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, Jan 23, 2010
CRACKED TAILGATE FRAME UNDER THE WINDOW, FROM TOP TO BOTTOM. *TR
Structure, Jan 21, 2010
MY 2004 FORD EXPLORER BACK HATCH HAS A BIG CRACK ON THE LEFT SIDE OF THE FORD EMBLEM. THIS HAPPENED OVERNIGHT WITH THE WEATHER CHANGE. I HAVE RESEARCHED THE INTERNET TO SEE THOUSANDS OD SIMILAR STORIES WITH THE SAME ISSUE. *TR
Structure, Jan 21, 2010
I HAVE A 2004 FORD EXPLORER XLT AND I WAS CLOSING THE REAR HATCH WHEN THE HINGE PINS SNAPPED AND LUCKILY I WAS HOLDING IT WHEN IT BROKE. IF THERE WAS A PROBLEM WITH OTHER VEHICLES THEN I THINK THERE SHOULD BE A RECALL ON ALL 2004S. *TR
Structure, Jan 21, 2010
THE REAR PANEL UNDER THE BACK WINDOW OF MY 2004 FORD EXPLORER IS CRACK, THERE WERE NO EVENTS LEADING TO THIS FAILURE, LIKE SO MANY OTHERS IT JUST CRACKED. *TR
Structure, Jan 15, 2010
A CRACK ON MY 2004 EXPLORER UNDER THE BACK WINDOW. THERE ARE 1000'S OF OTHERS ON THE ROAD ALSO HAVE SEE ALL THE COMPLAINTS ON THE INTERNET. THIS HAS TO BE RECALLED BEFORE THE BACK WINDOW FALLS OUT. *TR
Structure, Jan 15, 2010
MY BACK GATE TO MY 2004 FORD EXPLORER HAS CRACKED AND I HAVE READ WHERE THIS IS A SEVERE PROBLEM AS MY WINDOW COULD FALL OUT. THIS IS A VERY SERIOUS PROBLEM AND BY READING ONLINE THERE ARE HUNDREDS OF THOUSANDS OF THESE THAT HAVE DONE THIS. WHICH MEANS THERE NEEDS TO BE A RECALL. *TR
Structure, Jan 13, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. SHE STATED THAT WHEN CLOSING THE LIFT GATE THE HITCH SNAPPED AND THE GLASS ALMOST FELL OUT AS A CONSEQUENCE. THE DEALER WAS CONTACTED AND THEY STATED THAT THERE WERE RECALLS FOR THE SAME PROBLEM FOR THE 2002 AND 2003 VEHICLES. NHTSA ACTION NUMBER, RQ08003, STRUCTURE BODY, HATCHBACK/LIFTGATE, SUPPORT DEVICE VISIBILITY GLASS, SIDE /REAR STRUCTURE BODY, HATCHBACK/LIFTGATE, HINGE AND ATTACHMENTS WERE RELATED TO THE FAILURE AND WAS CLOSED ON OCTOBER 24, 2008. THE CONTACT TEMPORARILY REPAIRED THE VEHICLE. THE CONTACT IS AFRAID TO DRIVE THE VEHICLE SINCE THE HINGE COULD SNAP AND POTENTIALLY CAUSE SERIOUS INJURIES AND/OR A CRASH. THE FAILURE AND CURRENT MILEAGES WERE 79000.
Structure, Jan 12, 2010
WENT TO OPEN REAR DOOR AND NOTICED A CRACK RUNNING DOWN THE BACK PANEL BELOW THE REAR WINDOW. MY FORD EXPLORER IS A 2004 WITH LESS THAN 60,000 MILES THIS SHOULD NOT OF HAPPENED THIS IS A DEFECT THAT FORD SHOULD TAKE CARE OF. INSTEAD I WAS TOLD TO CALL MY INSURANCE COMPANY ARE YOU KIDDING THIS IS FORDS PROBLEM NOT MINE. IT COULD FALL OFF WHILE I'M DRIVING AND HURT SOMEONE WHAT IS GOING ON IN AMERICA. *TR
Structure, Dec 29, 2009
NO ACCIDENT INVOLVED, WALKED OUT OF MY HOUSE INTO THE DRIVEWAY AND NOTICED "THE EXPLORER CRACK" ON THE LEFT SIDE OF THE FORD EMBLEM. TEMP WAS 26 DEGREES THAT NIGHT. *TR
Structure, Dec 27, 2009
MONTHS AFTER PURCHASING THIS CAR THE REAR LIFT GATE PANEL CRACKED DUE POOR DESIGN. *TR
Structure, Dec 24, 2009
2004 FORD EXPLORER XLT V6 REAR PANEL UNDER WINDOW ON TAILGATE CRACKING AND FALLING OFF ALSO TRANSMISSION FAILURE AT 60,000 MILES WAS OUTRAGED BY FORD WHEN THEY STATED THAT AFTER THE CAR LEAVES THE FACTORY ITS NOT THEIR PROBLEM. *TR
Power train, Structure, Dec 18, 2009
THE BACK HATCH HAS A CRACK UNDERNEATH THE WINDOW IN THE MIDDLE AROUND THE FORD EMBLEM. JUST APPEARED....AS I'VE NOTICED SEVERAL FORD 2004 EXPLORERS IN THIS AREA HAVE THE EXACT SAME DEFECT. RECALL IS VERY MUCH NECESSARY. AS WELL AS THE CAR JOLTING INTO DRIVE AND REVERSE....I STILL OWE SEVERAL THOUSAND DOLLARS ON THIS LOAN AND REFUSE TO PAY FOR ANY REPAIRS....FORD SHOULD DO A RECALL ON BOTH...THEY NEED TO HIRE SOME JAPANESE WORKERS SINCE THEIR CARS SEEM NOT TO HAVE THESE TYPES OF ISSUES.....I BOUGHT THIS CAR IN FEB OF 2008 AND HAD THE TRANSMISSION PROBLEMS RIGHT AFTER THAT.....CAR ONLY HAD 48K MILES ON IT. *TR
Structure, Dec 15, 2009
A CRACK FORMED BELOW THE REAR GLASS PANEL ON OUR 2004 FORD EXPLORER. THE CRACK FORMED DUE TO A FLAW IN THE REAR DOOR PANEL. I HAVE NOTICED THE SAME CRACK ON THE SAME SPOT ON EITHER SIDE OF THE FORD EMBLEM ON NEARLY 80% OF THE FORD EXPLORER'S WE SEE ON THE HIGHWAY 'S IN THE ATLANTA AREA. *TR
Structure, Dec 15, 2009
2004 EXPLORER/EDDIE BAUER - THE PLASTIC TRIM BELOW THE REAR WIDOW CRACKED. AS STATED IN MANY OF THE OTHER COMPLAINTS, THE FORD DEALER SAYS THERE IS NOTHING THEY CAN DO, IT'S A FORD PROBLEM. CURRENT MILEAGE IS 76,000. *TR
Visibility, Structure, Dec 10, 2009
CRACKS APPEARED BELOW THE REAR WINDOW OF MY FORD EXPLORER. THERE WAS NO ACCIDENT. *TR
Structure, Dec 7, 2009
2005 FORD EXPLORER HAS A CRACK IN THE REAR HATCH. OUR FRIENDS HAD THE SAME ISSUE AND THE REAR WINDOW EVENTUALLY SHATTERED WHILE THEY WERE DRIVING. THIS SEEMS TO BE DANGEROUS BUT FORD HAS NOT ISSUED A RECALL. *TR
Structure, Dec 2, 2009
CRACKED TAILGATE PANEL WHERE "FORD" EMBLEM IS. CRACKED WHILE VEHICLE WAS SITTING IN DRIVEWAY. HAVE NOTICED A LOT OF OTHER EXPLORERS WITH SAME CRACKS. I BELIEVE IT'S DEFECTIVE MATERIALS BEING USED AND FORD SHOULD TAKE CARE OF THE PROBLEM. *TR
Structure, Nov 30, 2009
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE MANUALLY OPENING THE REAR LIFT-GATE, IT SPONTANEOUSLY CLOSED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR INSPECTION, AND THE LIFT-GATE HINGE KIT WAS ORDERED FOR THE REPAIR, BECAUSE THE LIFT-GATE HINGE HAD FRACTURED. THE FAILURE MILEAGE WAS 69,400. THE CURRENT MILEAGE WAS 69,450.
Structure, Nov 30, 2009
PAINT ON THE ROOF OF MY VEHICLE HAS PEELED OFF ONLY TO REVEAL RUST. OF COURSE, THE WARRANTY STATES THAT IF THERE IS NO PERFORATION THEN NOT THEIR FAULT IF MORE THAN 60 MONTHS HAVE PASSED. *TR
Structure, Nov 18, 2009
MY 2004 FORD EXPLORER XLT HAS A CRACK IN THE TAILGATE/BACK HATCH. IT STARTS UNDER THE WINDOW SEAL AND CONTINUES DOWN TO THE HATCH LEVER. I'M AFRAID THE GLASS WILL BECOME COMPROMISED DUE TO THE DEFECT IN CRAFTMANSHIP. I WAS ON ANOTHER FORUM WHERE 387 COMPLAINTS FOR THE SAME ISSUE. HTTP://WWW.CARCOMPLAINTS.COM/FORD/EXPLORER/2002/BODY_PAINT/CRACKED_PANEL_BELOW_THE_REAR_WINDOW.SHTML I DON'T HAVE THE MONEY TO PAY FOR POOR CRAFTMANSHIP ISSUES. I FEEL AS IF FORD SHOULD RECTIFY THE SITUATION IMMEDIATELY AT NO COST TO IT'S CUSTOMERS. *TR
Structure, Nov 10, 2009
1. THE EVENTS LEADING TO THE FAILURE WERE NORMAL USE OF THE VEHICLE. 2. REAR LIFT-GATE HINGES ON 2004 FORD EXPLORER XLT BEGAN FAILING WITH A LOUD BANG FROM THE REAR OF THE VEHICLE. THE REAR WINDOW BEGAN TO SAG AND OVER THE COURSE OF SEVERAL MONTHS CRACKS APPEARED IN THE HINGE STRUCTURE. I HAVE PURCHASED NEW HINGES, BUT AT THIS TIME I STILL NEED TO INSTALL THEM. *TR
Structure, Nov 5, 2009
CRACKED REAR PANEL BELOW WINDOW, THIS CRACK ONE DAY, NO APPARENT REASON. *TR
Suspension, Power train, Electrical system, Structure, Vehicle speed control, Nov 5, 2009
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. WHEN HE ACTIVATED THE CRUISE CONTROL WHILE DRIVING, IT DEACTIVATED ITSELF WITHOUT WARNING. HE HAD TO RESTART THE VEHICLE TO RE-SET THE ERROR CODE. THE FAILURE OCCURRED INTERMITTENTLY, AND MOSTLY ON THE INTERSTATE. ALSO WHEN HE WOULD TURN ON THE TURN SIGNALS, THE AUTOMATIC WARNING SYSTEM WOULD MAKE AN ALARM NOISE AND BLINK UNTIL THE TURN SIGNAL WOULD CUT OFF. THE AUTOMATIC TRANSMISSION APPEARED TO LOSE FLUID, WHEN HE SHIFTED INTO REVERSE. HE HEARD A ROARING NOISE NEAR THE TIRE AREA. HE WAS TOLD BY THE DEALER THAT THE HUBS NEEDED TO BE REPLACED. LASTLY, THE AESTHETIC PIECE ON THE LOWER HALF OF THE HATCH-BACK HAD CRACKED AND SEPARATED FROM THE VEHICLE. HE TOOK THE VEHICLE BACK TO THE DEALERSHIP AND WAS ADVISED THAT THERE WAS AN ELECTRICAL FAILURE. NO REPAIRS WERE MADE. THE MANUFACTURER REFERRED HIM TO NHTSA. THE CURRENT MILEAGE WAS APPROXIMATELY 68,000. THE FAILURE MILEAGE WAS APPROXIMATELY 52,000.
Visibility, Structure, Oct 8, 2009
FORD DESIGNED A PLASTIC PIECE OF MOLDING THAT IS GLUED TO THE BACK GLASS OF EVERY EXPLORER. THIS HAS CRACKED ON EVERY EXPLORER I HAVE SEEN. IT HAS BEEN FIXED ONCE BY FORD, BUT IT HAS BROKE AGAIN. I ASSUME THAT IF IT HAS BROKE EVERY TWO YEARS SO FAR, IT WILL CONTINUE TO BREAK. FORD HAS REFUSED TO FIX THIS DEFECT. *TR
Structure, Oct 2, 2009
REAR PANEL OF THE 2004 FORD EXPLORER IS CRACKED, WE ARE AFRAID TO OPEN AND CLOSE WITH THE POSSIBILITY THAT THE WINDOW WILL FALL OUT AND POSSIBLE HURT SOME ONE. *TR