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: structure
446 reports, newest first. Show all
Structure, Jul 12, 2010
CLOSING THE GLASS LIFTGATE ON A 2004 FORD EXPLORER, THE HINGE PIN PULLED THROUGH THE HINGE STRUCTURE CAUSING THE GLASS TO DROP. WHILE ATTEMPTING TO CATCH THE GLASS HAND WAS PINNED, BUT NO INJURY WAS SUFFERED. *TR
Structure, Jul 7, 2010
2004 FORD EXPLORER CRACK BACK TRUNK LIFT. *TR
Structure, Jun 9, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR LIFT GATE PANEL WAS CRACKED BELOW THE GLASS AND THE VEHICLE HAD NEVER BEEN INVOLVED IN ANY ACCIDENTS. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALERSHIP WHERE THE CONTACT WAS INFORMED THAT THE FAILURE WAS KNOWN BUT SHE WOULD BE RESPONSIBLE FOR REPAIR COSTS. THE VEHICLE HAD NOT BEEN REPAIRED AT THE TIME OF THE COMPLAINT. THE FAILURE MILEAGE WAS APPROXIMATELY 34,000. THE CURRENT MILEAGE WAS 35,373.
Structure, Jun 4, 2010
LETTER TO THE DEPUTY ADMINISTRATOR FROM SENATOR BURR ON BEHALF OF CONSTITUENT CONCERNING A CRACK IN THE PLASTIC SURROUNDING THE REAR WINDOW OF HER 2004 FORD EXPLORER *TGW
Structure, Jun 2, 2010
ON FRIDAY, MAY 28, 2010 MY HUSBAND ATTEMPTED TO OPEN THE LIFTGATE ON OUR 2004 FORD EXPLORER WHEN THE GLASS SEPARATED FROM THE VEHICLE AND LANDED IN HIS HANDS. IT DID NOT SHATTER BECAUSE HE WAS HOLDING ONTO IT. UPON INSPECTION, WE DISCOVERED THAT THE LEFT HINGE THAT CONNECTS THE LIFTGATE TO THE VEHICLE HAD SNAPPED. THE LIFTGATE IS CURRENTLY HANGING ON THE RIGHT HINGE AS WE DO NOT HAVE THE RESOURCES AT THIS TIME TO HAVE IT REPAIRED. I HAVE SINCE LEARNED THAT INVESTIGATION OF THE SAME PART WAS OPENED IN JUNE 23, 2004 AND CLOSED ON OCTOBER 24, 2008. ALTHOUGH ON PAGE 12 OF THE RESPONSE TO NHTSA FORD MOTOR COMPANY ADMITS THAT THIS FAILURE IS CAUSED BY "THE USE OF NON-OPTIMAL COATING ON THE STEEL PIN THAT JOINS THE TWO ZINC DIE-CAST SECTIONS OF THE HINGE", THE COMPANY ASSUMES NO FINANCIAL RESPONSIBILITY IN COVERING THE REPAIRS BECAUSE NO RECALL HAS BEEN ISSUED. I URGE YOU TO TAKE A PROACTIVE APPROACH TO THIS ISSUE AS IT COULD CAUSE SERIOUS INJURY AND THERE ARE NUMEROUS COMPLAINTS FROM CONSUMERS WHO ARE NOT AWARE THAT THEY CAN REPORT THEM TO THIS AGENCY. *TR
Structure, May 25, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THE PLASTIC LINING UNDER THE TAILGATE WINDOW WAS CRACKED. THE MANUFACTURER WAS CONTACTED SEVERAL TIMES BUT WOULD NOT PROVIDE ANY ASSISTANCE. THE DEALER ADVISED THEY WERE AWARE OF THE FAILURE HOWEVER THEY WERE NOT LIABLE FOR THE FAILURE WITHOUT A RECALL. THE CONTACT STATED THAT EVERY YEAR AND MODEL OF HIS VEHICLE THAT HE HAS OBSERVED EXHIBITS THE SAME FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE APPROXIMATELY 52,000. UPDATED 07/23/10*JB
Structure, May 17, 2010
THE REAR HATCH PANEL ON MY FORD 2004 EXPLORER CRACKED FOR NO APPARENT REASON. WHEN I WENT TO THE LOCAL DEALER HE SAID IT IS A COMMON DEFECT. WHEN I ASKED HOW MUCH IT WOULD COST TO REPAIR HE QUOTED ME $650.00 I HAVE SEEN DOZENS OF THIS MODEL IN MY DAILY DRIVING EXPERIENCE IN AZ. WHY HASN'T FORD MADE A REPLACEMENT FOR ALL OF US WHO HAVE THIS PROBLEM. IT IRRITATES ME THAT THEY SAY QUALITY IS NUMBER ONE BUT WON'T OWN UP TO A DEFECT THAT IS REPLETE IN EMAILS ON LINE? *TR
Structure, May 10, 2010
REAR HATCH CRACKED ON MY 2004 FORD EXPLORER. *TR
Structure, Apr 30, 2010
NOTICED THE LIFT GATE HINGE OF OUR 2004 FORD EXPLORER IS CRACKED. WE'VE NOW REMOVED THE GLASS FROM THE LIFT GATE AND ARE TRYING TO FIND PARTS FOR IT. THIS IS A POTENTIAL DANGER, NOT KNOWING WHEN THE GLASS CAN CRACK/SHATTER. THIS IS OBVIOUSLY A DEFECT IN THE MANUFACTURING OF THE PART. *TR
Structure, Apr 16, 2010
THE BACK PANEL UNDER THE BACK WIDOW CRACKED AND FORD WAS CONTACTED TO SEE IF ANY RECALLS WERE IN PLACE FOR THAT PART. WE WERE TOLD THERE WAS NOT A RECALL FOR THAT ISSUE. MY HUSBAND WAS SLOWING DOWN TO TURN INTO A PARKING LOT AND WENT OVER A BUMP. BECAUSE THE GLASS RUNS UNDER THE PANEL, IT GOT STRESSED AND BUSTED. WE HAVE REPLACED THE PART WITH ANOTHER FORD BACK HATCH. *TR
Structure, Apr 14, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE SITTING IDLE, THE CONTACT PRESSED THE PASSENGER REAR WINDOW RELEASE BUTTON AND THE HINGE FRACTURED FROM THE VEHICLE. THE MANUFACTURER WOULD NOT PROVIDE ANY ASSISTANCE. THE VEHICLE HAD NOT YET BEEN REPAIRED. THE CURRENT AND FAILURE MILEAGES WERE 74,800. UPDATED 06/03/10*BF UPDATED 06/07/10.*JB
Structure, Latches/locks/linkages, Apr 6, 2010
THE HATCHBACK HINGE ON MY 2004 FORD EXPLORER BROKE YESTERDAY, LUCKILY I CAUGHT IT BEFORE IT HIT MY 4 YEAR OLD IN THE HEAD. THE SAME THING HAPPENED ON A 2002 FORD EXPLORER I OWNED BEFORE, BUT THAT WAS RECALLED AND FORD FIXED IT. THIS MODEL IS NOT INCLUDED IN THE RECALL, BUT THE PART IS OBVIOUSLY DEFECTIVE. IT COULD HAVE EASILY HIT SOMEONE AND HURT THEM, OR FALLEN OFF WHILE I WAS DRIVING AND CAUSED AN ACCIDENT. *TR
Structure, Apr 3, 2010
THE REAR LIFT GLASS HINGES ON OUR 2004 FORD EXPLORER BROKE DURING USE OF THE LIFT GLASS. THE PIN BROKE RIGHT THROUGH THE HINGE. WE WERE NOT DRIVING IT AT THE TIME THANKFULLY, AND ALSO CAUGHT THE GLASS BEFORE IT HAD A CHANCE TO HIT THE GROUND.
Structure, Mar 27, 2010
2004 FORD EXPLORER CRACKED REAR PANEL.
Structure, Mar 16, 2010
I AM SO ANGRY., I OWN A 2003 AND A 2004 EXPLORER. THE 2004 HAS A CRACK THAT SUDDENLY APPEARED IN THE REAR PANEL. FORD KNOWS THIS IS AND HAS BEEN A PROBLEM WITH A DEFECT IN THEIR PRODUCT AND TALK CONDESCENDINGLY TO THEIR CUSTOMERS ON THE PHONE IF YOU TRY TO DISCUSS IT WITH THEM. THEY ARE NOT CAPABLE OF DOING ANYTHING BUT READING A RESPONSE FROM A CARD, THEY ARE UNABLE TO HAVE ANY TYPE OF CONVERSATION OTHER THAN READING THEIR CANNED RESPONSE. THIS IS THE LAST TIME THAT I WILL BUY A FORD. *TR
Structure, Mar 8, 2010
2004 FORD EXPLORER. LARGE CRACK IN HATCH BACK BETWEEN GLASS AND HANDLE (AROUND THE FORD LOGO). THIS OCCURRED WITH NORMAL VEHICLE USE AND DEALER REFUSES TO FIX. CRACK CONTINUES TO EXPAND. AFRAID THAT IF CRACK IS LEFT UNFIXED IT WILL EVENTUALLY CAUSE THE BACK GLASS TO FALL OUT OF THE HATCH DUE TO LACK OF PROPER SUPPORT. *TR
Structure, Feb 24, 2010
REAR GLASS ON EXPLORER BECAME DISCONNECTED FROM BRACKETS. THIS MATCHES PRIOR COMPLAINT NUMBER RQ08003. *TR
Structure, Feb 24, 2010
MY COMPLAINT ISN'T SAFETY RELATED BUT I HAVE SAW THIS ON SO VERY MAY FORD EXPLORERS. THE REAR PLASTIC BELOW THE REAR HATCH WINDOW CRACKS ON EITHER SIDE OF THE FORD EMBLEM. I THOUGHT MAYBE IT WAS JUST MINE.. BUT I HAVE SEEN THIS ON SO MANY OF FORD EXPLORERS. TO ME THIS IS A DEFECT AND FROM WHAT I READ FORD SAYS ITS NOT A RECALL ISSUE. BUT TO ME IT IS, ITS A DEFECT THAT ALL THOUGH IT IS NOT SAFETY RELATED IS STILL A DEFECT NONE THE LESS.. *TR
Structure, Feb 17, 2010
2004 FORD EXPLORER CRACKED REAR PANEL. *TR
Structure, Feb 14, 2010
WENT TO LOAD SOMETHING IN THE BACK OF MY EXPLORER AND NOTICED A BLACK LINE RUNNING DOWN BETWEEN THE WINDOW AND TAILGATE AND COULD NOT BELIEVE IT WAS CRACKED,,DID NOTHING TO CAUSE IT TO CRACK. I GOT ONLINE AND FOUND THAT MANY OTHER OWNERS HAVE HAD THE EXACT SAME THING TO HAPPEN. I SUPPOSE IT WILL BE TREATED LIKE THE TRANSMISSION ISSUES THAT I AND MANY MANY OTHER OWNERS HAVE HAD ALSO, JUST IGNORED BUT NEVER RECALLED ALTHOUGH CASE AFTER CASE AFTER CASE HAVE BEEN REPORTED. *TR
Structure, Feb 11, 2010
2004 FORD EXPLORER RIGHT REAR LIFTGATE HINGE PIN HAS CORROSION CAUSING THE HINGE TO BREAK LOOSE FROM THE GLASS. WHEN OPENING THE WINDOW IT BROKE AND FELL ON MY HUSBAND WHILE LOADING CARGO. THE RIGHT SIDE SHOCK (STRUT) HAS SEEMED TO GET STUCK AT TIMES MAKING IT HARD TO CLOSE THE HATCH. *TR
Structure, Feb 8, 2010
CRACK IN REAR PANEL ON LIFT GATE BELOW WINDOW AT THE FORD EMBLEM. *CN
Structure, Feb 6, 2010
ON DECEMBER 15, I WENT SHOPPING AND WHEN I WENT TO PLACE ITEMS IN THE BACK OF MY VEHICLE, I NOTICED A CRACK ALL THE WAY FROM THE BACK WINDOW TO THE BOTTOM OF THE PANEL. I TAKE VERY GOOD CARE OF MY VEHICLE. THERE WAS NO INDICATION THAT THE VEHICLE HAD BEEN HIT AS THERE WERE NO DAMAGES. *CN
Structure, Jan 30, 2010
PLASTIC UNDER BACK GLASS AROUND FORD LOGO CRACKED AFTER A COOL MORNING. (MAYBE 35 DEGREES) NOW THE CRACK STRETCHES OPEN AND CLOSED VARIOUS AMOUNTS EACH DAY. *TR
Structure, Jan 24, 2010
I OWN A 2004 FORD EXPLORER THAT HAS JUST EXPERIENCED A RANDOM CRACK IN THE BODY IN THE HATCHBACK. THE CRACK APPEARS IMMEDIATELY BELOW THE REAR WINDOW, ABOVE AND BELOW THE FORD EMBLEM. THERE WAS NO PRECIPITANT TO THE EVENT AND THERE IS NO OBVIOUS TRAUMA TO THE VEHICLE. I HAVE HAD NO REPAIRS OR PROBLEMS WITH THIS AREA PREVIOUSLY. THE FORD DEALERSHIP I DO BUSINESS WITH SAID THEY HAVE SEEN SEVERAL VEHICLES WITH THE SAME ISSUE AND COULD FIX IT FOR BETWEEN $600 & $700. I SPOKE TO FORD MOTOR CO. WHO SAID THIS IS NOT UNDER MY WARRANTY BECAUSE IT IS NOT A RECALL. I DO NOT UNDERSTAND HOW A STRUCTURAL DEFECT ON MY VEHICLE, NOT CAUSED BY MYSELF OR A 3RD PARTY, CAN NOT CONSTITUTE A RECALL. HOW CAN FORD SAY THIS ISN'T DANGEROUS? IF A PIECE OF THE BODY WERE TO FLY INTO ANOTHER VEHICLE WHILE I AM DRIVING OR THE GLASS CRACKS AND SHATTERS, THERE COULD BE SERIOUS DAMAGE TO SOMEONE ELSE. WHY WOULD A "RECALL" ONLY BE INSTATED IF SOMEONE WERE TO BE HURT? WHY WAIT? I THINK FORD SHOULD FIX THIS ISSUE AT NO CHARGE TO ME, THE OWNER. *TR