NHTSA Complaint #10596809 — 2004 FORD F-150

WE ALWAYS TAKE OUR TRUCK TO THE FORD DEALER FOR SERVICE.I HAD BEEN TELLING THE SERVICE ADVISOR FOR YEARS THAT WE HEARD AN AIR BUBBLE NOISE WHEN ACCELERATING. THEY KEPT SAYING EVERYTHING IS FINE. AS SOON AS OUR EXTENDED WARRANTY WAS OVER, THEY THEN SAID I HAD AN EXHAUST LEAK. I TOOK IT TO A 3RD PARTY MECHANIC AND IMMEDIATELY THEY WERE ABLE TO DETERMINE IT WAS BOTH EXHAUST MANIFOLDS AND IS VERY COMMON IN F150'S. THE PROBLEM IS WITH THE BOLTS BREAKING WHEN TRYING TO GET OUT, AND DUE TO FORD'S POOR DESIGN MORE THAN LIKELY WILL WARP AGAIN. THIS REPAIR COST IS OVER $1000 (FORD DEALER QUOTED $2165) AND SHOULD HAVE BEEN COVERED UNDER OUR EXTENDED WARRANTY IF DEALER WOULD HAVE ADMITTED IT HAD LEAK WHEN WE MENTIONED THE SOUND BEFORE. THE 3RD PARTY MECHANIC SAID ANY MECHANIC SHOULD HAVE BEEN ABLE TO DIAGNOSE THE DISTINCT SOUND JUST BY HEARING IT FOR A FEW SECONDS. MANIFOLD LEAKS ARE APPARENTLY FAIRLY NORMAL IN TRUCKS HOWEVER ONCE AGAIN FORDS DESIGN MAKES IT MUCH MORE DIFFICULT THAN MOST OTHER TRUCK MAKES TO REPAIR, ADDING MUCH MORE ADDITIONAL COST TO THE CONSUMER. *TR