Wow, I musta got a good one.
Only things I have had gone bad are:
the venerable 3rd brake lite seal
rolling fan clutch replace
rearend clutch pak
Otherwise Im lovin it!

 

Coming on 82,000 here

Had rotors replaced & rear axle seals fixed. At no cost

Only issue I have now is replacing lower ball joints.
Otherwise my truck has held up pretty good. No major complaints here

Better than my truck B4 (01 Chevy-Silverado)!

 

Lets see, 04 XLT 5.4L SC 60K mi. currently.At 53K 3 broken spark plugs from dealer, engine and trans removed because of it. Cam phasers replaced at same time of sparkplugs. Alternator replaced at 57K. And passanger front power window won't roll up. And now the steering wheel shimmy on the highway. I think ball joints are going.

 

hmm i got shimmy in my steering too. Perfectly fine below 40 though, I blame it on the 35's figure I need to get them rebalanced and aligned.

 

Trans replaced manifold split only got 45000km on her yet other then that no trouble

little boys wear bow ties big boys drive ford

 

I have 26000 miles on mine and the only real problem was the a/c wasn't
getting cold. The dealer found a leaking seal. Replaced and recharged the
system and now is ice cold. I keep mine garaged so it still looks and drives
like a brand new one. The undercarrage isn't even dirty. Probably helps
waxing the real wheel wells and washing everything I can reach. It's
still quiet but I have a magnaflow cat-back because I wanted to hear
a little v-8 sound. Still very quiet on the freeway but sounds real nice
accelerating. I also have a nagging surge at parking lot speeds when
a partially warm engine has been restarted, but that's about it. No
squeaks or rattles whatsoever. It's still the nicest driving vehicle I've
ever had and I've been driving since 1966. Has a lot better brake feel
than my 95 Camaro Z-28. Just like a big luxury car to me. I did have the
plugs changed at 23000 miles just for peace of mind. It never fails to
amaze me how some can be so problem free like mine and others have
a ton of issues. Mine was built in Kansas City in 02/04. Tires still look new
too.

 

I see you have the 2.5" leveling kit, I just removed mine. Maybe you should check your ball joints too.

 

Good point, mine was assembled in Canada. The guys with issues should post where the truck was assembled. Maybe has some bearing?

 

I don't think it really matters where the truck was built. Mine came from Kansas City November '03. The only thing I can say about mine is it's a first run build.

 

well my front left wheel almost fell off today, pretty sure the bearing went out

both front hubs are busted

and I've got a loud and annoying whine comin from the rear end when I'm on the gas

 

Bought my '04 Screw FX4 used with around 30K on it in Feb of '06. I have just under 60K now. Until recently, it has been great, aside from the rear diff leak, which was fixed no problem. A couple weeks ago, it started bogging down really bad. Took it to the Ford dealership 3 times, and $400 later, still bogging. It is now at the Lincoln dealership, and has been for the last 10 days. They can't seem to figure out the reason for the bogging. They replaced the intake manifold and the intake runner control actuator, thinking that was the problem. Well, it seems that now, the truck will go into shutdown mode at 40-50% throttle. The service manager is on the phone with Ford engineers daily. I love my truck and I am depressed because I have not been able to drive it for almost 2 weeks now

As far as the '09's are concerned, I am pretty sure that they are going to be basically the same truck, with a front end that resembles the new Expeditions. No big secret to me. I will wait until '10 or '11 to get a new one (as long as they can fix my '04!)

 

08/04 build date and I purchased in 08/04. Warranty expires in a few weeks. 24,000 miles and no trips to the dealer. However, I have been living with a few minor issues.

1. Flapping noise coming from the driver side fender at 75 mph when I have a cross wind only (happens alot in Kansas).
2. Engine noise (assume it is the cam phasers).

Issue #1: I think it is from the fender shroud. I bought metal to fabricate some braces, but haven't built yet. I do have a Bugflector brand bug deflector which sits higher than the Ford. I assumed the dealer would blame the issue on dirty air so I never took it in. Anyone else have this issue?

Issue #2: I only hear the "diesel" sound when I am outside the vehicle and it is running (rare) so I never took it in. Is this issue something I need to address while under warranty?

 

68,000 on my 04 SCREW 4X4 the following items have been replaced/or had problems; Front Rotors replaced under warranty, Control Head of A/C unit replaced under warranty, Electric Rear Window stopped working, Leaky 3rd Brake Light, 3 Coil Packs replaced at 57,000 miles, went ahead and replaced all plugs at that time, and just this week I started to have a terrible squeak from the front left/driver side suspension, diagnosed as lower ball joint gone bad. I probably will replace all shocks at that time with new Bilsteins. Leather drivers seat is showing a lot of wear. Otherwise it has been a good reliable truck

 

Still LOVE it!!! Nothing to complain about. 53K miles and still going. Have only had to replace pads and rotors.

 

I saw my old 2004 on a flat bed tow truck the other day!