2004 Ford Explorer
Problems, recalls and owner-reported issues
Power train is the leading concern among 1,408 owner complaints filed for this model year. This is the 7th highest complaint count among 26 Explorer model years with reports.
Of the 2004 reports, 75 involved a crash and 16 involved a fire. 105 people were injured.
What owners report most often
Recalls and investigations
Exterior lighting, headlightsMay 11, 2009
DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
DOPE, INC. WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON JULY 28, 2009. OWNERS MAY CONTACT DOPE, INC. AT 1-626-272-1798.
Campaign 09E025000 on NHTSA.gov
Visibility, glass, side/rearDec 11, 2007
CERTAIN CURVED TEMPERED REPLACEMENT GLASS MANUFACTURED BY HANGZHOU SAFETY GLASS LTD AND SUPPLIED TO SAFELITE BY AUTO TEMP INC., IDENTIFIED AS DOT-430, AND SOLD FOR USE ON CERTAIN DOMESTIC AND FOREIGN VEHICLES MAY NOT BREAK INTO SMALL PIECES AS EXPECTED OF TEMPERED GLASS AND FAILS TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 205, "GLAZING MATERIALS."
IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT(S) MAY BE SERIOUSLY INJURED BY SHATTERED GLASS.
SAFELITE WILL NOTIFY ITS RETAIL CUSTOMERS AND REPLACE THE GLASS FREE OF CHARGE. RETAIL CUSTOMERS CAN CONTACT SAFELITE TOLL FREE AT 1-888-843-2906. SAFELITE WILL NOTIFY ITS WHOLESALE CUSTOMERS AND REIMBURSE WHOLESALE CUSTOMERS FOR CURRENT INVENTORY AND AT A SPECIFIED RATE FOR REPLACING THEIR CUSTOMER'S GLASS. WHOLESALE CUSTOMERS CAN CONTACT SAFELITE'S WHOLESALE DIVISION, SERVICE AUTOGLASS TOLL FREE AT 1-888-246-6298. THE RECALL BEGAN ON JANUARY 15, 2008.
Campaign 07E104000 on NHTSA.gov
Exterior lightingMay 24, 2006
CERTAIN CK MOTORSPORTS COMBINATION HEADLIGHTS, CLEAR CORNER, BUMPER, AND SIDE MARKER LIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON THE PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
CK MOTORSPORT WILL NOTIFY OWNERS AND REPLACE THE NONCOMPLIANT LAMPS FREE OF CHARGE. THE RECALL BEGAN ON JULY 1, 2006. OWNERS MAY CONTACT CK MOTORSPORT AT 1-909-610-7211.
Campaign 06E049000 on NHTSA.gov
Exterior lightingMar 23, 2006
CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
PRO-A MOTORS WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE LAMPS. THE RECALL BEGAN ON APRIL 3, 2006. OWNERS MAY CONTACT PRO-A MOTORS AT 323-838-2988.
Campaign 06E026000 on NHTSA.gov
Representative owner complaints: engine and engine cooling
78 reports, newest first. Show all
Service brakes, Hydraulic, Engine and engine cooling, Power train, Jul 30, 2007
MULTIPLE PROBLEMS WITH MY EXPLORER. WHEN SHIFTING INTO REVERSE CAR JOLTS WITH A CLUNKING NOISE. ABS LIGHT IS ON AND 4X4 HIGH LIGHT FLASHES. SERVICE ENGINE LIGHT ON BUT NO HOSE LEAKS CAN BE FOUND. WRENCH LIGHT COMES ON EVEN AFTER TPS REPLACEMENT SUGGESTED BY OBD-II. VERY UNHAPPY WITH THIS VEHICLE. I HAVE OWNED 7 FORDS, THIS IS THE WORST I HAVE OWNED. *TR
Engine and engine cooling, Power train, Apr 24, 2007
FORD MOTOR COMPANY REGARDING DISSATISFACTION WITH LACK OF PERFORMANCE, RELIABILITY AND QUALITY OF 2004 FORD EXPLORER XLT**CC CONSUMER STATES HAS HAD MULTIPLE PROBLEMS WITH 2004 FORD EXPLORER SUCH AS VERY HARD SHIFTING GEARS FROM A PARKED POSITION, THE VEHICLE SHUT DOWN ON I95 HIGHWAY TWICE AND PEDALS BECAME INOPERABLE, VEHICLE ALSO SLAMS INTO GEAR AT HIGH SPEED AND WANTS TO REIMBURSED FOR THE MULTIPLE PROBLEMS OF HIS 3 YEAR OLD TRUCK. *TR
Engine and engine cooling, Mar 20, 2007
WE HAVE A 2004 FORD EXPLORER EDDIE BAUER, ORIGINALLY PURCHASED IN MAY 20'06 WITH APPROXIMATELY 30,000 MILES . AT APPROXIMATELY 36,000 MILES IN AUGUST 2006 WE WERE TOLD THAT THE HARMONIC BALANCER NEEDED TO BE REPLACED. THAT WAS ABOUT $500. MY HUSBAND DROVE IT TO WORK ON 3-19-07 AND EVERYTHING WAS FINE. HE TOOK IT TO LUNCH, EVERYTHING WAS STILL FINE, AND WHEN HE CAME OUT, HE TRIED TO START THE VEHICLEM AND IT WOULD NOT START. THERE WERE NO CHECK ENGINE LIGHTS, NO NOISES, NOTHING OUT-OF-THE-ORDINARY AT ALL. WE HAD IT TOWED TO A FORD DEALERSHIP, WHO RAN SOME TESTS, AND INITIALLY COULD NOT FIGURE IT OUT. THEY RAN MORE TESTS, AND CAME TO THE CONCLUSION THAT THE CAMS ARE NOT WORKING. THEY TOLD US THAT THE ENGINE NEEDS TO BE REPLACED. $5,600.00 TO REPLACE THE ENGINE WITH 46,000 MILES. FORD IS NOT OFFERING US ANY HELP. THEY REFUSE TO STAND BEHIND THEIR PRODUCT. THEY SAID IF WE HAD THE EXTENDED WARRANTY IT WOULD BE COVERED. BUT THE POINT IS THAT IT HAS 46,000 MILES. I NEED SOMEONE TO HELP ME BEFORE I EXPLODE! *AK
Engine and engine cooling, Mar 8, 2007
TL*- THE CONTACT STATED THAT WHILE PULLING THE 2004 FORD EXPLORER SPORT TRAK WITHN 30000 FAILURE MILEAGE INTO THE DRIVEWAY THE CONTACT PUT THE VEHICLE INTO PARK AND BEGAN TO HEAR A TAPPING FROM THE FRONT OF THE ENGINE. THE VEHICLE WAS TAKEN TO A DEALER, WHO DETERMINED THAT THE VALVE SPRING WAS WORN. THE VEHICLE HAS NOT BEEN REPAIRED. THE CURRENT MILEAGE WAS 33000.*AKI
Engine and engine cooling, Jan 3, 2007
ON THREE SEPARATE OCCASIONS, MY EXPLORER WOULD TURN OVER BUT REFUSE TO START. THE THIRD TIME IT TOOK 2 DAYS FOR IT TO FINALLY START. ON THE WAY TO THE SERVICE APPOINTMENT AT THE DEALER, THE SUV STALLED IN THE MIDDLE OF A VERY BUSY INTERSECTION. THE DEALER SAID THAT THEY COULDN'T PIN-POINT ANY PARTICULAR CAUSE BUT THEY DID HAVE A SERVICE BULLETIN THAT CALLED FOR UPDATING OF SOME SOFTWARE. *NM
Engine and engine cooling, Nov 21, 2006
DT*: THE CONTACT STATED WHILE DRIVING VARIOUS SPEEDS, THE ENGINE STALLED WITHOUT WARNING. AFTERWARDS, THE ENGINE WAS RESTARTED AFTER SEVERAL ATTEMPTS. THE VEHICLE WAS INSPECTED BY A DEALER WHO WAS UNABLE TO DUPLICATE THE PROBLEM. THE MANUFACTURER WAS NOT ALERTED.
Engine and engine cooling, Sep 21, 2006
STARTED OF BEING AN ENGINE VIBRATION, 2 MONTH LATER CRANKSHAFT PULLEY FAILURE. JUST MADE IT TO THE DEALERSHIP, THEY FIXED IT BUT MY CONCERNS ABOUT THE PULLEY COMING OFF ON THE HIGHWAY WORRY ME. *NM
Engine and engine cooling, Power train, Sep 8, 2006
DT*: THE CONTACT STATED THE AUTOMATIC TRANSMISSION WAS SLIPPING BETWEEN GEARS AND MADE CLUNKING NOISES. THE VEHICLE ALSO MADE HUMMING SOUNDS FROM THE ENGINE WHILE ACCELERATED OVER 55 MPH. THE VEHICLE HAS NOT BEEN TO A SERVICE DEALER.
Engine and engine cooling, Exterior lighting, Vehicle speed control, Aug 23, 2006
DT*: THE CONTACT STATED WHEN THE VEHICLE WAS STARTED, THE CHECK ENGINE LIGHT ILLUMINATED CONSTANTLY. THE VEHICLE WAS TAKEN TO A SERVICE DEALER WHERE THE SPEED CONTROL SWITCH, TURN SIGNAL SWITCH, AND OXYGEN SENSOR WERE ALL REPLACED.
Engine and engine cooling, Jul 19, 2006
AUTO GOES INTO FAIL SAFE MODE WHILE BEING DRIVEN. HAS HAPPENED 5 TIMES SINCE MAR. 10, 2006. I HAVE HAD IT IN THE SHOP ON MAR. 14, APRIL 22, APRIL 27, MAY 25, AND JUNE 12, ALL FOR THE SAME CONCERN. THE ENGINE BOGS DOWN TO 4 CYLINDERS AND LOSES POWER. THE FIRST 3 TIMES IT HAPPENED WHILE DRIVING AT AROUND 35 MPH THE LAST TWO TIMES IT HAS HAPPENED WHILE MERGING INTO TRAFFIC ON THE HIGHWAY COMING OFF A FEEDER ROAD. I'M AM AFRAID I WILL END UP IN A SERIOUS ACCIDENT. I PUT IT IN THE SHOP ON JUNE 12, 2006 AND JUST PICKED IT UP YESTERDAY ON JULY 17,2006. IT WAS IN THE SHOP FOR OVER A MONTH. AS I WAS FEEDING INTO TRAFFIC YESTERDAY EVENING OF JULY 17, THE ENGINE AGAIN DOWNSHIFTED INTO FAIL SAFE MODE CAUSING ME TO BOG DOWN. I HAVE LOST ALL FAITH IN THIS VEHICLE AND DO NOT WANT IT ANYMORE. I HAVE OWNED FORDS FOR THE LAST 35 YEARS AND HAVE NEVER HAD THIS KIND OF PROBLEM BEFORE WITH A FORD. *NM
Engine and engine cooling, Tires, May 9, 2006
I HAVE TWO ISSUES WITH A 2004 FORD EXPLORER. FIRST ISSUE THE SYSTEM THAT NOTIFIES TIRE PRESSURE HAS FAILED MULTIPLE TIMES. THE INDICATOR LIGHTS GO ON OR OFF WHEN THE TIRES ARE PROPERLY INFLATED OR NOT PROPERLY INFLATED. VEHICLE IS STILL UNDER ORIGINAL WARRANTY. DEALERSHIP WILL NOT FIX OR CHECK THE SENSORS ASSOCIATED WITH THIS AREA THEY CAN NOT RECREATE THE ISSUE. I HAVE DOCUMENTATION FROM PASSENGERS AND ANOTHER TIRE COMPANY OF THE ISSUE HAPPENING. SECOND ISSUE. 2004 FORD EXPLORER STALLED WHILE TURNING BRAKING AND STEERING LOCKED UP. IDENTICAL REACTION AS TO THE PROBLEM STATED IN THE FAILURE OF THE CAMSHAFT POSITION SENSOR IN OTHER VEHICLES FROM FORD THAT IS BEING INVESTIGATED. *NM
Engine and engine cooling, Feb 16, 2006
DT*: THE CONTACT STATED WHILE DRIVING 20MPH AND BELOW, THE ENGINE INTERMITTENTLY STALLED. THIS OCCURRED PRIMARILY WHEN THE VEHICLE ATTEMPTED TO SLOW DOWN OR STOP. THE VEHICLE WAS TAKEN TO THE LOCAL DEALERSHIP NUMEROUS TIMES FOR INSPECTION. THE DEALER WAS UNABLE TO DUPLICATE THE PROBLEM, THEREFORE NO REPAIRS WERE MADE.
Engine and engine cooling, Vehicle speed control, Feb 5, 2006
2004 EXPLORER HAS STALLED SEVERAL TIMES WITHOUT ANY WARNING. RESTARTS FINE. SEEMS TO BE WITH CRUISE ON AND GOING DOWN HILL AT SPEEDS BETWEEN 30 AND 40. HAS BEEN TO DEALERSHIP 3 TIMES AND THEY SAY THEY CAN'T DUPLICATE. HAVE CALLED FORD THEY SAY TAKE TO DEALERSHP. SEE SEVERAL OF SAME COMPLAINTS ON YOUR SITE. VERY DANGEROUS. HAS HAPPENED NUMEROUS TIMES DON'T KNOW WHAT TO PUT FOR INCIDENT DATE. *JB
Engine and engine cooling, Aug 15, 2005
DT: 2004 FORD EXPLORER. THE VEHICLE STALLED WHILE DRIVING, THIS HAPPENED AT DIFFERENT SPEEDS. WHEN THIS OCCURRED THE VEHICLE HAD TO BE ROLLED OFF OF THE ROAD. THE VEHICLE COMPLETELY SHUT DOWN. THE VEHICLE HAD TO BE TURNED OFF IN ORDER FOR IT COMES BACK ON. THE VEHICLE HAS BEEN TO THE DEALERSHIP, AND THEY COULD NOT FIND THE CAUSE OF THE PROBLEM. ALSO, COULD NOT DUPLICATE IT. *AK
Engine and engine cooling, Jun 16, 2005
WHILE DRIVING DOWN THE ROAD THE ENGINE WILL STALL. HAS HAPPENED SEVERAL TIMES, REPLACED MASS AIR FLOW SENSOR TOLD THIS WOULD FIX IT, BUT IT DID NOT. ALL BUT ONCE THE CAR HAS STARTED BACK UP IMMEDIATLY.
Engine and engine cooling, Jun 3, 2005
THE CONSUMER WAS MAKING A LEFT HAND TURN AND THE VEHICLE JUST SHUT OFF, COULDN'T STEER, AND COULDN'T PULL OFF. THE VEHICLE WAS IN THE MIDDLE OF THE ROAD AND THE CONSUMER RESTARTED THE VEHICLE ABOUT A MINUTE DOWN THE ROAD, WHEN IT HAPPENED AGAIN. THE BATTERY LIGHT CAME ON AND BRAKE LIGHT CAME ON, BUT FELT LIKE THEY WERE STILL WORKING.*AK *SB *NM
Engine and engine cooling, Power train, May 20, 2005
2004 FORD EXPLORER ENGINE SHUTS OFF AND THERE IS DIFFICULTY SHIFTING GEARS.***NO ANSWER REQUIRED***. *MR BOTH OF THESES MALFUNCTIONS PRESENT A DANGER AND A HAZARD AND ARE VERY SERIOUS DEFECTS. *BF *NM
Engine and engine cooling, Jan 22, 2005
'04 EXPLORER ENGINE SHUTS OFF AND STEERING WHEEL LOCKS UP WHILE DRIVING, CAR JERKS WHEN PUT IN REVERSE, FALSE FUEL READING TOOK TRUCK BACK TO DEALERSHIP, THEY DO NOT THINK ANY THING IS WRONG WITH THE TRUCK, THIS HAS HAPPEN FOUR TIMES. *JB
Engine and engine cooling, Power train, Jan 19, 2005
CAR TRANSMISSION WAS NOT RESPONDING CORRECTLY. AFTER SEVERAL TRIPS TO THE DEALER TO HAVE IT CHECKED OUT, THE REPLACED THE SOLENOID PACK SEVERAL WEEKS LATER WARNING LIGHT CAME ON WITH A BATTERY SYMBOL AND SAID HI TEMP LOW OIL. ENGINE DIED WHEN GOING TO PARK AND THEN AGAIN AT STOP LIGHT THE NEXT DAY. DEALER COULD NOT REPLICATE PROBLEM. TWO WEEKS LATER, ENGINE AGAIN DIED WITH A WRENCH SYMBOL AND SAID ENGINE FAILSAFE MODE. DEALER HAS HAD IT A WEEK AND CANNOT REPLICATE PROBLEM. DID FIND A PROBLEM WITH AND REPLACED ABS IN COMPUTER SYSTEM. *NM
Engine and engine cooling, Dec 14, 2004
WHILE DRIVING VEHICLE STALLED. CONSUMER WAS UNABLE TO RESTART VEHICLE, AND HAD IT TOWED TO THE DEALER. MECHANIC INFORMED CONSUMER THAT THE PROBLEM COULD NOT BE DUPLICATED. *AK
Engine and engine cooling, Structure, Nov 5, 2004
WHILE DRIVING SMOKE BEGAN COMING FROM THE ENGINE COMPARTMENT, THE ENGINE BOGGED DOWN AND THE ENGINE STALLED. *NM THE ENGINE RAN ROUGHLY AND SMOKE EMITTED FROM THE VEHICLE. SINCE THE REPAIR THE CONSUMER NOTICED A HISSING NOISE COMING FROM THE AIR CONDITIONER. AIR COMING THROUGH THE WINDSHIELD WAS THE REASON FOR THE NOISE COMING FROM THE AIR CONDITIONER. THE WINSHIELD WAS REMOVED AND RESEALED. *TC *JB
Engine and engine cooling, Oct 31, 2004
I BOUGHT A 2004 FORD EXPLORER XLT AT DARCARS TOYOTA IN SILVER SPRING MD. IT HAD ONLY 28,000 MILES. THE PLASTIC VALVE COVER WAS FOUND TO HAVE A CRACK WHERE ONE POURS THE OIL IN. THERE WAS AN OIL LEAK AROUND THIS AREA. APPLE FORD IN COLUMBIA, MD. SAID THIS WOULD NOT BE COVERED BY FORD WARRANTY. I THOUGHT FORD'S WARRANTY COVERS TO 3 YEARS OR 36,000 MILES. THIS VALVE COVER WAS OVER $400.00. WHY SHOULDN'T THIS BE COVERED. I SIGNED A PAPER THAT STATES THAT THE FORD WARRANTY SHOULD STILL BE IN EFFECT TO 36,000 MILES. I DON'T KNOW HOW OR WHEN THIS CRACK OCCURRED, BUT I HAVE ONLY HAD THE VEHICLE FOR 3 WEEKS. I THINK THIS SHOULD BE COVERED BY FORD WARRANTY. *JB
Engine and engine cooling, Sep 13, 2004
WHILE DRIVING VEHICLE STALLED. CONSUMER PULLED OVER AND RESTARTED THE VEHICLE. DEALERSHIP WAS NOTIFIED, BUT DID NOT RESOLVE THE PROBLEM. *AK
Engine and engine cooling, Aug 31, 2004
WHILE DRIVING AT ANY SPEED VEHICLE LOST POWER. *AK
Engine and engine cooling, Aug 3, 2004
VEHICLE STALLED ON 3 SEPARATE OCCASIONS WHEN DRIVING DOWN HILLS. VEHICLE WAS TAKEN TO THE DEALER, AND THEY WERE UNABLE TO DUPLICATE THE PROBLEM. *AK