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, Dec 31, 2007
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE GLASS ON THE REAR HATCH DOOR HAS CRACKED AND THE CONTACT FEELS THAT IT MAY SHATTER AT ANY MOMENT WHILE DRIVING. THE DEALER STATED THAT IT IS NOT A DEFECT AND THE CONTACT WOULD HAVE TO PAY FOR THE REPAIR. THE VIN, ENGINE SIZE, AND NUMBER OF CYLINDERS WERE UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 49,000.
Structure, Dec 31, 2007
2004 FORD EXPLORER'S REAR HATCH/TAILGATE HINGES BROKE. *TR
Structure, Dec 17, 2007
A LARGE CRACK HAS FORMED ON THE REAR LIFT GATE PANEL RIGHT NEXT TO THE FORD EMBLEM. THE CRACK RUNS VERTICALLY AND RUNS THE LENGTH OF THE PANEL WHICH IS SEVERAL INCHES. THIS CRACK IS NOT DUE TO ANY PHYSICAL DAMAGE AND APPEARS TO EXPAND/CONTRACT IN DIFFERENT OUTDOOR TEMPERATURES. THIS PANEL SUPPORTS THE GLASS IN THE REAR LIFT GATE. *TR
Structure, Dec 13, 2007
CRACKED PANEL BELOW THE REAR WINDOW. *TR
Structure, Dec 4, 2007
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT NOTICED A CRACK ON THE REAR HATCH OF THE LIFTGATE. THE DEALER INSPECTED THE VEHICLE AND STATED THAT THE FAILURE IS A COMMON OCCURRENCE. AS OF DECEMBER 4, 2007, THE DEALER HAD NOT REPAIRED THE VEHICLE. THE MANUFACTURER OFFERED RESTITUTION OF $150; HOWEVER, THE CONTACT DECLINED THE OFFER. THE FAILURE MILEAGE WAS 27,846 AND CURRENT MILEAGE WAS 27,946. UPDATED 01-11-08. *KB THE CONSUMER STATED THE COST OF REPAIRS SHOULD NOT BE PASSED ONTO THE CONSUMER. UPDATED 12/31/07 *TR
Structure, Dec 3, 2007
A CRACK HAS APPEARED IN THE PLASTIC PANEL BELOW THE WINDOW ON THE REAR LIFT GATE. IT EXTENDS FROM TOP TO BOTTOM JUST LEFT OF THROUGH FORD EMBLEM. IT HAS NOT BEEN HIT OR DAMAGED IN ANY WAY. IT SPLIT ON ITS OWN. *TR
Structure, Nov 7, 2007
I HAVE A CRACK ON THE REAR LIFT GATE OF MY 2004 FORD EXPLORER. IT RUNS VERTICALLY FROM UNDER THE WINDOW, AROUND THE LEFT SIDE OF EMBLEM, TO THE BOTTOM OF PANEL. I UNDERSTAND THAT THIS IS A COMMON DESIGN FLAW. I HAD THIS REPAIRED ONCE ALREADY IN SEPTEMBER 2006. THIS IS THE 2ND OCCURRENCE AND FORD IS NOT REPAIRING IT UNDER WARRANTY, BECAUSE MY 12 MONTH PERIOD ENDED 6 WEEKS AGO. I FEEL THIS NEEDS TO BE RECTIFIED, AS IT IS A 2ND OCCURRENCE AND OBVIOUSLY A MANUFACTURER FLAW. *TR
Structure, Oct 31, 2007
BUBBLING AND BLISTERING OF THE PAINT FROM THE HOOD OF 2004 FORD EXPLORER. *TR
Structure, Oct 30, 2007
THE REAR WINDOW LIFTGATE HINGE ON MY 2004 FORD EXPLORER FRACTURED. THIS WAS OBVIOUSLY A DEFECTIVE HINGE IN THAT IT SHOULDN'T HAVE WORN OUT LIKE IT DID. I HAD TO BRING IT TO THE DEALER WHO REPLACED BOTH HINGES FOR APPROX $165. THEY TOLD ME THERE WAS A RECALL FOR THIS SAME PROBLEM FOR THE YEARS PRIOR TO MY MODEL YEAR. THEY ALSO SAID THAT THE HINGE WAS THE SAME TYPE THAT WAS FAILING IN THE PRIOR MODEL YEARS. I AM FILING THIS COMPLAINT IN ORDER TO HAVE ANY OF THIS TYPE OF HINGE THAT WAS USED TO BE INCLUDED IN THE RECALL. THE RECALL WAS # 04V442000. *TR
Structure, Oct 29, 2007
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE LIFT GATE FELL OFF THE HINGES WHEN IT WAS BEING CLOSED. THE CONTACT WAS FORCED TO DRIVE THE VEHICLE WITH THE LIFT GATE DISCONNECTED. A MECHANIC STATED THAT IT NEEDED TWO GLASS BRACKETS AND THE HINGES NEEDED TO BE REPLACED. THE REPAIR COST WOULD BE MORE THAN $600 AT THE OWNER'S EXPENSE. THERE WERE NO WARNING SIGNS THAT THE LIFT GATE WAS LOOSE. THE DEALER STATED THAT THERE WAS NO WARRANTY AVAILABLE. THE FUEL SYSTEM WAS UNKNOWN. THE FAILURE AND CURRENT MILEAGES WERE 45,000. UPDATED 11/14/07
Structure, Oct 18, 2007
FOUND A CRACK IN THE LIFTGATE PANEL. NO IMPACT WAS SUFFERED TO THE PANEL. CRACK GOES FROM TOP TO BOTTOM RIGHT THOUGH THE FORD EMBLEM. *TR
Visibility, Structure, Oct 17, 2007
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE USING THE REMOTE TO OPEN THE REAR WINDOW, THE GLASS HINGE FAILED AND CAUSED THE WINDOW TO FALL FROM THE WINDOW FRAME. THE CONTACT NOTIFIED THE DEALER AND MANUFACTURER AND THEY STATED THAT HIS VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER 01I010000 (VISIBILITY:GLASS, SIDE/REAR). THE WINDOW HAS YET TO BE REPAIRED. THE CURRENT AND FAILURE MILEAGES WERE 33,500 UPDATED 01/02/08. UPDATED 01/02/08.*LJ
Structure, Oct 14, 2007
2004 FORD EXPLORER EDDIE BAUER. PANEL UNDER TAILGATE CRACKED. CLEAR CRACK FROM TOP TO BOTTOM WHERE FORD EMBLEM IS, APPEARED OVERNIGHT. WAS NOT INVOLVED IN ANY ACCIDENT. 53,385 MILES *JB
Engine and engine cooling, Power train, Structure, Vehicle speed control, Sep 25, 2007, fire
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE VEHICLE WOULD NOT START. SHE DEPRESSED THE ACCELERATOR PEDAL AND THE VEHICLE STARTED AND BEGAN TO VIBRATE. SHE THEN PLACED THE VEHICLE IN REVERSE AND HEARD A LOUD CLUNKING NOISE. SHE SMELLED A STRONG GAS ODOR INSIDE THE PASSENGER COMPARTMENT. THE CONTACT LOOKED IN HER REARVIEW MIRROR AND NOTICED A LARGE AMOUNT OF SMOKE COMING FROM THE EXHAUST SYSTEM. SHE PARKED THE VEHICLE AND HAD IT TOWED. SHE THEN NOTICED THAT ALL OF THE RADIATOR FLUID LEAKED OUT. THE MECHANIC STATED THAT THE VALVE FAILED AND DAMAGED THE ENTIRE ENGINE. THE MECHANIC ALSO STATED THAT THE ENGINE NEEDED TO BE REPLACED AND APPEARED TO BE A MANUFACTURER DEFECT. THE CURRENT AND FAILURE MILEAGES WERE 63,000. THE CONSUMER ALSO STATED HAD PROBLEMS PRIOR TO INCIDENT WITH SUN VISOR FALLING OFF, GEAR SHAFT WOULD NOT SHIFT INTO PARK, ENGINE SLUGGISH, AND WHILE USING CRUISE CONTROL VEHICLE WOULD JUST SHUT OFF. UPDATED 10/22/07 *TR
Visibility, Structure, Sep 16, 2007
CRACK IN PANEL BELOW REAR WINDOW NEXT TO FORD EMBLEM. BOTH REAR WINDOWS WILL NOT GO UP OR DOWN. *TR
Structure, Sep 16, 2007
2004 FORD EXPLORER 33,663. MILES PANEL UNDER WINDOW OF HATCHBACK HAS CRACKED DOWN THE MIDDLE. AFTER VIEWING THE SAME COMPLAINT FROM OWNERS OF THIS SAME VEHICLE, I DO NOT UNDERSTAND WHY THEIR HAS NOT BEEN A RECALL. *TR
Structure, Sep 13, 2007
DEVELOPED CRACK IN BACK PANEL UNDER REAR WINDOW ON LIFTGATE. NOTHING TOUCHED IT. CAME OUT ONE MORNING AND FOUND IT THERE. FORD WILL NOT FIX IT WITHOUT ME PAYING $150. I'VE SEEN 200+ COMPLAINTS ON THE INTERNET WITH THE SAME PROBLEM. I BET OVER 50% OF THE EXPLORERS SOLD DO THIS. THIS IS NOT NORMAL.
Structure, Sep 11, 2007
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. AFTER DRIVING 55 MPH, THE CONTACT NOTICED PAINT CHIPPING ON THE HOOD OF THE VEHICLE. SHE TOOK THE VEHICLE TO THE DEALER AND THEY STATED THAT THE FAILURE WAS NOT COVERED BY THE WARRANTY AND ADVISED HER TO REPAIR IT HERSELF. SHE TOOK THE VEHICLE TO A MECHANIC AND HE STATED THAT THE FAILURE WAS A MANUFACTURER DEFECT AND SHE SHOULD NOT HAVE TO PAY FOR THE PAINT JOB. THE CURRENT AND FAILURE MILEAGES WERE 46,500.
Structure, Sep 3, 2007
Y 2004 EXPLORER (BOUGHT IN NOV. 2004) HAS THE SAME PROBLEM WITH THE CRACK IN THE PANEL BELOW THE LIFTGATE WINDOW. THE CRACK JUST MIRACULOUSLY APPEARED ABOUT THREE WEEKS AGO. THE CRACK STARTS RIGHT BELOW THE WINDOW THEN CURVES AROUND THE RIGHT SIDE OF THE FORD LOGO BEFORE TRAVELING STRAIGHT DOWN AGAIN FOR ANOTHER 3-4 INCHES. THE DEALER STATED IT WAS NOT COVERED BY MY WARRANTY. I HAVE NOTICED A FEW OTHER EXPLORERS AROUND TOWN WITH THE SAME ISSUE. I SEARCHED THE WEB A FOUND THE SAME ISSUE AS WELL. *JB
Structure, Aug 10, 2007
FORD EXPLORER 2004, BACK TAILGATE WINDOW FELL OFF VEHICLE. THERE WAS A RECALL FOR THE 2003, FORD REFUSES TO PAY FOR REPAIR, CLAIMING THAT THEY HAVEN'T HAD ENOUGH COMPLAINTS TO WARRANT AN ADDITIONAL RECALL. THIS BACK WINDSHIELD FELL OFF THE VEHICLE INTO MY HUSBANDS HANDS. THANK GOD MY CHILDREN WEREN'T THE IN THE WAY OR INJURED. THIS RECALL OF THE 2003, TO PLACE ON SEPTEMBER 13,2004, WELL AFTER MY VEHICLE WAS MADE AND PURCHASED. I FEAR FOR THE OWNERS OF THIS $35,000.00 VEHICLE, AND WHAT MAY HAPPEN WHILE FORD DRAGS THEIR FEET WITH THIS RECALL. I IS SOMEWHAT APPARENT THAT THE SAME HINGES WERE USED ON THIS VEHICLE AS THE 2003. PLEASE LET THE PUBLIC KNOW. THANKS. *JB
Visibility, Structure, Jul 10, 2007
THE HINGES ON THE LIFT GATE WINDOW ON MY 2004 FORD EXPLORER BROKE CAUSING THE REAR WINDOW TO FALL OUT OF THE WINDOW FRAME. FORD MOTOR COMPANY TOLD ME THAT THERE IS A RECALL FOR THE PROBLEM ON THE 2002 AND 2003 MODELS BUT WERE NOT "AWARE" OF ANY SIMILAR PROBLEMS WITH THE 2004 MODEL. *TR
Structure, Jul 5, 2007
I OWN A 2004 FORD EXPLORER 4 DOOR. ON JULY 5, 2007 WHILE CLOSING THE WINDOW PORTION OF THE BACK HATCH THE GLASS CAME LOOSE FROM THE HINGES. I TOOK THE VEHICLE TO GULLO-HASS FORD IN CONROE TEXAS TO HAVE THEM REPAIR IT, AND I WAS TOLD THAT THE HINGES AND BACK WINDOW SECTION WERE THE SUBJECT OF A TECHNICAL SERVICE BULLETIN. IT WAS APPARENT THAT FORD WAS AWARE OF A POTENTIAL PROBLEM WITH THE BACK HATCH WINDOW AND THE HINGES, SINCE ,IT SENT OUT A TSB ADVISING ITS SERVICE PERSONNEL ON THE BEST WAY TO FIX THE PROBLEM. *AK RESEARCH SHOWED THAT THE TSB WAS ISSUED ON 1/1/05. FORD WAS AWARE OF THIS PROBLEM AND THE QUICKEST WAY TO FIX IT WHILE MY VEHICLE WAS STILL UNDER WARRANTY. FORD FAILED TO ADVISE ME AS AN OWNER THAT THERE WAS A POTENTIAL PROBLEM WITH THE REAR WINDOW HATCH AREA. THIS CONCERNS ME AS A SAFETY ISSUE. IF THE GLASS HAD BEEN OPEN AND I WAS STANDING UNDER THE GLASS WHILE LOADING OR UNLOADING MY VEHICLE, I COULD HAVE BEEN SERIOUSLY HURT BY THE FALLING GLASS OR KILLED AS WELL AS ANY OTHER PERSON STANDING NEXT TO ME OR A CHILD NEXT TO ME. FORD ADVISED ME THAT BECAUSE IT HAD NOT BEEN FORCED BY THE GOVERNMENT TO ISSUE A RECALL THEY DIDN'T HAVE TO ADVISE VEHICLE OWNERS OF THE PROBLEM.
Structure, Jun 25, 2007
ON JUNE 4 2007, I OPENED THE HATCH ON MY 2004 FORD EXPLORER XLT. WHEN I SHUT THE HATCH, THE WHOLE ASSEMBLY FELL AND THE GLASS HATCH SHATTERED SHOWERING ME AND THE EXPLORER AND THE GARAGE WITH THOUSANDS OF SHARDS. I SUSTAINED SOME SMALL CUTS ON MY FACE. I WAS LUCKY THAT MY SON WAS ALREADY IN THE CARSEAT AND NOT OUTSIDE BY THE SUVLIKE HE USUALLY DOES. OTHERWISE HE WOULD HAVE BEEN HURT BY THE THOUSANDS OF GLASS SHARDS. LATER, I NOTED THAT THE HINGE ON WHICH THE HATCH WAS SUSPENDED, THE ONE SIDE BROKE OFF CAUSING THE WHOLE HATCH ASSEMBLY TO FALL AND THE GLASS TO SHATTER.I WAS ALSO LUCKY I WAS WEARING MY SUNGLASSES(WHICH BROKE). I NOTICED THAT THE METAL PART ON WHICH THE HATCH WAS HUNG WAS PUT ON COCKEYED WHICH PROBABLY CAUSED THE PROBLEM. HATCHES ARE MEANT TO BE OPENED AND CLOSED AND THE WHOLE HATCH ASSEMBLY IS NOT SUPPOSED TO FALL DOWN ON SIMPLY CLOSING THE HATCH. I E MAILED FORD AND TOLD THEM ABOUT THE DEFECT BUT THEY WERE LESS THAN HELPFUL. MY SUV IS STILL IN THE SHOP. I TOOK IT TO A FORD DEALER. I HAVE PICTURES OF THE DAMAGE AND THE GLASS SHARDS WHICH WENT OVER THE EXPLORER ALL THE WAY TO THE FRONT WINDSHIELD.
Structure, Jun 25, 2007
ON JUNE 21, 2007 I USED THE KEYLESS ENTRY REMOTE TO OPEN THE REAR WINDOW OF THE 2004 FORD EXPLORER FOR MY 11 OLD DAUGHTER TO PUT MY SON'S BABY BAG IN THE BACK. WHEN THE GLASS OPENED THE DRIVER'S SIDE HINGE FATIGUED AND BROKE, TWISTING THE GLASS HARD ENOUGH TO CAUSE A DENT IN THE WINDOW RECESS AND FALLING ON MY DAUGHTER'S HEAD, BENDING BOTH STRUTS. AFTER INVESTIGATING OTHER MODELS I DISCOVERED THAT MODEL YEARS UP TO 2003 WERE COVERED UNDER A RECALL ,BUT THE 2004 WAS NOT. I CONTACTED FORD MOTOR COMPANY AND EXPLAINED THE SITUATION ,AND THEY WERE ABSOLUTELY NO HELP, TELLING ME THAT THE VEHICLE WAS NOT COVERED UNDER ANY WARRANTY AT THE TIME. THE VEHICLE HAS 72,000 MILES ON IT. THE LOCAL DEALERSHIP WAS NOT MUCH MORE HELP, REPLACING MY HINGES WITH THE 2003 RECALL PACKAGE AND INFORMING ME THAT 33% OF THE TIME WHEN THEY REPLACE THE HINGES THE GLASS BREAKS AND THE REPLACEMENT COST WILL BE AT THE OWNER'S EXPENSE. THE PARTS WERE $102 AND THE LABOR $100. *AK
Structure, May 31, 2007
I HAVE AN 2004 FORD EXPLORER WITH THE CRACK IN THE PANEL BELOW THE REAR WINDOW/HATCH. I THINK THAT FORD MOTOR CORP NEEDS TO REPAIR THESE FOR ALL OF THE CUSTOMERS WHO HAVE PURCHASED THESE VEHICLES AND ARE HAVING ISSUES WITH THE CRACK LEADING TO WATER DAMAGE. *TR