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 28, 2008
1. OPENED REAR HATCH GLASS ON 2004 FORD EXPLORER. 2. HINGES FAILED ON GLASS HATCH DISCONNECTED FROM BODY. 3. THIS JUST HAPPENED. HAVE TO BUY REPLACEMENT HINGES. *TR
Structure, Jul 27, 2008
AS I STOPPED TO GET GAS I NOTICED MY VEHICLE HAD A CRACK RIGHT ON THE PLASTIC ALONG THE RIGHT SIDE OF THE FORD EMBLEM DIRECTLY UNDER THE TAIL GATE GLASS. I CALLED THE DEALER AND WAS TOLD IT IS WAS A COMMON ISSUE BUT COULD NOT DO ANYTHING ABOUT IT UNLESS I PAY OUT OFF POCKET FOR IT OR THE COMPANY RECALL THE PART. I HAVE NO PROBLEM PAYING TO RESOLVE THE ISSUE, THE PROBLEM I HAVE IS I TAKE GOOD CARE OF MY CAR ALOT (I OWN A SHOW STYLE CAR) AND THIS SEEMS TO BE A RECURRING ISSUE EVERYWHERE ELSE WITH THIS SAME TYPE OF VEHICLE AND I WOULD LIKE TO KNOW WHAT THE FORD CO IS TRYING TO DO TO ADDRESS THIS ISSUE? I GO THIS SITE FROM A FORUMS SITE ( HTTP://WWW.CARCOMPLAINTS.COM/FORD/EXPLORER/2004/BODY_PAINT/CRACKED_PANEL_BELOW_THE_REAR_WINDOW.SHTML ) WHAT CAN BE DONE TO ADDRESS THIS ISSUE? *TR
Structure, Jul 25, 2008
I NOTICED A PAINT BUBBLE ON THE HOOD OF MY 2004 FORD EXPLORER. IS THIS A PAINT DEFECT THAT IS CAUSING MY VEHICLE TO RUST? I WOULD LIKE TO KNOW IF FORD IS DOING ANYTHING TO FIX THIS PROBLEM SINCE IT SEEMS THAT MANY OTHER OWNERS ARE HAVING THE SAME PROBLEM. *TR
Structure, Jun 26, 2008
JUST NOTICED AFTER 32,000 MILES AND ABOUT 3 AND ONE-HALF YEARS OF OWNERSHIP THAT PAINT ON FRONT EDGE OF HOOD OF 2004 FORD EXPLORER IS BLISTERED IN SEVERAL PLACES AND BEGINNING TO CHIP. *TR
Structure, Jun 16, 2008
PAINT HAS STARTED TO BUBBLE AND PEEL OFF OF THE HOOD OF MY 2004 EXPLORER. I WAS TOLD BY A FORD MECHANIC THEY HAVE BEEN SEEING ALOT OF THIS BECAUSE OF THE METAL USED IN THE HOODS- SHOULD NOT BE HAPPENING FOR A CAR BARELY 4 YEARS OLD. MY OLD EXPLORER WAS MUCH OLDER AND NEVER HAD THIS PROBLEM. *TR
Structure, Jun 1, 2008
2004 FORD EXPLORER REAR BACK PANEL HAS A SIGNIFICANT CRACK WHICH CAME ON SUDDENLY. I DID NOT REALIZE THAT THIS PROBLEM HAS HAPPENED TO OTHERS UNTIL I STARTED CHECKING ON HOW TO FIX IT VIA THE NET. *TR
Structure, May 21, 2008
EXTERIOR PAINT ON THE HOOD OF MY FORD EXPLORER 2004 IS BLISTERING AND CHIPPING. I DON'T THINK THIS SHOULD BE HAPPENING. *TR
Visibility, Structure, May 13, 2008
THE REAR WINDOW LIFTGATE HINGES ON MY 2004 FORD EXPLORER FAILED. HINGE PINS ARE CORRODED AND JUST SHEARED RIGHT OFF. LOOKS LIKE THE HINGES BECOME LOOSE AND GO SLIGHTLY OUT OF ALIGNMENT AND WHEN HATCH IS OPENED THE PINS BREAK. APPEARS THERE WAS A RECALL FOR THIS SAME PROBLEM FOR THE YEARS PRIOR TO MY MODEL YEAR. FROM THE REVIEW OF THIS WEBSITE DOES NOT LOOK LIKE FORD HAS SOLVED THE HINGE PROBLEMS. THE EARLIER RECALL WAS # 04V442000. CAN THE RECALL BE EXTENDED TO COVER THE 2004 (AND MAYBE LATER YEARS)? *TR
Structure, May 12, 2008
CLOSED THE BACK GLASS OF THE TAILGATE WITH NORMAL AMOUNT OF FORCE AND CRACK APPEARS FROM GLASS TO FIBERGLASS ( RIGHT NEXT TO FORD SYMBOL). *TR
Fuel system, Other, Structure, May 4, 2008
MY GAS GAUGE ON MY 2004 FORD EXPLORER HAS FAILED ME MANY TIMES. I TOOK IT TO MY DEALERSHIP & THEY TOLD ME TO ADD SOME FUEL ADDITIVE TO MY GAS TANK & THIS WOULD CURE THE PROBLEM. WELL IT HAS NOT & MY WARRANTY IS OUT!!! I'M VERY CONCERNED FOR MY WIFE'S SAFETY IF SHE RUNS OUT OF GAS, SO WE HAVE TO KEEP A WRITTEN LOG AS TO THE MILEAGE BEFORE FILL-UP'S. I'M TOLD THE SENSOR IS BAD & WOULD COST CLOSE TO $1,000.00 TO REPAIR. I HAVE COMPLAINED TO FORD & THEY REFUSE TO REPAIR SINCE THE WARRANTY IS OUT. I HAVE ALSO COMPLAINED TO FORD ABOUT A BACK HATCH PANEL THAT HAS CRACKED FOR NO APPARENT REASON DIRECTLY UNDER THE EXTERIOR FORD EMBLEM & THEY WILL NOT REPAIR THIS SINCE IT IS OUT OF WARRANTY. THESE ARE BOTH FOR SURE MANUFACTURER DEFECTS, THAT FORD SHOULD BE MADE TO REPAIR AT THEIR COST. *TR
Structure, Apr 25, 2008
MY FORD EXPLORER HAS A TWO PART REAR LIFT GATE. THE MAIN LIFTGATE WORKS FINE, HOWEVER, THE SMALLER GLASS LIFT GATE "COLLAPSED" WHEN I WAS OPENING IT. IT IS A HINGED LIFT GATE WITH HINGES THAT ATTACH TO THE GLASS. ONE OF THE HINGES FAILED AND THE GLASS DOOR COLLAPSED (HITTING ME ON THE HEAD AND CUTTING MY HAND). THE HINGE THAT BROKE LOOKS AS IF IT MAY HAVE CRACKED RIGHT WHERE THE RETAINING PIN IS LOCATED SECURING THE GLASS DOOR TO THE HINGE ATTACHED TO THE BODY. THE HINGE APPEARS TO BE MADE OF A CAST IRON OR "POT METAL", WHICH COULD BE SUBJECT TO BREAKING OR CRACKING. WHEN IT BROKE IT ALSO CAUSED THE OTHER HINGE TO COME DISCONNECTED. THE DOOR IS JUST "HANGING" BY THE DOOR SHOCKS. THE AUTO IS A 2004 FORD EXPLORER. I AM TAKING IT IN TO HAVE IT REPAIRED, BUT WANTED TO FILE THIS REPORT DUE TO THE NATURE OF THE FAILURE OF THE PART AND THE POTENTIAL FOR PHYSICAL INJURY. *TR UPDATED 05/05/08. *JB
Visibility, Structure, Apr 15, 2008
MY 2004 BACK REAR WINDOW PANEL CRACKED- DEFECTIVE PANEL FROM FORD, APPROX EVERY FORD EXPLORER HAS THE SAME PROBLEM AND FORD WILL NOT RECALL AS A MFG DEFECT YOU CAN FIND HUNDREDS OF COMPLAINTS FOR THE SAME PROBLEMS ON ALL FORD EXPLORERS 2002 TO 2005. *TR
Structure, Apr 14, 2008
PAINT ON TOP OF HOOD BUBBLING AT TWO SPOTS ON FRONT PASSENGER SIDE AND ALSO ON NUMEROUS LOCATIONS ON UNDER SIDE EDGE ON FRONT OF HOOD, A LARGE PAINT BLISTER ON UNDERSIDE AT HOOD LATCH AND SEVERAL PAINT BLISTERS ON BACK UNDER SIDE OF HOOD BY DRIVER WINDSHIELD. *TR
Structure, Apr 10, 2008
A CRACK APPEARED ABOVE AND BELOW THE FORD EMBLEM ON THE BACK FLIP UP WINDOW AT APPROX 50,000 MILES. *TR
Structure, Apr 5, 2008
OUR 2003 FORD EXPLORER TAILGATE BACK PANEL WITH THE FORD EMBLEM CRACKED FROM TOP TO BOTTOM ON THIS PANEL RIGHT NEXT TO THE EMBLEM. KNOW IDEA HOW IT HAPPENED BUT WE SEE MOST OF THE EXPLORERS HAVE THIS SAME PROBLEM. CHEAP MATERIALS BY FORD TO CUT COSTS TO MAKE A PROFIT. *TR.UPDATED 09/16/08. *LJ
Structure, Apr 3, 2008
PAINT PEELING FROM VEHICLE. *TR
Structure, Mar 27, 2008
2004 FORD EXPLORER EDDIE BAUER EDITION. REAR LIFT GATE CRACKS WITHOUT CAUSE. RESEARCH HAS INDICATED THIS IS A KNOWN PROBLEM SINCE EARLY 2000 WITH NO CORRECTIVE RESOLUTION BY FORD. WHAT HAPPENS IF THESE PIECES FALL OFF DURING INITIAL CRACKS WITHOUT DRIVE AWARENESS AND INJUIRES SOMEONE OR PROPERTY? I BELIEVE FORD SHOULD BE MADE TO FIX THIS KNOWN ERROR BEFORE ACCIDENTS OCCUR AND NOTIFY CUSTOMERS THE CHANCES OF THIS OCCURRING IS HIGH. *TR
Structure, Mar 10, 2008
I HAVE A 2004 FORD EXPLORER WITH PEELING PAINT ON THE ROOF OF THE VEHICLE. I CONTACTED FORD'S HOME OFFICE AND WAS TOLD THAT THEIR MECHANISM TO REPAIR THE DEFECT EXPIRED AFTER 12 MONTHS OR 12,000 MILES. THE VEHICLE IS NOT OLD ENOUGH OR EXPOSED ENOUGH TO THE ELEMENTS FOR THIS TO HAPPEN. *TR
Structure, Feb 25, 2008
NOTICED THAT THE BACK PANEL OF TAILGATE IS CRACKED ON FRIDAY, FEBRUARY 22, 2008. THE CRACK RUNS FROM UNDERNEATH THE REAR WINDSHIELD TO THE FORD EMBLEM AND THE CONTINUES TO THE HANDLE OF THE TAILGATE. THE CRACK IS OPEN, AND I HAVE CUT MY FINGER ON IT WHEN CLOSING THE TAILGATE. I'M TRYING TO CLOSE IT ANOTHER WAY, BUT THERE'S NO OTHER PLACE TO PUT YOUR HAND TO CLOSE THE TAILGATE BECAUSE THE CRACK COMES DOWN TO THE MIDDLE OF THE HANDLE. I AM AFRAID THAT THE PANEL WILL FALL COMPLETELY OFF OR THE REAR GLASS WILL DISLODGE AND FALL OUT. I AM TAKING THE VEHICLE TO THE DEALERSHIP THIS WEEK TO DETERMINE HOW TO GET IT FIXED. *TR
Structure, Feb 21, 2008
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. IN AN ATTEMPT TO LOAD THE REAR OF THE VEHICLE, THE CONTACT NOTICED AN 1/8 INCH WIDE AND 6 INCH LONG CRACK IN THE CENTER BELOW THE REAR WINDOW. THE REAR WINDOW WOULD NOT CLOSE DUE TO THE CRACK. THE DEALER WAS NOTIFIED OF THE FAILURE. THE CURRENT MILEAGE WAS 52,000 AND FAILURE MILEAGE WAS 49,551. UPDATED 05/06/08. *LJ THE TOP PORTION OF THE HATCH HAS SHIFTED. UPDATED 05/06/08
Structure, Feb 16, 2008
THE BACK PANEL OF THE CAR UNDERNEATH THE WINDOW HAS DEVELOPED A 4 INCH VERTICAL CRACK OVERNIGHT. THE HATCH HAS NOT BEEN OPEN OR CLOSED FOR SEVERAL WEEKS AND HAS NOT BEEN BUMPED OR HIT TO MY KNOWLEDGE. *TR
Structure, Feb 16, 2008
MY WIFE AND I NOTICED A CRACK UNDER THE REAR WINDOW, (1/8 BY 6") TO THE LEFT OF THE FORD EMBLEM IN THE CENTER OF THE REAR HATCH.. THERE WAS NO IMPACT INVOLVED, IT JUST APPEARED OVERNIGHT. LATER THE REAR WINDOW WAS RAISED AND THE HINGE ON THE LEFT SIDE IS LOOSE, AND CANNOT BE TIGHTENED. NOW WE CAN'T CLOSE THE THE REAR WINDOW ALL THE WAY. WHEN IS SOMETHING GOING TO BE DONE ABOUT THIS ONGOING PROBLEM WITH THE 2004 EXPLORERS? FORD IS VERY AWARE OF THIS PROBLEM AND AND THEY COULD CARE LESS. I COULD HAVE TAKEN OUR EXPLORER TO A KIA DEALER INSTEAD OF A FORD DEALER AND RECEIVED THE SAME TYPE OF SERVICE..NO HELP AT ALL. IT SEEMS THAT FORD DOESN'T CARE ABOUT QUALITY ANYMORE AND ONLY ABOUT THE MIGHTY DOLLAR, NO MATTER HOW THEY GET IT! *TR
Structure, Feb 13, 2008
THE PAINT ON MY HOOD IS PEELING AWAY. I DID NOT NOTICE SOME PAINT "BUBBLING" ON THE HOOD OF MY 2004 FORD EXPLORER WHEN I BOUGHT IT BRAND NEW. AFTER WASHING IT I SAW THE PAINT WAS CLEARLY DEFECTED. IT DID NOT BOTHER ME AT FIRST, BUT NOW AFTER 3 YEARS AND 52,000 MILES THE PAINT IS CHIPPING AWAY WHERE IT WAS "BUBBLED". THE AREA IN QUESTION IS THE FRONT LEFT CORNER OF THE HOOD, IN TWO SMALL PLACES. WHEN I NOTICED IT WAS CHIPPING AWAY THERE WAS ALREADY 4" SQUARE INCHES OF SHEET METAL SHOWING. I TOOK IT TO THE DEALER WHERE I BOUGHT IT AND THEY SAID IT WAS A KNOWN ISSUE (FORD TSB 04-25-1) BUT THEY COULD NOT DO ANYTHING ABOUT IT SINCE MY TRUCK IS OUT OF THE WARRANTY PERIOD. THEY EXPLAINED THE ALUMINUM HOOD IS THE PROBLEM AND AN ENTIRE NEW HOOD WOULD COST $1300. THEY EXPLAINED THAT FORD KNOWS ABOUT THE PROBLEM BUT HAS DECIDED NOT TO ISSUE A RECALL. *TR
Service brakes, Hydraulic, Structure, Latches/locks/linkages, Equipment, Feb 13, 2008
WHILE GOING TO OPEN THE REAR HATCH OF MY 2004 FORD EXPLORER, I NOTICED A CRACK IN THE HATCH DOOR FROM JUST BELOW THE WINDOW DOWN TO THE NEXT PANEL. WHEN I OPENED THE WINDOW ON THE HATCH DOOR, I NOTICED THAT THE LEFT HINGE THAT HOLDS THE GLASS IS COMING LOOSE. I AM UNABLE TO UTILIZE THE REAR CARGO AREA OF MY VEHICLE NOW FOR FEAR THAT THE LEFT HINGE WILL BREAK OFF RESULTING IN THE ENTIRE DOOR COMING OFF THE VEHICLE AND FALLING OR DROPPING ONTO ME OR ONE OF MY CHILDREN, CAUSING SEVERE PERSONAL INJURIES. THE MILEAGE ON MY VEHICLE IS APPROXIMATELY 70,000 MILES. NOTHING HAS BEEN DONE YET TO CORRECT THIS FAILURE BECAUSE AFTER READING OTHER PEOPLE'S EXPERIENCE WITH HAVING FORD REFUSE TO ACKNOWLEDGE THE PROBLEM AND THE GOVERNMENT THUS FAR REFUSING TO ISSUE A RECALL, MY HANDS ARE TIED. I DO NOT WANT TO PAY FOR THE REPAIR MYSELF BECAUSE I HAVE ALREADY BEEN BURNED BY FORD ON OTHER ISSUES RELATING TO THIS VEHICLE, I.E., THE ABS MODULE AND THE AIR CONDITIONING SYSTEM. *TR
Visibility, Structure, Electrical system, Jan 17, 2008
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE VEHICLE WAS QUALITY CHECKED WITH A 115 POINT INSPECTION; HOWEVER, SHE WAS LATER NOTIFIED THAT THE VEHICLE WAS IN A MAJOR CRASH. THE DRIVER SIDE DOOR IS MISALIGNED. THE SUNROOF WAS REPLACED WITH TAPE. SHE DOESN'T KNOW IF THE VEHICLE IS EQUIPPED WITH AIR BAGS. THE WINDOWS HAVE CONDENSATION ON THE INSIDE OF THE VEHICLE. THE SPEEDOMETER DOES NOT REGISTER THE PROPER SPEED IN THE VEHICLE. THE APPROXIMATE SPEED CAN RANGE FROM 20 TO 50MPH. THE FUEL PUMP AND SENSORS WERE REPLACED. THE VEHICLE WAS PURCHASED MARCH 20, 2007. THE DEALER STATED THAT THE VEHICLE IS CURRENTLY OPERATING NORMALLY. THE DEALER HAS DIAGNOSED THE FAILURE ON SEVERAL OCCASIONS. THE FAILURE MILEAGE WAS 20,000 AND THE CURRENT MILEAGE WAS 23,000.