NHTSA Complaint #10387309 — 2004 FORD F-150

WHILE TRAVELING ON I-70, WESTBOUND THROUGH ILLINOIS, MY FORD F-150 BEGAN SHAKING VIOLENTLY AND WAS BARELY CONTROLLABLE. THERE WAS NO PREVIOUS WARNING OF ANY KIND THAT THERE WAS A PROBLEM WITH THE TRUCK. I MANAGED TO GET TO AN EXIT AND GOT THE TRUCK TO THE NEAREST FORD DEALER, IN THE SMALL TOWN OF GREENVILLE, IL. THE FORD MECHANIC DIAGNOSED THE PROBLEM AS CATASTROPHIC ENGINE FAILURE. AT LEAST TWO VALVE STEMS HAD BROKEN AND THE VALVES HAD FALLEN INTO THE CYLINDERS. THEY COULD NOT TELL ME WHAT CAUSED THE FAILURE BUT SHOWED ME A FEW OF THE PARTS THEY HAD REMOVED (A BROKEN VALVE SPRING, PIECES OF VALVE STEM AND A FROZEN ROCKER ARM). THE ENGINE HAD BEEN SCRUPULOUSLY MAINTAINED AND THE OIL AND FILTER WERE CHANGED AT LEAST EVERY 5000 MILES. THE ENGINE WAS CLEAN AND THERE WAS PLENTY OF OIL. I HAVE SINCE SEEN SEVERAL ON-LINE POSTS ABOUT THIS ENGINE (FORD'S 5.4 LITER V-8 GAS) FAILING DUE TO FAULTY VALVE SPRINGS FAILING. I BELIEVE THIS ENGINE HAS SERIOUS FLAWS THAT MIGHT CAUSE SERIOUS PROBLEMS IF ENGINE FAILURE HAPPENS AT HIGH SPEED IN TRAFFIC. FORTUNATELY, I WAS IN VERY LIGHT TRAFFIC WHEN THE FAILURE HAPPENED.