Top 5 1997 to 2004 Ford F150 Problems

While there’s nothing particularly wrong with the Ford F-150, here are the top 1997 to 2004 Ford F-150 problems owners run into with the 10th generation.

Ford F150 Problems: 10th Gen (1997 to 2004)

1A Auto mechanic reviewing the top 5 problems with the 1997 to 2004 Ford F-150, 10th generation

1. Exhaust Manifold Ticking

Symptoms of a Bad Exhaust Manifold

  • Ticking from the engine area

Causes of Exhaust Manifold Ticking

The 1997 to 2004 Ford F-150’s exhaust manifold can crack, warp, or the studs can break.

How to Fix Exhaust Manifold Ticking

Replace the exhaust manifold.

More on how to inspect an exhaust manifold

2. Differential Pressure Feedback (DPFE) Sensor Failure

Symptoms of a Bad DPFE Sensor

  • Check engine light

Causes of a Faulty DPFE Sensor

The DPFE sensor has to do with the EGR system. It takes measurements of the exhaust flow exiting and, basically by vacuum, let’s the computer (PCM) know when to open or close the EGR. The DPFE sensor circuit board can melt if the catalytic converter is clogged. Hoses can melt from the heat rising, and the plastic board in the sensor can melt also.

How to Fix a DPFRE Sensor

The DPRE sensor is located on driver side of the intake. We don’t recommend just replacing the hoses and sensor. Check the catalytic converter, because it’s likely clogged if you have this problem.

3. Howling Rear Differential

Symptoms of Problems with the Rear Differential on the 1997 to 2004 Ford F-150

  • Howling from the rear differential when driving or turning
  • Differential fluid leaking

Causes of a Howling Rear Differential

The clutch kits can fail and can need an updating and replacement. The differential can also leak fluid and cause issues.

How to Fix a Howling Rear Differential

Before fixing the differential, check and make sure a leak isn’t causing any problems. Ford released a technical service bulletin (TSB) for this problem. To fix this, steps include rebuilding with a new differential bearing kit.

4. Heater Not Working

Symptoms of a Heater Not Working

  • Might feel heat coming from the floor but not the vents or defrost
  • Heat is turned on but no heat

Causes of a Heater Not Working

The blend door actuator can fail and cause issues when trying to use the heat. The blend door actuator can crack or freeze up and stay locked in the position of pushing cold air.

How to Fix Problems with the Heater Not Working in the 1997 to 2004 Ford F-150

If the blower motor or fan is working, there’s likely a problem with the blend door actuator. You can access and replace the blend door actuator from under the dash.

5. Spark Plug Problems

Symptoms of Spark Plug Problems in the 10th Gen Ford F-150

  • Spark plugs blow out of the engine
  • A loud pop sound from the engine and a check engine light flashing

Causes of Spark Plug Problems with the 1997 to 2004 Ford F-150

The spark plug can run into issues staying secure in the Triton engines.

How to Fix Spark Plug Problems

Threaded insert to fix spark plugs blowing out on the 97 to 04 Ford F150

If the spark plug pops out of the engine, you’ll need to install a threaded insert to bore out the hole larger.

Shop Quality Auto Parts

Fix common 10th gen Ford F150 problems yourself with quality auto parts at 1aauto.com

Ford F-150 10th Generation Model Years

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Top 5 1997 to 2004 Ford F-150 Problems - 10th Generation - 1A Auto
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Top 5 1997 to 2004 Ford F-150 Problems - 10th Generation - 1A Auto
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Learn the top 5 issues owners experience with the 10th gen Ford F-150 as our expert mechanics at 1A Auto review the most common 1997 to 2004 Ford F150 problems drivers may have
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1A Auto
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One thought to “Top 5 1997 to 2004 Ford F150 Problems”

  1. Now do films about 2005 Ford F-150 5.4L engines. You may need to write an encyclopedia about this!!!
    Thank you and will look forward to hear about 2005 F-150’s.

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