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, Jun 13, 2014
WHEN CLOSING REAR PANEL, THE PANEL CRACKED. *JS
Structure, May 15, 2014
THE DOORS DON'T OPEN GOOD AND THE DOOR HANDLES BREAK. WE HAVE HAD FIXED TWICE AND THE PREVIOUS OWNER HAD FIXED ALSO! *TR
Structure, May 12, 2014
REAR GLASS LIFT GATE: CRACKS APPEARED IN THE REAR HATCH ON BOTH SIDES OF THE REAR FORD LOGO.( I NOW NOTICE MANY FORD EXPLORERS WITH SAME CRACKS). TOP RIGHT GLASS HINGE TWISTED SIGNIFICANTLY AND TOP LEFT GLASS HINGE TWISTED SLIGHTLY. THE FASTENING BOLTS FOR BOTH GLASS HINGES ARE RUSTED THROUGH. THIS RESULTED IN THE REAR GLASS WINDOW SHIFTING, APPARENTLY CAUSING THE CRACKS IN THE TAIL GATE. I CONTACTED SUNSHINE FORD'S SERVICE DEPT. IN NEWBURGH, NY AND WAS TOLD FORD IS NOT RESPONSIBLE FOR FIXING/REPLACING THIS DEFECT. THEY CHOSE THEIR WORDS CAREFULLY. THEY EMPHASIZED THAT "MY MODEL YEAR" WAS NOT RECALLED FOR THIS DEFECT. I ASKED IF "ANY" EXPLORERS HAD A RECALL FOR THIS DEFECT. THEY WOULD NOT SAY; BUT INSTEAD REPEATED,"MY MODEL YEAR" WAS NOT RECALLED FOR THIS DEFECT. NHTSA HAS ALREADY RECEIVED CONSUMER COMPLAINTS OF INJURIES FROM OWNERS WHOSE LIFT GATE GLASS BROKE OFF ITS MOUNTING HINGE WHILE OPEN, AND CAUSED HEAD INJURIES. IT IS ONLY A MATTER OF TIME BEFORE A REAR LIFT GLASS PANEL DETACHES FROM AN EXPLORER IN MOTION ON A HIGHWAY. THAT COULD EASILY LEAD TO A MULTI VEHICLE ACCIDENT ALONG WITH MULTIPLE FATALITIES. I CHECKED AND FORD HAD A SIMILAR PART RECALL FOR 2002 & 2003 EXPLORERS. FORD CHANGED THE PART THEN AND HAS NOT MET THE # OF COMPLAINTS TO BE FORCED TO RECALL 2004 AND UP EXPLORERS. UNFORTUNATELY, I THINK MANY EXPLORER OWNERS CHECK WITH THE DEALER AS TO WHETHER OR NOT THERE WAS/IS A RECALL AND GIVE UP UPON HEARING NO. WE NEED TO GET ANYONE WE KNOW WITH THIS PROBLEM TO FILE A COMPLAINT WITH THE NHTSA. IT IS ONLY A MATTER OF TIME BEFORE SOME INNOCENT PERSON DIES AS A RESULT OF THIS "KNOWN" DEFECT! AS I UNDERSTAND IT, THIS IS A KNOWN DEFECT FOR WHICH FORD IS NOT WILLING TO TAKE RESPONSIBILITY. FORD SHOULD FIX THIS PROBLEM AT NO COST. *TR
Structure, Mar 7, 2014
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR LIFT GATE WAS FRACTURED DIRECTLY ON THE LOGO WHERE THE LIFT GATE LOCK WAS LOCATED. THE DEFECT COULD HAVE CAUSED THE REAR LIFT GATE TO OPEN WHILE DRIVING. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 14,000 AND THE CURRENT MILEAGE WAS 16,000. *TR
Structure, Mar 6, 2014
CRACKED PANEL BELOW REAR WINDOW, WENT TO GARAGE AND FOUND THIS, CRACKED ALL THE WAY THRU. *TR
Seat belts, Structure, Feb 27, 2014
REAR LIFT GATE PLASTIC CRACKED THROUGH FORD LOGO WITH NO CONTACT. THIRD ROW SEATBELT STUCK AND HARD TO RELEASE.
Structure, Feb 16, 2014
CRACK IN REAR HATCH BELOW REAR WINDOW. AS I UNDERSTAND IT, THIS IS A KNOWN FAULT FOR WHICH FORD IS NOT WILLING TO TAKE RESPONSIBILITY. FORD SHOULD FIX PROBLEM AT NO COST. *TR
Structure, Feb 10, 2014
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR LIFTGATE WAS CRACKED. THE VEHICLE WAS NOT TAKEN TO A DEALER OR AN INDEPENDENT MECHANIC FOR REPAIRS. THE MANUFACTURER WAS NOTIFIED OF THE ISSUE. THE APPROXIMATE FAILURE MILEAGE WAS 89,846.
Structure, Jan 27, 2014
TL* THE CONTACT OWNS A 2004 FORD FORD EXPLORER. THE CONTACT STATED THERE WAS A CRACK UNDERNEATH THE WINDOW OF THE TAILGATE. THE VEHICLE WAS NOT TAKEN TO A DEALER OR AN INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING OR TO BE REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 8,627. ..UPDATED 03/25/14 *BF
Structure, Jan 5, 2014
MY CAR WAS PARKED OUTSIDE OF THE GROCERY STORE. I OPENED THE REAR HATCH TO LOAD MY GROCERIES. AS I REACHED UP TO CLOSE THE HATCH THE RIGHT SIDE OF IT COLLAPSED AND FELL RIGHT ON MY HEAD LEAVING A LARGE LUMP. UPON INVESTIGATION I FOUND THAT THE HINGE ON THE RIGHT SIDE OF THE HATCH HAD SNAPPED AND THE WEIGHT OF THE HATCH HAS TWISTED THE HINGE ON THE LEFT SIDE. LUCKILY, I BROKE THE FALL OF THE HATCH OR THERE WOULD HAVE BEEN SHATTERED GLASS EVERYWHERE. DEFINITELY A SAFETY ISSUE. *TR
Structure, Nov 27, 2013
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT NOTICED A CRACK ON THE LIFT GATE NEAR THE MANUFACTURER'S EMBLEM. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 147,000.
Structure, Nov 26, 2013
THE REAR LIFTGATE PANEL CRACKED FOR NO APPARENT REASON. *TR
Structure, Nov 12, 2013
TL* THE CONTACT OWNS A 2004 FORD EXPLORER XLT. THE CONTACT STATED THAT UPON INSPECTION, THE LEFT HINGE THAT HELD THE TRUNK WINDOW SNAPPED UNEXPECTEDLY. THE WINDOW WAS HELD BY THE CONTACT WHILE ANOTHER PERSON LATCHED THE WINDOW BACK INTO PLACE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS 25,000.
Structure, Oct 23, 2013
THE FORD MOTOR COMPANY IS WELL AWARE OF THE PROBLEM WITH ITS FORD EXPLORERS PRODUCED 2002-2008. THE BACK DOOR PANEL CRACKS ALL THE WAY THROUGH JUST UNDER THE WINDOW. THERE ARE THOUSANDS OF OWNERS WITH THIS PROBLEM AND MANY DOCUMENTED WHO HAVE BEEN DRIVING THE VEHICLE AND HAD THE BACK WINDOW COMPLETELY EXPLODE. THERE IS NO TELLING WHEN THIS IS GOING TO HAPPEN ONLY TO ALARM THE DRIVER AND CAUSE A MAJOR FREEWAY ACCIDENT. RIGHT NOW THERE IS A CLASS ACTION LAWSUIT MOVING TO GET THE FORD COMPANY TO REPAIR THIS PROBLEM. BUT THEY ARE WAITING FOR A MAJOR ACCIDENT, INJURY OR LOSS OF LIFE TO DO THE RIGHT THING. *TR
Structure, Oct 7, 2013
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT HE OPENED THE REAR TRUNK WINDOW AND THE LEFT HINGE BECAME FRACTURED. THE WINDOW FELL ONTO THE CONTACT UNEXPECTEDLY, WHICH SAVED THE WINDOW FROM FALLING AND SHATTERING. THE VEHICLE WAS TAKEN TO A DEALER WHERE THE MECHANIC STATED THAT THE HINGE WOULD NEED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS 80,602.
Structure, Sep 17, 2013
WHILE DRIVING AT 45MPH NOTICED TOO MUCH BODY ROLL AND BOUNCING. INSTALLED NEW SHOCKS AND SWAY BARS AND HAD IT ALIGNED AND IT STILL HAD TOO MUCH BODY ROLL AND BOUNCING. HAD IT UP ON A LIFT AN NOTICED THE BODY BUSHING WERE ALL DETERIORATED AND FALLING APART. GOOGLED THIS ITEM AND FOUND MANY SPORT TRAC OWNERS HAVING THE SAME PROBLEM. IT SEEMS FORD PURCHASED INFERIOR BODY BUSHINGS FROM A VENDOR AND HAS NEVER CORRECTED THIS ISSUE. THE VEHICLE FEELS VERY UNSAFE TO DRIVE! IN ORDER TO CHANGE THESE OUT YOU HAVE TO REMOVE THE INTERIOR OF THE VEHICLE 1ST. THIS IS A VERY EXPENSIVE REPAIR AND IF LEFT UNDONE THE VEHICLE IS UNSAFE TO DRIVE. I HAVE NEVER HEARD OF THIS BEING A MAINTENANCE ITEM ON ANY OTHER VEHICLE. *TR
Structure, Sep 3, 2013
TL* THE CONTACT OWNS A 2004 FORD EXPLORER SPORT TRAC. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 40 MPH, THE SPARE TIRE DETACHED FROM THE TIRE WELL FROM UNDER THE CARRIAGE. THE FAILURE WAS RELATED TO A FRACTURED CABLE HARNESS. VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 97,600.
Power train, Electrical system, Structure, Engine, Aug 28, 2013
ON THE BODY THE TAILGATE PANEL KEEPS CRACKING THIS MAKES MY TRUCK LOOK BAD COMPARED TO THE MONEY I PUT INTO IT. MY ENGINE OR TRANSMISSION ACTS AS IF SOMETHING IS WRONG IT IS NOT SHIFTING GEAR RIGHT. ON THE ELECTRICAL TIRE PRESSURE LIGHT KEEPS COMING ON AND IT ALSO KEEPS LEAKING WATER FROM SOMEWHERE. FORD NEEDS TO GO OUT OF BUSINESS FOR SELLING THESE PIECES OF JUNK. IT MAKES NO SENSE. *TT
Structure, Aug 22, 2013
REAR LIFT GATE HINGES CRACKING AT PIN CAUSING REAR GATE GLASS TO SHIFT DOWN AND TAILGATE NOT TO LATCH CORRECTLY. *TR
Structure, Visibility/wiper, Jun 9, 2013
I OPENED THE LIFT GATE WINDOW TO LOAD GROCERIES WHEN THE RIGHT SIDE OF THE WINDOW SUDDENLY LET GO UP NEAR THE HINGE. THIS CAUSED THE RIGHT SIDE OF THE WINDOW TO DROP AND THEN THE LEFT HINGE BROKE, CAUSING THE ENTIRE REAR WINDOW TO DROP. I WAS ABLE TO CATCH IT SO IT DIDN'T BREAK AND EVENTUALLY RELEASE THE SUPPORT STRUTS SO I COULD GET IT INTO THE BACK OF THE VEHICLE. IT APPEARS THAT THE FASTENER NEAR THE HINGE WAS CORRODED THROUGH AND WHEN I TRIED TO OPEN THE WINDOW THE WEIGHT WAS FINALLY TOO MUCH FOR IT SO IT SNAPPED, RELEASING THE WINDOW ON THAT SIDE. FORTUNATELY THIS FASTENER FAILED IN A PARKING LOT AND NOT ON A FREEWAY OR THE WHOLE REAR WINDOW MAY HAVE COME OFF AND POSED A DANGER TO THE CARS BEHIND. FORD HAS ALREADY ISSUED A RECALL FOR 2002 AND 2003 MODELS WHICH USED THE SAME HINGE ASSEMBLY, DON'T KNOW WHY 2004 WAS NOT INCLUDED. *TR
Structure, May 23, 2013
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR HATCH WAS DEFECTIVE AND THE PLASTIC THAT COVERED THE LICENSE PLATE AREA ON THE HATCH BECAME FRACTURED. AS A RESULT, WHEN THE HATCH WAS OPENED, THE CONTACT AND TWO CHILDREN SUSTAINED LACERATIONS TO THE HANDS. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 35,000 AND THE CURRENT MILEAGE WAS 114,000.
Structure, May 13, 2013
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE HORIZONTAL PANEL UNDER THE REAR LIFT GATE WAS FRACTURED. THE VEHICLE WAS NOT TAKEN TO A DEALER. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE AND CURRENT MILEAGE WAS 99,000. *TR
Structure, May 8, 2013
THE RIGHT HINGE ON THE REAR WINDOW LIFT GATE IS CORRODED AND AS A RESULT IS HALF BROKEN OFF. THE WINDOW RATTLES DUE TO IT BEING LOOSE. THE LEFT HINGE IS NOW STARTING TO DO THE EXACT SAME THING. THERE HAVE BEEN TIMES WHEN I TURN THE VEHICLE ON AND THE MESSAGE CENTER WILL INDICATE 'REAR LIFTGATE AJAR' AND IT IS THE WINDOW HATCH THAT IS AJAR. I FEEL THIS ISSUE W/THE HINGE WILL AJAR FROM THE LATCH. I CALLED A LOCAL DEALERSHIP TO SEE IF THIS WAS A RECALL AND HE STATED NOT ON MY SPECIFIC VEHICLE AFTER GIVING HIM MY VIN. I FEEL THIS IS A HUGE SAFETY ISSUE. I REFRAIN USE OF THE WINDOW IN THE FEAR IT WILL FALL ON ME. NOW MY FEAR IS THE WINDOW WILL FALL COMPLETELY OFF WHILE DRIVING.
Exterior lighting, Air bags, Structure, May 1, 2013, crash
DRIVING 65 MPH, LOST CONTROL OF MY VEHICLE WHILE SWITCHING LANES TO AVOID A HIGH SPEED VEHICLE APPROACHING BEHIND ME. RAN IN TO A MEDIAN 2 TIMES BEFORE STOPPING FACED TRAFFIC HEAD ON. FORTUNATELY, I WASN'T CRITICALLY INJURED, BUT SERIOUS ENOUGH. NEITHER AIR BAG DEPLOYED!!!! I WOULD LIKE TO KNOW WHY NOT???? *TR
Structure, Apr 30, 2013
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE HORIZONTAL PANEL UNDER THE REAR LIFT GATE WAS FRACTURED. THE VEHICLE WAS NOT TAKEN TO A DEALER. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE AND CURRENT MILEAGE WAS 85,000. *TR