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, Apr 16, 2009
2004 EXPLORER REAR TAIL GATE CRACK NEXT TO FORD EMB. *TR
Structure, Apr 14, 2009
WIFE CAME BACK FROM SCHOOL AND TOLD ME THE PROBLEM. WE HAVE A 2004 FORD EXPLORER WITH A CRACK ON THE REAR TRUNK LID BELOW THE REAR GLASS WHERE THE FORD EMBLEM IS, LOOKING THROUGH THE INTERNET AND FOUND OUT THAT THERE ARE A HANDFUL OF COMPLAINTS REGARDING THIS PANEL BECOMING CRACK WHAT SO EVER AND STILL NO RECALL. *TR
Structure, Apr 14, 2009
BACK HATCH PANEL ON MY 2004 FORD EXPLORER CRACKED INTO TWO PIECES FOR NO REASON. LOOKED ONLINE AND MANY OTHER OWNERS ARE HAVING THE SAME PROBLEM AND NO RECALL ON THIS PART HAS BEEN ISSUED. I HAVE NOT REPLACED THE PART YET AS IT IS A $400 REPAIR THAT IS OBVIOUSLY DUE TO POOR QUALITY OF PARTS USED BY FORD. *TR
Structure, Apr 13, 2009
2004 FORD EXPLORER WITH THE BACK PLASTIC DOOR BEEN SPLIT IN HALF, IT LOOKS LIKE THIS IS HAPPENING TO A LOT OF FORD EXPLORERS, WE HAVE TAKEN THE TRUCK TO THE DEALER. THE PROBLEM IS NOT ON A RECALL AND IT WILL BE ON OUR OWN EXPENSES. *TR
Structure, Apr 11, 2009
PAINT CRACKED AND PEELING ON BOTH SIDES OF ROOF RACK. DEALER WAS NOTIFIED AND SAID THERE WOULDN'T BE ANY PROBLEM IN SUBMITTING THE CLAIM ON THE PAINT. AFTER MY RESEARCH AND A MONTH OF RUN AROUND THE DEALER FINALLY ACKNOWLEDGED THERE WAS A PAINT PROBLEM. I WAS TOLD BY DEALERSHIP THAT I WAS WASTING MY TIME ON THE CLAIM BECAUSE FORD WAS NOT GOING TO BACK IT'S VEHICLE UP..WHAT A WASTE OF TIME AND MONEY ON MY PART. FORD WILL NEVER SEE MY BUSINESS AGAIN!!! I HOPE THIS GOES ALONG WITH ALOT OF OTHER PEOPLE CONCERNING THIS MATTER!! *TR
Structure, Apr 4, 2009
I WALKED AROUND TO THE BACK OF MY EXPLORER TO PUT GROCERIES IN THE BACK TRUNK AREA TO FIND THE PLASTIC CRACKED BY THE FORD EMBLEM. IT RUNS THE LENGTH OF THE FLIP OPEN GLASS PANEL THAT HAS NOW BROKEN THE INTEGRITY OF THE CAR LEAVING IT MUCH EASIER FOR SOMEONE TO BREAK IN. THE CAR WAS NOT INVOLVED IN ANY SORT OF COLLISION, NO OTHER MARKS WERE SEEN. *TR
Structure, Apr 3, 2009
WE HAVE A 2004 FORD EXPLORER THAT HAD A SPONTANEOUS CRACK OCCUR ON THE BACK LIFT GATE BELOW THE GLASS AND THROUGH THE FORD EMBLEM. WE HAVE SEEN MANY EXPLORERS ON THE ROAD WITH THIS DEFECT AND WERE TOLD THAT THIS IS NOT GOING TO BE RECALLED AND WOULD BE RESPONSIBLE FOR FIXING. ALTHOUGH WE CONSIDERED; MOST PEOPLE THAT HAVE HAD THIS FIXED; THE CRACK HAPPENS AGAIN. THIS WOULD COST 4-8 HUNDRED DOLLARS TO FIX AND WILL PROBABLY OCCUR AGAIN. *TR
Structure, Mar 28, 2009
WALKED OUTSIDE ONE DAY AND NOTICED A CRACK IN THE PLASTIC PANEL BELOW MY REAR WINDOW. I HAVE SEEN MANY OTHER EXPLORERS WITH THE SAME PROBLEM. *TR
Structure, Mar 25, 2009
THE REAR TAILGATE CRACKED FROM THE BOTTOM OF THE REAR GLASS AND PROPAGATED DOWNWARD AROUND THE FORD EMBLEM AND FINALLY TO THE BOTTOM OF THE LIFTGATE PANEL. THIS HAS HAPPENED ON A 2004 FORD EXPLORER LIMITED, V8 WITH . *TR
Structure, Mar 22, 2009
WENT INTO MY GARAGE TO GET INTO MY EXPLORER AND NOTICED A CRACKED PANEL BELOW REAR WINDOW. SEEN OTHER FORD SUV'S WITH SAME CRACKED PANEL BY THE FORD EMBLEM ON REAR PANEL. CALLED FORD AND ASKED IF THERE WAS A RECALL ON THIS AND THEY TOLD ME NO AND REFUSED TO HELP ME GET THE PROBLEM FIXED. I DID NOTHING. THE CRACK JUST CAME OUT OF NO WHERE. IT WASN'T SOMETHING I DID. ITS A MANUFACTURE PROBLEM SEEING THAT THERE IS OTHER SUV JUST LIKE MINE WITH THE SAME PROBLEM AND A CRACK IN THE EXACT SAME AREA! *TR
Structure, Mar 16, 2009
FORD EXPLORER LIFT GATE PANEL CRACKED I HAVE NOT REPLACED IT YET I SEE A LOT OF THESE ON THE ROAD SINCE MY HAS CRACKED. *TR
Structure, Mar 16, 2009
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE LIFTGATE GLASS STRUT BECAME DISENGAGED FROM THE HINGE, WHICH ALLOWED THE GLASS TO LOOSEN. THE GLASS APPEARS THAT IT COULD FALL OUT AT ANY MOMENT WHILE DRIVING VARIOUS SPEEDS. THE CONTACT FOUND RECALLS ON THE 2002 AND 2003 EXPLORERS, BUT NOT FOR 2004. THE DEALER STATED THAT THERE WERE NO RECALLS FOR HER VEHICLE AND IT COULD NOT BE REPAIRED ACCORDING TO NHTSA CAMPAIGN ID NUMBER 04V442000 (STRUCTURE:BODY:HATCHBACK/LIFTGATE:HINGE AND ATTACHMENTS). THE FAILURE MILEAGE WAS 90,000.
Structure, Mar 15, 2009
PAINT ON THE HOOD OF MY 2004 FORD EXPLORER BEGAN TO BUBBLE AND SUBSEQUENTLY PEEL OFF. NEEDED OTHER, UNRELATED BODY WORK, AND HAD THE DEALER SHIPFIX THE PAINT PROBLEM ALONG WITH OTHER BODY WORK. FORTUNATELY, THE BODY SHOP GUY ONLY CHARGED ME $100, SINCE HE ALREADY HAD THE PAINT (AND I THINK FELT A LITTLE SORRY FOR ME). HAVE HAD NO FURTHER PROBLEMS WITH THE PAINT. *TR
Structure, Mar 15, 2009
CRACK APPEARED ON PANEL BELOW REAR WINDOW. CRACK EXTENDS FROM THE REAR WINDOW TO THE BOTTOM OF THE TOP REAR HATCH. NO MISTREATMENT OF VEHICLE HAS OCCURRED; CRACK APPEARED SPONTANEOUSLY WHILE UNOCCUPIED IN MY GARAGE. WILL BRING TO FORD DEALERSHIP TOMORROW TO INQUIRE ABOUT REPLACEMENT. *TR
Structure, Mar 15, 2009
MY 2004 FORD EXPLORER HAS A CRACKED REAR LIFT GATE JUST BELOW THE WINDOW, ADJACENT TO THE CENTER FORD EMBLEM. IT WAS DESCRIBED TO ME BY MY LOCAL FORD DEALER AS A MANUFACTURED DEFECT AS A RESULT OF THE HORIZONTAL PLASTIC DECK LID BEING GLUED TO THE METAL LIFT GATE. DURING CONTRACTION AND EXPANSION OF THESE TWO MATERIALS DURING FLUCTUATIONS IN WEATHER, THE LID WILL CRACK. I HAVE NOTICED APPROXIMATELY 30-40% OF 2002-2005 EXPLORERS WITH THE SAME PROBLEM. FORD COULD ELEVATE THIS PROBLEM BY REPLACING THE PLASTIC PANELS WITH A BETTER MATERIAL OR GLUE. MY WARRANTY EXPIRED AT 36K AND I NOTICED THIS PROBLEM WON'T OCCUR UNTIL THE VEHICLE IS ABOUT 50K-75K OF 3-4 YEARS. FORD WANTS $500 TO REPAIR PLUS PAINT FOR A TOTAL OF $700 DOLLARS. *TR
Structure, Mar 12, 2009
I BOUGHT THIS 2004 FORD EXPLORER IN 2006. THE PANEL BELOW THE BACK WINDOW WAS LOOSE. THEY SENT A GLASS DEALER OUT TO FIX IT. THEY JUST PUT HOT GLUE OR SOMETHING TO MEND IT FOR THE TIME. NEEDLESS TO SAY IT'S 1/2 FALLING OFF NOW. *TR
Structure, Mar 12, 2009
PAINT IS PEELING ON THE ROOF OF MY 2004 FORD EXPLORER. WENT TO THE DEALER WHERE I BOUGHT THE VEHICLE AND HAD THEM LOOK AT IT. THEY SAID I"N 6 YEARS I AM ONLY THE 2ND PERSON TO HAVE THIS PROBLEM" AND "THAT IT IS NOT COVERED UNDER WARRANTY". THEY WOULD NOT ACKNOWLEDGE A MANUFACTURER DEFECT OR PROBLEM. I AM JUST WRITING HERE TO GET THIS INFORMATION ON RECORD, BECAUSE IT IS MY UNDERSTANDING THAT THIS IS NOT AN UNCOMMON PROBLEM AND THAT THIS IS VERY TYPICAL WITH FORD VEHICLES. THANK YOU *TR
Structure, Mar 11, 2009
I NOTICED A CRACK ON THE REAR PANEL OF THE TAILGATE OF MY 2004 FORD EXPLORER. IT IS IN THE MIDDLE, RIGHT NEXT TO THE FORD EMBLEM. I TOOK THE VEHICLE TO THE FORD DEALERSHIP. THE SERVICE MANAGER EXPLAINED THAT THIS WAS A COMMON PROBLEM THAT PEOPLE ARE BRINGING IN TO THEM. THEY SAID THAT THERE WAS NO RECALL FOR IT. THEY SAID MY ONLY OPTION WAS TO PAY TO GET IT REPAIRED, WHICH WOULD COST ABOUT $450.00. MY VEHICLE ONLY HAD ABOUT 48,000 MILES, BUT WAS NO LONGER COVERED UNDER THE 3 YEAR WARRANTY. THE MANAGER ALSO SAID THAT IF I DO CHOOSE TO GET IT FIXED, TO KEEP THE RECEIPT BECAUSE IF THERE EVER IS A RECALL ON IT, I COULD BE RE-IMBURSED. *TR
Structure, Feb 26, 2009
THE TAILGATE ON MY 2004 FORD EXPLORER CRACKED LAST WINTER. I TOOK IT TO THE DEALER AND THEY SAID THAT IT WAS NOT RECALLED. I NOTICED MANY OF THE SAME VEHICLES WITH THE SAME PROBLEM. I BELIEVE THAT THIS IS A MANUFACTURING ISSUE THAT SHOULD BE RESOLVED BY FORD. *TR
Structure, Feb 25, 2009
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THERE WAS A PLASTIC TRIM PIECE IN THE REAR OF THE VEHICLE THAT WAS GLUED ONTO THE REAR LIFTGATE WINDOW, WHICH HOLDS THE FORD EMBLEM. HE NOTICED THAT THE PIECE WAS CRACKED RIGHT DOWN THE MIDDLE AND THAT SEVERAL OTHER VEHICLES OF THE SAME YEAR, MAKE, AND MODEL HAD THE SAME FAILURES. HE CONSULTED A PLASTIC EXPERT, WHO STATED THAT THE PART WAS DEFECTIVE AND MOLDED INCORRECTLY. THE CONTACT FEELS THAT THE FAILURE WAS DUE TO A MANUFACTURER DEFECT. THE MANUFACTURER STATED THAT THE COMPLAINT WOULD BE ESCALATED. THE LOCAL DEALER STATED THAT THEY COULD NOT ASSIST WITH THE DEFECTIVE PART. THE FAILURE AND CURRENT MILEAGES WERE LESS THAN 35,000.
Visibility, Structure, Feb 23, 2009
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. SINCE NOVEMBER OF 2008, THE CONTACT HAS BEEN EXPERIENCING ISSUES WITH THE REAR HATCH DOOR. THERE IS A CRACK DIRECTLY IN THE CENTER OF THE HATCH WHERE THE LOCK IS LOCATED. AS A RESULT, THE REAR WINDOW OPENS WITHOUT WARNING. WHILE DRIVING OVER SPEED BUMPS OR POTHOLES, THE WINDOW OPENS. THE VEHICLE WAS TAKEN IN FOR INSPECTION, BUT THE CONTACT WAS INFORMED THAT THE WARRANTY WAS EXPIRED. SHE FEELS THAT THIS IS A SAFETY ISSUE, WHICH COULD CAUSE A SERIOUS CRASH. THE CURRENT AND FAILURE MILEAGES WERE 42,106.
Structure, Feb 21, 2009
CRACKING TAILGATE PANEL BELOW REAR TAILGATE WINDOW EXTENDING TO THE BOTTOM OF THE TAILGATE. THE CRACK EXTENDS ALONG THE LEFT SIDE OF THE FORD EMBLEM. THIS IS THE SECOND CRACK SINCE I HAVE HAD IN 2 YEARS IN EXACTLY THE SAME LOCATION. THE PREVIOUS CRACK APPEARED IN JANUARY 2007 AND WAS REPAIRED BY DEALER AT NO COST. THIS TIME THE DEALER WANTS TO CHARGE ME $450 TO REPAIR AN OBVIOUS DEFECT IN WORKMANSHIP AND OR MATERIAL. *TR
Structure, Equipment, Feb 19, 2009
I TAKE VERY GOOD CARE OF MY 2004 FORD EXPLORER. WHEN I WAS HAND WASHING IT I NOTICED A CRACK IN MY BACK HATCH. *TR
Power train, Structure, Feb 19, 2009
BACK REAR HATCH CRACKED. JUST LIKE THE 100'S OF OTHERS I FOUND ON MY INTERNET SEARCH OF THE PROBLEM. OUR TRANSMISSION ALSO FAILED AND HAD TO BE REPLACED, AT OUR OWN COST. *TR
Power train, Structure, Feb 19, 2009
I HAVE HAD 2 PROBLEMS WITH MY FORD EXPLORER. 1. CRACK IN THE REAR WINDOW PANEL, FORD WON'T FIX. 2. TOTAL TRANSMISSION FAILURE, HAD TO REPLACE AT MY COST. *TR