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, Sep 28, 2009
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. HE STATED THAT HIS VEHICLE DEVELOPED A VERTICAL CRACK IN THE PLASTIC TAILGATE WHICH IS ATTACHED TO THE REAR GLASS. THE CRACK APPEARED TO THE LEFT OF THE FORD EMBLEM. THE VEHICLE WAS TAKEN TO THE DEALER AND THEY STATED THAT THEY WOULD REPAIR IT AT THE OWNERS EXPENSE WITH A DISCOUNT. THE DEALER ALSO STATED THAT THE WARRANTY DOES NOT APPLY. THE UPPER PART OF THE GLASS IS MADE OF FIBER GLASS AND THE BOTTOM IS MADE OF METAL. THE CONTACT STATED THE MATERIAL IS DEFECTIVE AND THAT HE WAS NOT AWARE THAT FIBER GLASS WAS INCLUDED. THE COLD WEATHER COULD CAUSE THE CRACK IN THE WINDOW TO EXPAND. THE FAILURE AND CURRENT MILEAGES WERE 76356. UPDATED 10/20/09 *CN THE CONSUMER STATED THE CRACK IS AT THE CENTER OF THE EMBLEM AS WELL AS IN THE FIBER GLASS PART, NOT THE GLASS. UPDATED 10/22/09.*JB
Structure, Sep 23, 2009
WHILE OPERATING 2004 FORD EXPLORER, STOPPED AT STOP SIGN AND THE REAR HATCH GLASS LITERALLY EXPLODED. UPON LOOKING, IT WAS REALIZED THE HATCH ARMS/ SPRINGS LET GO, BENDING THE HATCH CAUSING THE GLASS TO COMPLETELY SHATTER. *TR
Structure, Sep 21, 2009
LIFTGATE GLASS APPLIQUE CRACKED. *TR
Structure, Sep 15, 2009
THE REAR LIFTGATE GLASS HATCH ON MY MODEL YEAR 2004 FORD EXPLORER BROKE OFF AND LEFT THE GLASS HATCH HANGING ON ONE HINGE ALMOST FALLING OFF, WHILE I WAS OPENING THE GLASS HATCH FROM THE REAR OF MY VEHICLE. I IMMEDIATELY CALLED THE DEALER TO REPORT THE PROBLEM. I BROUGHT THE CAR TO THE DEALER AND WAS CHARGED $415.01. NOT INCLUDING RENTAL CAR COST,TO REPAIR MY CAR. I LITERALLY OPEN THE HATCH DOOR AND IT FELL OFF. NO ONE SHOULD OPEN A CAR DOOR AND IT FALLS OFF. THIS COULD HAVE BEEN ONE OF MY CHILDREN OPENING THE DOOR AND THEY COULD HAVE BEEN INJURED BADLY BY THIS DEFECT IN THE CAR. *TR
Structure, Sep 10, 2009
MY 2004 EXPLORER DEVELOPED A VERTICAL CRACK IN THE PLASTIC TAILGATE ATTACHED TO THE BACK GLASS. CRACK APPEARED TO THE LEFT OF THE FORD EMBLEM. ONCE THE CRACK APPEARED IT EVENTUALLY STARTED TO MOVE DOWN THE PLASTIC PIECE, WAS VISIBLE ON MY VEHICLE FOR APPROXIMATELY 5 MONTHS. ON SEPTEMBER 7, 2009 AS I WAS DRIVING DOWN THE HIGHWAY AND MY BACK GLASS SHATTERED AND THE PLASTIC TAILGATE PIECE UNATTACHED ITSELF AT THE SIDES FROM THE VEHICLE. VERY DANGEROUS. COULD HAVE AFFECTED OTHER DRIVERS ON THE ROAD HAD SOMEONE BEEN BEHIND ME. I ALSO HAVE A 3RD ROW SEAT IN VEHICLE WHICH WAS NOT IN USE AT THE TIME OR THEY COULD HAVE BEEN HIT BE DEBRIS AS WELL. *TR
Structure, Sep 7, 2009
THE REAR LIFT GLASS HINGES ON OUR 2004 FORD EXPLORER BROKE DURING USE OF THE LIFT GLASS. THE PIN BROKE RIGHT THROUGH THE HINGE. THIS IS A VEHICLE THAT HAS BEEN PARKED IN A GARAGE WITH ONLY MINIMAL USE OF THE ACTUAL LIFT GLASS. WE ARE NOW SEARCHING JUNK YARDS FOR REPLACEMENT HINGES BUT ASSUME THESE WILL ALSO BE BAD. *TR
Structure, Aug 13, 2009
MY VEHICLE IS A 2004 FORD EXPLORER - EDDIE BAUER. IN MAY OF 2009 THE PAINT BEGAN TO BUBBLE IN PLACES ALONG THE FRONT OF THE HOOD. THESE SPOTS BECAME LARGER AND EVENTUALLY THE PAINT CHIPPED OFF, REVEALING A CORRODED BARE ALUMINUM SURFACE. THE HOOD IS NOT METAL, THEREFORE IT CAN NOT RUST. IT MUST BE A PAINT DEFECT. *TR
Structure, Aug 5, 2009
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE PLASTIC UNDERNEATH THE WINDOW OF THE REAR LIFTGATE HAS CRACKED. THE MANUFACTURER STATED THAT THE FAILURE WAS NOT COVERED UNDER WARRANTY; THEREFORE, THE CONTACT WOULD HAVE TO PAY FOR THE REPAIRS. SHE FEELS THAT THIS IS A SAFETY ISSUE BECAUSE THE FRAME AROUND THE WINDOW COULD CRACK AND CAUSE THE WINDOW TO FALL OUT. THE CURRENT MILEAGE WAS 79,900 AND FAILURE MILEAGE WAS 56,000.
Structure, Latches/locks/linkages, Aug 4, 2009
I NOTICED MY 2004 FORD EXPLORER HAS DEVELOPED A VERTICAL CRACK IN THE PLASTIC TAILGATE ATTACHED TO THE REAR WINDOW LEFT OF THE FORD EMBLEM. I TOOK IT TO THE DEALERSHIP AND THEY RECOGNIZED IT AS A COMMON PROBLEM WITH THE 2004 EXPLORER AND ALSO WARNED ME THE HINGES ON THE REAR GLASS FAIL OFTEN AS WAS THE CASE ON MY VEHICLE. SERVICE TECH STATED THERE WAS NO RECALL AS YET AND I GOT TO PAY FOR THE NEW HINGES AND HOLDING OFF ON THE CRACK THINKING FORD MADE DO THE RIGHT THING AND REPAIR THE FAULT. *TR
Visibility, Structure, Jul 28, 2009
THE PANEL BELOW MY REAR WINDOW HAS CRACKED ON MY 2004 FORD EXPLORER. I DID NOT DRIVE IT THAT DAY, SO I KNOW I WAS NOT HIT, OR THE DOOR WAS NOT SLAMMED. *TR
Structure, Jul 10, 2009
MY 2004 FORD EXPLORER HAS A CRACK IN THE REAR HATCH. IT APPEARED OUT OF NOWHERE. IT WAS NOT PRECEDED BY AN ACCIDENT OR ANYTHING. UPON TALKING TO A FRIEND WHOSE CAR HAS THE SAME PROBLEM, I RESEARCHED THIS PROBLEM ON THE INTERNET AND FOUND THAT IT HAPPENS A LOT. *TR
Structure, Jun 17, 2009
I HAVE 2004 FORD EXPLORER. I HAVE A CRACKED PANEL BELOW THE REAR WINDOW, IT CRACKED IN TWO PLACES. WHILE DRIVING THAT PIECE CAN FALL OFF AND HIT A PERSON WALKING OR HIT THE CAR BEHIND, WHICH WOULD RESULT IN PAYING THE OTHER PERSON FOR DAMAGES OR HOSPITAL BILLS. THIS PROBLEM OR DEFECT, RECALL WHICH EVER YOU WANT TO CALL IT, FORD HASN'T DONE ANYTHING ABOUT IT SO FAR. THERE ARE NUMEROUS PEOPLE WITH THE SAME VEHICLES, WITH THE PROBLEM. I THOUGHT CAN BRING THIS UP TO YOUR COMPANY AND SEE WHERE THIS GOES. THANK YOU FOR TIME HOPE TO HEAR THAT THIS CAN BE RESOLVED. *TR
Structure, Jun 2, 2009
2004 FORD EXPLORER XLT CLOSING LIFTGATE GLASS AND HINGES SHEARED ON BOTH SIDES. HINGES NEED TO BE REPLACED WAITING FOR PART. HAVE ORIGINAL HINGE PARTS. NO REAR GLASS ON VEHICLE UNTIL REPLACEMENT PARTS ARE AVAILABLE. *TR
Structure, Jun 1, 2009
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR PANEL WAS CRACKING ON HER VEHICLE NEAR THE FORD EMBLEM. THE MANUFACTURER COULD NOT ASSIST WITH THE REPAIRS. THE MOTOR FOR THE REAR WINDSHIELD WIPERS CAUSED THE REAR PANEL TO CRACK. THE CURRENT AND FAILURE MILEAGES WERE LESS THAN 80,000.
Structure, Jun 1, 2009
FAILURE OF THE LIFT GATE HINGE PIN. *TR
Power train, Structure, May 25, 2009
I HAVE A 2004 FORD EXPLORER. I HAVE TWO COMPLAINTS WITH THIS VEHICLE. THE FIRST IS THAT THE BACK GATE CRACKED FROM THE WINDOW. THE SECOND COMPLAINT IS THAT MY TRUCK IS MAKING A LOUD THUMP IN REVERSE, AND AFTER I PUT IT IN DRIVE AFTER BEING IN REVERSE, THE TRANSMISSION IS SLIPPING MAKING IT DANGEROUS TO PULL OUT INTO TRAFFIC. I WAS ALMOST HIT TWICE PULLING INTO TRAFFIC FROM THE ENGINE SLIPPING. *TR
Structure, May 21, 2009
NOTICED MY 2004 FORD EXPLORER HAD A CRACK IN THE PLASTIC PANEL UNDER THE REAR WINDOW WHEN I WAS WASHING IT IN MY DRIVEWAY. NOT SURE IF THIS IS A RECALL BUT I SEE ABOUT 100 OTHERS HAVE FILED A COMPLAINT ABOUT IT. IT SHOULD BE A RECALL. *TR
Structure, May 4, 2009
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT NOTICED A CRACK ON THE REAR LIFTGATE PANEL. THE MANUFACTURER ADVISED HIM TO TAKE THE VEHICLE TO THE DEALER FOR INSPECTION. THE FAILURE MILEAGE WAS 55,000.
Structure, May 4, 2009
I OWN A 2004 FORD EXPLORER SPORT. THE GLASS HATCH HAS BECOME INCREASINGLY HARD TO CLOSE IN THE LAST COUPLE OF MONTHS, BECAUSE OF THIS AT TIMES THE HATCH IS NOT COMPLETELY LATCHED AND WILL POP OPEN UNEXPECTEDLY. THIS PAST SATURDAY, 05/02/09, THE GLASS HATCH HINGE COMPLETELY BROKE OFF WHEN I WENT TO CLOSE IT. MY FRUSTRATION IS THAT I AM WILLING TO PAY FOR PROBLEMS THROUGH NORMAL WEAR AND TEAR AND OF COURSE THROUGH MY OWN ERROR, BUT THIS IS MANUFACTURING DEFECT. *TR
Structure, May 3, 2009
CRACK IN PANEL UNDER BACK GLASS. *TR
Structure, Apr 29, 2009
PAINT ON ROOF OF VEHICLE IS CHIPPING AND BODY IS RUSTING. *TR
Structure, Apr 28, 2009
2004 FORD EXPLORER; REAR PANEL BELOW WINDOW CRACKED. *TR
Structure, Apr 27, 2009
ALL OF THE PAINT ON MY 2004 FORD EXPLORER IS FALLING OFF JUST ON THE ROOF. *TR
Structure, Apr 21, 2009
A CRACK APPEARED ON THE LIFT GATE TOP PANEL JUST BELOW THE WIPER. THE CRACK RUNS VERTICAL FROM THE TOP OF THE PANEL AROUND THE FORD EMBLEM TO THE BOTTOM OF THE PANEL. I NOTICED THAT OTHERS ARE HAVING THIS SAME PROBLEM AT AROUND 70,000 ON THE 2004 FORD EXPLORER EDDIE BAUER EDITION. *TR
Structure, Apr 20, 2009
THE PANEL BELOW THE REAR WINDOW CRACKED FOR NO APPARENT REASON. I LOADED MY GYM BAG INTO THE BACK AND CLOSED THE HATCH. WHEN I CAME BACK 5 MIN LATER TO WIPE THE DEW OFF THE WINDOW I NOTICED 2 VERTICAL CRACKS ON THE PANEL. THE CRACKS SEEM TO BE GETTING LONGER AND I FEAR THE WINDOW MAY FALL OUT. *TR