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 6, 2015
CAR WAS PARKED. I OPENED REAR HATCH (JUST THE WINDOW PART) AND THE PASSENGER SIDE HINGE BROKE CAUSING HATCH TO FALL DOWN ON MY HEAD (QUITE PAINFUL!). ABOUT A YEAR AGO THIS SAME THING HAPPENED WITH THE DRIVERS SIDE HINGE (THOUGH I WAS ABLE TO CATCH IT BEFORE IT HIT MY HEAD). I HAD THAT SIDE REPAIRED, BUT NOW IT LOOKS CORRODED SO I WORRY IT WILL HAPPEN AGAIN. *TR
Exterior lighting, Structure, May 5, 2015
MY REAR HATCH IN THE BACK OF MY EXPLORER HAS A CRACK IN IT. WHICH I THINK HAS CAUSED THE BACK WINDOW TO SHIFT WHICH IN TURN HAS CAUSED MY DOOR AJAR LIGHT TO FLASH WHILE THE DOOR CHIMES GO OFF AND THE INTERIOR FLICKER WHILE YOU ARE DRIVING DOWN THE ROAD BUT THERE ARE NO DOORS OPEN . THE LIGHTS FLICKERING MAKE IT HARD TO DRIVE IN THE NIGHT. I THINK FORD SHOULD FIX THIS PROBLEM FOR EVERYONE. *TR
Structure, Apr 9, 2015
THERE IS A VERTICAL CRACK ON THE TOP REAR LIFT GATE 10" TO THE LEFT OF THE VEHICLE LOGO TOWARD THE REAR DOOR. IN COLD TEMPERATURES, THE CRACK IS BARELY VISIBLE YET IN WARMER TEMPERATURES, THE CRACK WOULD EXPAND. *TR
Structure, Mar 25, 2015
THE LIFTGATE GLASS HINGE ON MY 2004 FORD EXPLORER BROKE AS I WAS CLOSING THE REAR WINDOW GLASS. WITHOUT WARNING IT JUST CAME UNDONE WITH THE SCREW POPPING LOOSE. CHEAPLY MADE MATERIAL OF THE LIFTGATE GLASS HINGE WAS CLEARLY THE CAUSE, ALONG WITH A FAULTY DESIGN THAT ALLOWS THE BOLT TO STRIP OUT OF THE HINGE. *TR
Structure, Mar 22, 2015
CRACKED REAR HATCH. I HAD HEARD ABOUT THIS PROBLEM AND MY HATCH DIDN'T CRACK TILL AFTER THIS COLD WINTER. BUT, THIS IS THE FIRST WINTER THAT THIS EXPLORER HAS BEEN KEPT OUTSIDE, NOT GARAGED. MY GARAGED IS UNDER MY HOUSE AND INSULATED. IT NEVER GETS BELOW FREEZING IN THE GARAGE. I CALLED FORD AND ASKED THEM IF THEY CAN HELP FINANCIALLY WITH THE REPAIRS. THEY SAID NO. *TR
Structure, Mar 16, 2015
HAD MY USED 2004 FORD EXPLORER FOR ONE WEEK AND THE LIFTGATE LATCHES BOTH BROKE. IF IT HADN'T BEEN FOR THE SHOCKS THAT WERE ON THE LIFTGATE, THE WINDOW WOULD HAVE CRASHED TO THE GROUND AND SHATTERED IN A THOUSAND PIECES. FROM WHAT I'M TOLD, I'M GOING TO HAVE TO CONTACT THE DEALERSHIP AND PAY GOD KNOWS WHAT TO HAVE IT FIXED. CAN'T EVEN USE MY TRUNK NOW. THE DEALERSHIP IS A JOKE. *TR
Structure, Mar 2, 2015
REAR CRACKED PANEL ON 2002-2005 FORD EXPLORER -WHEN IT RAINS WATER FRY THE REAR TAILLIGHTS . *TR
Structure, Mar 1, 2015
LIFTGATE HAS A CRACK AND THE HINGE TO THE LIFTGATE BROKE DUE TO CRACK. IT IS HAZARDOUS TO DRIVE DUE TO POSSIBLE FALLING WHILE DRIVING OR PARKED. *TR
Structure, Jan 2, 2015
I NOTICED ONE DAY THAT THE REAR PANEL OF MY 2004 FORD EXPLORER XLT WAS CRACKED. THERE WAS NO CRASH NOR INDICATION OF DAMAGE FROM OUTSIDE SOURCE. I BELIEVE THE CRACKED FORMED BECAUSE OF THE EXPANSION OF WATER WHICH SEEPED IN THROUGHOUT THE YEAR. THERE IS NO RECALL FOR THIS PROBLEM AND I SEE THE CRACK ON EVERY EXPLORER ON THE ROAD WITHIN A FEW YEARS OF MINE. I NEED TO GET A RECALL IN ORDER TO FIX THIS PROBLEM NOT CAUSED BY ME AND WHICH EVERYONE ELSE I KNOW WHO HAS THIS MODEL HAVE THE SAME PROBLEM. *TR
Structure, Dec 31, 2014
THE BACK HATCH HAS SPLIT NEXT TO THE FORD SIGN. IT GOT COLD AND WHEN I GOT UP TO CRANK MY TRUCK I SAW IT.IT WAS NOT HIT AND WAS IN THE SHED WHEN THIS HAPPEN. I WAS TOLD IT HAD A RECALL FROM SOMEONE THAT HAS THE SAME THING HAPPEN TO HER. WE ALSO HAVE HAD THE TRANSMISSION REPLACED.FORD REALLY NEED TO FIX THIS .I CAN SAY I WILL NEVER BUY ANOTHER FORD!!!!!!!!!!!!!!!!!!!!!!! *JS
Visibility, Structure, Dec 23, 2014
THE REAR LIFT GATE WINDOW OF MY 2004 FORD EXPLORER EXPLODED WHILE THE VEHICLE WAS PARKED. ACCORDING TO THE FORD DEALER, THIS APPARENTLY IS SOMETHING THAT IS KNOWN TO HAPPEN. *TR
Visibility, Structure, Dec 18, 2014
LEAVING WORK AT END OF DAY, PULLED OUT OF PARKING SPACE AND REAR GLASS SHATTERED. THE EDGES OF THE BACK HATCH PULLED AWAY FROM THE TRUCK AND CURLED UP CAUSING THE GLASS TO BLOW INTO THE TRUCK. A CRACK IN THE PLASTIC OF THE HATCH (WHICH I HAVE SEEN ON MANY OF THIS YEAR MODEL) HAS NOT BEEN RECALLED AND I HAVE EMAILED FORD MANY TIMES ABOUT THIS PROBLEM FOR FEAR OF WATER GETTING IN BEHIND THE PANEL. MY BELIEF IS THAT WATER DID GET BEHIND THE PANEL AND THAT IS WHAT CAUSED THE PLASTIC PANEL TO PULL AWAY AND BLOW IN THE GLASS. LUCKILY MY CHILDREN WERE NOT SITTING IN THE 2ND OR 3RD ROW SEATING OR THIS WOULD HAVE BEEN A MUCH LARGER PROBLEM. I BELIEVE FORD SHOULD HAVE THIS PROBLEM ADDRESSED AND RECALLED BEFORE SOMEONE GETS SERIOUSLY HURT FROM THAT FLYING GLASS. *TR
Structure, Nov 28, 2014
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE DRIVING APPROXIMATELY 55 MPH, THE REAR HATCH OPENED WITHOUT WARNING. THE FAILURE RECURRED SEVERAL TIMES. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 60,000. UPDATED 01/09/15*LJ THE CONSUMER STATED THE GLASS HAS SHATTERED ONCE BEFORE. THE LIFTGATE DEVELOPED A CRACK. UPDATED 9/28/2015 *JS
Structure, Nov 24, 2014
THE REAR LIFT GATE ON MY EXPLORER CRACKED ON THE LEFT SIDE OF THE FORD EMBLEM. THE GATE CRACKED DURING NORMAL OPERATION OF THE VEHICLE. I HAVE A HABIT OF LOOKING OVER MY VEHICLE. THE CRACK WAS DISCOVERED WHEN I INSPECTED MY VEHICLE BEFORE GOING INTO MY HOME. ON MY NEXT SERVICE VISIT I ASKED MY FORD DEALER IF THERE HAD BEEN A RECALL FOR THIS DEFECT. I WAS TOLD THAT FORD HAD NOT GENERATED A RECALL FOR THIS DEFECT. THERE MAY BE THOUSANDS OF EXPLORERS WITH THIS DEFECT, I SEE THEM EVERY DAY. I AM VERY DISAPPOINTED WITH THE FORD COMPANY FOR NOT TAKING CARE OF THIS DEFECT. I HAVE PURCHASED MY LAST FORD. *TR
Structure, Oct 23, 2014
VERTICAL CRACK DOWN THE MIDDLE AREA OF THE REAR LIFT DOOR AROUND THE FORD EMBLEM. *TR
Structure, Oct 14, 2014
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR LIFTGATE BACK PANEL DEVELOPED MULTIPLE CRACKS, WHICH CAUSED THE LIFTGATE WINDSHIELD TO BECOME VERY UNSTABLE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 98,000.
Suspension, Fuel system, Gasoline, Power train, Structure, Service brakes, Engine, Aug 25, 2014
EXACT DATES ARE VARIOUS , VEHICLE HAS 39000 MILES ON IT PRESENTLY , HAVE MULTIPLE VEHICLES , DRIVE OVER THE ROAD TRUCK DRIVER ... CHANGED BRAKES AND ROTORS TWICE , EMERGENCY BRAKE NOT WORKING , HAD FIXED , HAD TO HAVE EKG REPLACED AND SOME EXHAUST SENSOR , TIRES WORE OUT AT 29000 , EXHAUST SYSTEM REPLACED , BOTH BALL JOINTS REPLACED , PINION GEAR GASKET LEAKING FROM REAR END , BOTH CV JOINTS LEAKING , APPEARS RIGHT CV JOINT NEEDS REPLACING , GETS 14 MPG ( 4.0 LITER ) PAINT PEELING FROM ROOF FOR QUITE AWHILE NOW , RUSTING AROUND FUEL TANK DOOR , AS ALL ARE ...... VEHICLE HAS BEEN A NIGHTMARE , GETTING RID OF THIS AT 39000 MILES , FORD HAS A BETTER IDEA , BUY ANOTHER ONE ! *TR
Structure, Aug 19, 2014
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT AFTER OPENING THE REAR GLASS LIFT GATE WINDOW, THE TWO ALUMINUM HINGES FRACTURED CAUSING THE LIFT GATE TO FALL. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN STATED THAT THE HINGES NEEDED TO BE REPLACED. THE VEHICLE HAS NOT BEEN REPAIRED SINCE THE PARTS WERE NOT AVAILABLE. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 85,000.
Visibility, Structure, Aug 4, 2014
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT AFTER OPENING THE REAR GLASS LIFT GATE WINDOW, THE TWO PLASTIC HINGES ATTACHED TO THE WINDOW FRACTURED CAUSING THE WINDOW TO FALL AND SEPARATE FROM THE VEHICLE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 141,500.
Structure, Other or unspecified, Jul 18, 2014
THE CAR WAS PARKED IN A GROCERY STORE LOT. I USED THE REMOTE TO OPEN THE BACK LATCH TO STORE MY GROCERIES. IT DID NOT OPEN. I TRIED AGAIN. SUDDENLY THE BACK WINDOW EXPLODED AND THE BACK HATCH CAME OFF IT HINGES. I AM UNABLE TO DRIVE THE CAR UNTIL IT IS REPAIRED. I FOUND MANY STORIES ONLINE THAT SAID THE SAME THING HAS HAPPENED TO OTHER 2004 EXPLORERS AND FORD HAS NOT DONE ANYTHING WITH THE COMPLAINTS. THIS EPISODE COULD HAVE BEEN VERY SERIOUS HAD IT OCCURRED WHILE DRIVING OR IF SOMEONE HAD BEEN HIT BY THE FLYING GLASS DEBRIS.
Structure, Jul 17, 2014
THE REAR HATCH DOOR CRACKED AND NOTICED SO TOOK TO AUTO BODY SHOP AND THEY TOLD US IT WAS A FORD DEFECT AND IF FIXED IT WOULD CRACK AGAIN DUE TO THE MAKE OF THIS CAR. *TR
Structure, Visibility/wiper, Jul 9, 2014
LIFTGATE GLASS HINGES BOTH BROKE CAUSING GLASS TO FALL OFF OF REAR DOOR AND NOW GLASS CANNOT BE OPENED. THIS IS THE SAME PROBLEM AS THE 2002-2003 FORD RECALL #04S20. REF NHTSA CAMPAIGN ID NUMBER 04V442000. FORD DOES NOT INCLUDE THE 2004 EXPLORER IN THEIR RECALL BUT THE PROBLEM IS THE SAME. *TR
Visibility, Structure, Jul 5, 2014
UPON OPENING THE REAR GLASS HATCH, THE PASSENGER SIDE OF THE HINGE BROKE WHEN FULLY OPEN AND THE WINDOW FELL DOWN, HITTING ME IN THE HEAD. THE PANEL BELOW ON THIS SAME WINDOW TO THE LEFT OF THE FORD LOGO PLATE HAD ALSO CRACKED ABOUT 6 MONTHS AGO. *TR
Structure, Engine, Jun 24, 2014
THE BACK HATCH WINDOW DOESN'T SEEM TO LINE UP WITH THE LATCH. THE BACK HATCH ALSO CRACKED RIGHT NEAR THE FORD LOGO. I HAVE SEEN MANY OF THE EXPLORERS THAT THIS HAS HAPPENED TO. ITS TIME FORD FIXES THIS DEFECT. ALSO WHILE DOING AROUND 60-65 MPH MY TIMING CHAINS BROKE, ALL 3 OF THEM AT THE SAME TIME. I COULD UNDERSTAND 1 MAYBE BUT ALL 3 ? THIS TO HAS TO BE A MANUFACTURER DEFECT. *TR
Power train, Structure, Jun 18, 2014
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR WHEEL WELLS AND FRAME WERE RUSTED. AND THE REAR HATCH WAS FRACTURED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE MILEAGE WAS 40,000 AND THE CURRENT MILEAGE WAS 100,000. UPDATED 09/30/14*LJ THE CONSUMERS STATED THE TRANSMISSION JERKS INTO GEAR. UPDATED 02/25/2015 *JS