emergency brake. Could have been injuries and/or fatal. Towed vehicle to Ford dealer. Dealer performed eec test and received codes P0171 and P0174. Dealer found vacuum hose from intake manifold to ebrake booster broken. Dealer removed intake manifold, replaced vacuum hose and intake gaskets, and reinstalled intake manifold and cleared codes. I have old parts.

- Santa Clarita, CA, USA

: the contact stated while sitting inside the vehicle there was an odor of gasoline. The vehicle was inspected by the local dealership, and they replaced 7 fuel injectors, 8 spark plugs, and ordered a fuel rail. These attempts to solve the problem have been unsuccessful. Updated 01/25/06.

- Garnerville, NY, USA

A week after I had picked up my new 2005 Ford F150 lariat the 5.4L engine started knocking and sputtering. After taking it back to the dealer they determined that the problem was related to faulty sprockets on the cam shafts (bulletin ssm-18342). I brought it in for service and a week after getting it back the knocking and sputtering is still there and getting worse. Now I'm going back to the dealer insisting the engine be replaced. I don't expect a lot of cooperation.

- Monroe, CT, USA