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, May 30, 2007
REAR PANEL TO THE LEFT BELOW THE BACK WINDOW, NEXT TO THE FORD EMBLEM IS CRACKED. THE VEHICLE HAS NOT BEEN INVOLVED IN ANY ACCIDENT, IT JUST HAPPENED ON IT'S OWN. AFTER SEARCHING THE INTERNET, I HAVE FOUND THAT MANY 2004 FORD EXPLORERS HAVE HAD THE SAME PROBLEM. I WAS TOLD IT WOULD COST APPROX. $400 TO REPAIR. I THINK THERE SHOULD BE A RECALL ON THIS ISSUE, AS IT SEEMS TO BE A DEFECT. *TR
Structure, May 26, 2007
HINGE ON LIFTGATE GLASS FRACTURED AND BROKE. 2004 FORD EXPLORER. SEE 2003 NHSTA RECALL 04V442000. LIFTGATE GLASS HANGING OFF AND CAR UNUSABLE. METAL FATIGUE ON HINGE/GLASS ATTACH POINT ON GLASS. COULD MY CAR HAVE RECEIVED "OLDER" DEFECTIVE PARTS FROM PREVIOUS YEAR AS IT HAS A MANUFACTURE DATE OF 08/03? NUMEROUS PREVIOUS MODEL YEAR PROBLEMS WITH SAME PART. *TR
Structure, Apr 25, 2007
CRACK IN PANEL BELOW REAR WINDOW OF MY 2004 FORD EXPLORER. *TR
Structure, Apr 23, 2007
THE AREA ON THE BACK HATCH UNDERNEATH THE GLASS CRACKED IN A STRAIGHT LINE. I CAME OUT OF MY HOUSE AFTER A COLD MORNING AND THAT'S WHAT I FOUND. *TR
Structure, Mar 26, 2007
REAR PANEL BELOW REAR WINDOW CRACKED.*AK
Structure, Mar 15, 2007
TL*- THE CONTACT STATED THAT THE BACK OF THE HATCH OF THE 2004 FORD EXPLORER WITH 74050 FAILURE MILEAGE WAS CRACKED. THE CONTACT WAS CONCERNED THAT THE HATCHBACK GLASS COULD FALL OUT AND INJURE HER CHILDREN. THE VEHICLE HAD NOT BEEN TAKEN TO THE DEALER, BUT THEY HAVE BEEN CONTACTED AND WERE AWARE OF THE PROBLEM. THE CURRENT MILEAGE WAS 75,000.*AK
Structure, Mar 7, 2007
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE OPENING THE REAR GLASS HATCH THE CONTACT HEARD THE GLASS CRACK ,AND NOTICED THAT THE HINGE CAME LOOSE ON THE RIGHT HAND SIDE OF THE HATCH. THE CONTACT CAN PROVIDE PICTURES. THE CURRENT AND FAILURE MILEAGE WAS 51,283. *AK
Service brakes, Hydraulic, Electrical system, Structure, Latches/locks/linkages, Jan 16, 2007
WE HAVE EXPERIENCED MULTIPLE PROBLEMS WITH THE ELECTRICAL SYSTEMS OF OUR 2004 FORD EXPLORER ALONG WITH OTHER MISCELLANEOUS PROBLEMS. THE ELECTRICAL PROBLEMS HAVE NOT BEEN CORRECTED TO DATE. IN NOVEMBER 2006, THE REAR WINDOW OF THE LIFTGATE BROKE OFF THE HINGE. WE WERE TOLD THERE WERE NO RECALLS FOR THIS PROBLEM AND HAD TO PAY FOR THIS REPAIR OUT OF OUR POCKET. TODAY, JANUARY 16, 2007 THE FRAME OF THE REAR LIFTGATE CRACKED IN THE MIDDLE. *NNM
Structure, Nov 24, 2006
ON 11/23/2006, MY WIFE, PUT SOMETHING IN OUR 2004 FORD EXPLORER VIA THE REAR HATCH WHEN THE DRIVERS SIDE GLASS HINGE BROKE. THE GLASS REMAINED IN TACT, BUT TO BE ABLE TO CLOSE THE HATCH I HAD TO REMOVE THE TWO STRUTS. THIS APPEARS TO BE SIMILAR TO RECALL #04V442000 ON THE SAME MODEL VEHICLE IN 2002. *JB
Structure, Nov 21, 2006
DT*: THE CONTACT STATED THE WINDOW HINGE IN THE REAR LIFT GATE FRACTURED, AND THEN THE WEIGHT OF THE WINDOW FRACTURED THE SECOND HINGE. THE VEHICLE WAS TAKEN TO A SERVICE DEALER AND THE MANUFACTURER WAS NOTIFIED. THE MANUFACTURER INFORMED THE CONTACT THE VEHICLE WAS NOT INCLUDED IN RECALL #04V442000 REGARDING THE STRUCTURE: BODY: HATCHBACK/LIFTGATE: HINGE AND ATTACHMENTS, ALTHOUGH THE FAILURE WAS THE SAME.
Structure, Sep 27, 2006
THE HINGE ON THE REAR TAILGATE WINDOW CAME APART UNEXPECTEDLY. I HAD POPPED IT OPEN USING MY KEYFOB RELEASE BUTTON TO LOAD SOME BAGS INTO IT AND THE HINGE IMMEDIATELY FAILED. THE WINDOW ITSELF TWISTED AND WAS HANGING BY THE 2ND HINGE THAT HADN'T FAILED AND THE GAS SHOCKS THAT ENABLE THE WINDOW TO STAY OPEN WITHOUT HOLDING IT. I WAS ABLE TO FIT IT BACK TOGETHER TO CLOSE IT. THE FOLLOWING DAY, I CONTACTED THE DEALERSHIP TO ORDER PARTS. WHAT I WAS TOLD WAS THAT THERE WAS A RECALL ON THE 2003 BUT NO THE 2004 MODEL. I WAS ACTUALLY ABLE TO PICK UP A RECALL PACK THAT CONTAINED BOTH HINGES. THE PARTS MANAGER SOLD THEM TO ME @ COST BECAUSE THIS IS APPARENTLY A COMMON PROBLEM. THERE WERE NO INJURIES, HOWEVER, IF ONE OF MY CHILDREN HAD BEEN STANDING NEARBY IT IS QUITE POSSIBLE THAT THE WOULD HAVE GOTTEN HIT BY THE GLASS AS IT CAME DOWN. FINALLY, I WALKED AWAY ABOUT $20 POORER (BECAUSE I REPAIRED IT MYSELF) AND WITH SEVERAL SCRATCHES ON THE PAINT AROUND THE HINGE AND THE BACK TAILGATE. *NM
Structure, Jul 20, 2006
THE LEFT HINGE ON THE GLASS HATCH FAILED DURING A NORMAL CLOSING OPERATION. THE LIGHT ALUMINUM CASTING FAILED AS A RESULT OF METAL FATIGUE CAUSING THE FULL WEIGHT OF THE HATCH TO FALL ON MY WIFE. THE FORD DEALER CLAIMS THIS FAILURE IS NOT COVERED UNDER NHTSA RECALL CAMPAIGN NUMBER 04V442000 AND THAT MY WIFE MUST HAVE BRUTALIZED THIS TRUCK. THE REPLACEMENT PARTS THAT I PURCHASED FROM THE DEALER AND INSTALLED ARE CLEARLY MUCH HEAVIER CASTINGS. THE ISSUES CONCERNING CAMPAIGN NUMBER 04V442000 STILL EXIST ON THIS 2004 MODEL YEAR VEHICLE. I HAVE THE OLD PARTS AND PICTURES COMPARING THEM TO THE NEW ONES. *NM
Structure, May 18, 2006
REAR LIFTGATE GLASS HINGE FAILED AND GLASS STRUCK ME IN ARM AND CHEST AS I LOWERED GLASS. *JB
Structure, Jan 4, 2006
DT: THE CONTACT STATED THERE WAS NHTSA RECALL CAMPAIGN 04V442000 REGARDING HATCHBACK HINGE AND ATTACHMENTS. THE VEHICLE HAS THE SAME PROBLEMS AS INDICATED IN THE RECALL; HOWEVER, IT IS NOT INCLUDED IN THE RECALL DUE TO THE VIN. THE CONTACT TOOK THE VEHICLE TO AN INDEPENDENT REPAIR SHOP BUT NO REPAIRS WERE MADE. *AK UPDATED 1/25/2006 - THE HINGES SHEARED OFF AND THE HATCH ON THE LIFTGATE FELL OFF WHEN OPENING. THE PART HAS BEEN REPLACED BUT FORDS REPLACEMENT HINGES HAVE NOT BEEN MODIFIED TO CORRECT THE PROBLEM. FORD REFUSED TO PAY FOR REPAIR. *NM
Structure, Dec 9, 2005
1. OPENED THE BACK HATCH GLASS 2. THE LEFT HINGE BROKE AND THE GLASS FELL. I WAS ABLE TO CATCH THE GLASS TO KEEP IT FROM FALLING. I PUSHED THE GLASS BACK UP AND WAS ABLE TO GET THE GLASS CLOSED AND LATCHED. MY LEFT SHOULDER HAS BEEN HURTING SINCE THE INCIDENT. *JB 3. I TOOK THE TRUCK TO THE DEALER AND THEY REPLACED THE HINGE BRACKET. THEY REPLACED BOTH THE LEFT AND RIGHT HINGES.
Fuel system, Gasoline, Structure, Nov 22, 2005
ON THREE SEPARATE OCCASIONS MY FORD EXPLORER 4DOOR SPORT TRAC HAS STALLED, BECAUSE MY TEENAGE CHILDREN HAVE ACCIDENTALLY BUMPED/KICKED THE INERTIA CONTROL DEVICE FOR FUEL SHUT OFF WHILE THE VEHICLE WAS MOVING/DRIVING. THIS DEVICE HAS ITS OWN PUSH START BUTTON TO RESTART FUEL OPERATIONS ONCE THE VEHICLE STOPPED. I WAS ON THE BELTWAY 495 DOING 65 MPH THE LAST TIME IT HAPPENED. I HAD TO MAKE AN EMERGENCY PULL OFF AND ALMOST GOT HIT BY A TRACTOR TRAILER ON TWO OCCASIONS. ON 11-18-2005 THE DEALER FAILED TO COVER THIS DEVICE SAYING THERE WAS NOTHING WRONG WITH IT. HOWEVER THE TECHNICIAN STATED HE HAS SEEN SEVERAL CARS RETURNED FOR THE SAME THING. *NM
Service brakes, Hydraulic, Fuel system, Other, Visibility, Structure, Sep 29, 2005
DT: WHILE DRIVING ON SEPTEMBER 16, 2005 THE ABS FAILED. WHEN THIS OCCURRED IT CAUSED THE CONSUMER'S VEHICLE TO ALMOST HIT ANOTHER VEHICLE. THE ABS, MAINTENANCE, AND FOUR WHEEL LIGHTS CAME ON AND BLINKED WHEN HE LOST THE BRAKES. A DIAGNOSIS TEST WAS PERFORMED, AND IT SHOWED THAT THERE WAS A PROBLEM WITH THE SPEED SENSOR. THE DEALERSHIP REPLACED THE SPEED SENSOR IN THE REAR WHICH WAS CALLED ASY-T. THE FUEL GAUGE BROKE. IT SHOWED THE FUEL TANK LEVEL WAS HIGHER THAN WHAT IT REALLY WAS. THE DRIVER'S REAR WINDOW MOTOR HAD TO BE REPLACED. THE COVER OVER THE HATCHBACK HANDLE HAD TO BE REPLACED. ALSO, HAD TO REPLACE THE WEATHER STRIPPING. THERE HAS BEEN A REPAIR DONE TO THE FOUR BY FOUR UNIT. THERE WERE MULTIPLE PROBLEMS WITH THE VEHICLE. *AK
Service brakes, Hydraulic, Power train, Electrical system, Structure, Vehicle speed control, Tires, Nov 23, 2004
THE CONSUMER EXPERIENCED A PROBLEM WITH THE CRUISE CONTROL. THE CONSUMER WOULD SET THE CRUISE CONTROL AND THEN IT WILL SHUT DOWN BY ITSELF. THE CONSUMER TOOK THE VEHICLE TO THE DEALER WHO AS OF TODAY, WAS UNABLE TO FIND A DEFECT. *JB THE FAILURE RESULTED IN A LIFE THREATENING SITUATION WHEN THE VEHICLE REACHED SPEEDS IN EXCESS OF 100 MPH ON IT'S OWN WHILE HITTING THE RESUME BUTTON IN CRUISE CONTROL. THE VEHICLE HAD BEEN IN TO THE DEALER FOR THE REPAIR OF THE BRAKING AND TIRE PRESSURE GAUGES, THROTTLE CONTROL, TRANSMISSION SLIPPAGE, CRUISE CONTROL, TRACTION CONTROL DEFAULT, GENERAL COMPUTER DEFAULTS AND THE REAR TRIM PIECE AT THE LIFTGATE OPENING WAS DISTORTED. *SC
Engine and engine cooling, Structure, Nov 5, 2004
WHILE DRIVING SMOKE BEGAN COMING FROM THE ENGINE COMPARTMENT, THE ENGINE BOGGED DOWN AND THE ENGINE STALLED. *NM THE ENGINE RAN ROUGHLY AND SMOKE EMITTED FROM THE VEHICLE. SINCE THE REPAIR THE CONSUMER NOTICED A HISSING NOISE COMING FROM THE AIR CONDITIONER. AIR COMING THROUGH THE WINDSHIELD WAS THE REASON FOR THE NOISE COMING FROM THE AIR CONDITIONER. THE WINSHIELD WAS REMOVED AND RESEALED. *TC *JB
Structure, Jun 6, 2004
PAINT IS COMING OFF DRIVERS RUNNING BOARD. I HAVE OWNED THIS VEHICLE FOR ONLY 3 WEEKS. *AK
Structure, Feb 26, 2004
OTHE VEHICLE WAS RECEIVED ON 2/16/2004, ON 2/18/2004 THE DRIVERS SIDE RUNNING BOARD BROKE WHEN I STEPPED ONTO IT WHEN ENTERING THE VEHICLE ON THE DRIVERS SIDE I STEPPED UP ONTO THE RUNNING BOARD AND IT CRACKED AT THE SEAM CAUSING ME TO FALL BACK INTO THE DRIVING LANE. THE DEALER REPLACED THE DRIVERS SIDE RUNNING BOARD ON 2/24/2004. ON 2/26/2004, THE PASSENGER SIDE RUNNING BOARD CRACK IN THE SAME PLACE, THIS WAS ONLY THE SECOND TIME SOMEONE ENTERED ON THE PASSENGER SIDE OF THE VEHICLE. I AM WAITING FOR THE DEALER TO REPLACE THIS ONE. SHOULD THIS HAPPEN WHILE THERE IS TRAFFIC MOVING NEAR THE VEHICLE A PERSON COULD FALL BACK AND BE STRUCK BY ANOTHER VEHICLE.*AK