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, Aug 7, 2012
UPON OPENING THE REAR LIFT GATE, THE HINGES COMPLETELY GAVE OUT AND THE LIFT GATE FELL AWAY FROM THE TRUCK. I WAS FORTUNATE IN THAT I WAS ABLE TO CATCH AND HOLD IT, AS MY 5 YEAR OLD SON WAS STANDING BENEATH IN ORDER TO HAND ME HIS BEACH TOYS, AT THE TIME OF THE INCIDENT. I HAD TO HOLD THE (VERY HEAVY) LIFT GATE UNTIL A MECHANIC ARRIVED TO DETACH ELECTRICAL COMPONENTS AND PLACED THE LIFT GATE INSIDE THE 2004 FORD EXPLORER. I THEN HAD TO DRIVE HOME WITH NO LIFT GATE WHILE EXHAUST FUMES FILLED THE TRUCK. IT SHOULD BE NOTED THAT PRIOR TO THIS INCIDENT, THE TAILGATE CRACKED, WHICH I SEE IS A COMMON ISSUE WITH THIS PARTICULAR VEHICLE AND THE SUBJECT OF A CLASS ACTION LAWSUIT. *TR
Structure, Visibility/wiper, Aug 1, 2012
WE WERE DRIVING DOWN THE STREET AND THE HATCHBACK/LIFTGATE FELL OFF THE HINGES. I HAVE NOT BEEN ABLE TO DRIVE THIS CAR IN OVER TWO YEARS DUE TO THE FACT THAT I CANNOT AFFORD TO PAY FOR A MANUFACTURER'S DEFECT. I HAVE FILED NUMEROUS COMPLAINTS ON THIS VEHICLE OVER THE YEARS. IT HAS BEEN SITTING IN THE GARAGE. I KNOW THAT YOU INVESTIGATED IN 2008 RQ08003. I HOPE WE GET SOME ASSISTANCE. MY PREVIOUS COMPLAINT FILE NUMBERS ARE 05687908: LISTS THE ENGINE BLOWING UP, MIRROR FALLING OFF, CRUISE CONTROL SHUTTING OFF, ETC. BUT I HAVE RECEIVED NO ASSISTANCE FROM NHTSA. I HAVE SPENT OVER $3,000.00 ON THIS CAR FOR MANUFACTURING DEFECTS. (DOCUMENTED). *TR
Structure, Jul 30, 2012
THE REAR HATCH JUST CAME OFF AS I WAS DRIVING OUT OUT OF A STORE, THE HINGE JUST BROKE OFF. *TR
Structure, Jul 24, 2012
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE HINGES ON THE REAR LIFTGATE BROKE AND THE WINDOW FELL DOWN ON THE CONTACT'S SHOULDER, RESULTING IN A SHOULDER INJURY. THE CONTACT TOOK THE VEHICLE TO THE DEALER AND WAS INFORMED THAT THE HINGES ON THE REAR LIFTGATE NEEDED TO BE REPLACED. THE DEALER ALSO STATED THAT THE VEHICLE WAS NOT INCLUDED IN THE RECALL ASSOCIATED WITH NHTSA CAMPAIGN ID NUMBER: 04V442000 (STRUCTURE: BODY: HATCHBACK/LIFGATE: HINGE AND ATTACHMENTS). THE FAILURE AND CURRENT MILEAGES WERE 160,000.
Structure, Jul 18, 2012
THE LEFT (DRIVER SIDE) REAR LIFT GATE HINGE BROKE MAKING THE REAR LIFT GATE AND WINDOW UNUSABLE. THIS OCCURRED WHEN I WAS GOING TO CLOSE THE DOOR, THANKFULLY IT WAS ONLY THE WINDOW SECTION THAT WAS BEING CLOSED AS I'M SURE THE DOOR ITSELF IS PRETTY HEAVY. *TR
Visibility, Structure, Jul 5, 2012
THE HINGES THAT HOLD ON THE REAR WINDOW ARE STARTING TO BREAK. THE 02 AND 03 MODEL EXPLORERS WERE RECALLED FOR THIS BUT FORD REFUSES TO ISSUE A RECALL FOR THE 2004 MODELS EVEN THOUGH THIS APPEARS TO BE A HUGE ISSUE AFFECTING A LARGE NUMBERS OF EXPLORERS. I HAVE CAUGHT IT BEFORE TOTAL FAILURE BUT MANY PEOPLE HAVE HAD THE GLASS COME LOOSE AND INJURE THEM. IT IS A HUGE SAFETY ISSUE. *TR
Structure, Jun 29, 2012
THE HATCH BACK CRACKED DOWN THE MIDDLE. RIGHT BELOW THE WINDOWS. I JUST SHUT THE GLASS DOOR AND NOTICE A CRACK. *TR
Structure, Jun 29, 2012
RIGHT REAR LIFTGATE WINDOW HINGE FAILED (CRACKED) CAUSING HEAVY (APPRX 40 LB) GLASS LIFTGATE GLASS PANEL TO FALL ON A PERSON CAUSING MINOR INJURY. APPEARS 02/03 MODELS RECALLED FOR SAME ISSUE (DESPITE FORD'S RESPONSE ON THE FIRST INVESTIGATION OF THIS IT IS THE SAME ISSUE AS 02/03). THE HINGE PART IS INADEQUATE TO HOLD THE HEAVY GLASS PANEL IN PLACE OVER TIME WITH USE. SINCE THE BACK GLASS IS A HEAVY SLAB OF UNFRAMED, TEMPERED GLASS IT COULD "EXPLODE" IF IT FALLS POTENTIALLY CAUSING SERIOUS INJURY OR TRAFFIC ACCIDENTS TO TRAILING VEHICLES. FORD APPARENTLY DOES A GOOD BUSINESS IN SELLING THESE REPLACEMENT HINGES AT A COST OF OVER $100 EACH FOR A SMALL PIECE OF WEAK CAST METAL. FORTY POUND SLABS OF GLASS FALLING OFF OF VEHICLES WITH NO PRIOR WARNING IS A SAFETY ISSUE! RESEARCH INDICATED MANY OTHER OWNERS WITH THE SAME COMPLAINT. *TR
Structure, Jun 13, 2012
TL* THE CONTACT OWNS A FORD 2004 FORD EXPLORER. THE CONTACT STATED THAT THE LOWER PORTION OF THE LIFT GATE GLASS EXHIBITED A LONG STRESS CRACK. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 69,000. THE VIN WAS UNAVAILABLE.
Structure, Jun 12, 2012
THE PLASTIC PIECE OF MOLDING UNDERNEATH THE REAR GLASS WINDOW CRACKED AND FELL OFF. NOTHING WAS DONE TO PROMPT THIS. I HAVE READ THAT THOUSANDS OF OTHER VEHICLES HAVE THIS SAME ISSUE. *TR
Structure, May 22, 2012
THE LEFT REAR LIFT GATE WINDOW HINGE BROKE CAUSING THE WINDOW TO FALL AND BRUISE MY DAUGHTER'S ARM. TERRIBLE DESIGN AND FRAUGHT WITH PERIL. *TT
Engine and engine cooling, Structure, May 19, 2012
I WAS DRIVING DOWN THE STREET AND HEARD A NOISE. WE TURNED AROUND AND THE LIFTGATE HAD FALLEN OFF ITS ON HINGES AND WAS HANGING LOOSE ON BOTH SIDES. WE HAD TO HOLD IT ON AND DRIVE THE CAR BACK HOME. THE CAR HAS NOT BEEN DRIVEN SINCE THAT DATE IN 2010. FORD NEEDS TO BE RESPONSIBLE FOR THE 2004 MODEL AND ALL OF ITS DEFECTIVE PRODUCTS. THIS IS THE SECOND COMPLAINT THAT I HAVE FILED AGAINST FORD CONCERNING THIS CAR. THE FIRST WAS A #2 VALVE FALLING IN THE ENGINE AND CAUSING THE ENGINE TO BLOW UP. NHTSA PLEASE DO SOMETHING ABOUT FORD. SOMEONE HAS TO MAKE CAR MANUFACTURERS RESPONSIBLE TO THE CONSUMER. EVERY TIME THAT NHTSA IS CONTACTED NOTHING IS DONE UNTIL MILLIONS ARE NEGATIVELY AFFECTED. *TR
Structure, Apr 23, 2012
MY 11 YEAR OLD DAUGHTER WENT TO CLOSE THE REAR WINDOW GATE AND THE RIGHT HINGE BROKE OFF AT WHERE THE HINGE ATTACHES TO THE WINDOW. MY WIFE AND DAUGHTER TRIED TO GET IT LINED UP WITH THE HINGE AGAIN BUT WAS NOT ABLE TO DO ANYTHING WITH IT AND HAD TO DRIVE HOME WITH THE WINDOWS HANGING BY THE STRUTS. LATER WHEN I GOT HOME I NOTICED THAT THE RIGHT STRUT WAS NOT DECOMPRESSING AS WELL WHICH PROBABLY PUT SOME PRESSURE ON THE HINGE. I TRIED TO PUSH IT BACK UP MANUALLY IT WOULDN'T BUDGE. I WAS ABLE TO REMOVE THE RIGHT STRUT AND CLOSE AND LATCH THE WINDOW BUT NOW IT'S CROOKED AND OBVIOUSLY NOT WORKING. I DID RESEARCH AND SEE THERE ARE TONS OF COMPLAINTS ABOUT THIS SAME THING HAPPENING ON 04 EXPLORERS. I AM VERY CONCERNED THAT THE WINDOW WILL FALL OFF AND THIS ALMOST CAUSED BODILY HARM TO MY DAUGHTER WHEN IT FAILED AND FELL. *TR
Visibility, Structure, Apr 22, 2012
ON 19 APR 2012 WHILE OPENING THE BACK HATCH WINDOW, THE PASSENGER SIDE HINGE OF THE WINDOW FAILED. WHEN THIS OCCURRED THE DRIVER SIDE HINGE WAS BENT AND THE HYDRULIC LIFTS POPPED OPEN THE WINDOW RATHER RAPIDLY WHICH COULD HAVE SEVERELY INJURED ME IF IT HIT ME. I WAS UNABLE TO CLOSE THE WINDOW MYSELF SO I COULD DRIVE AGAIN. A BYSTANDER HELPED ME OUT TO CLOSE IT. AFTER READING OTHER REPORTS AND COMPLAINTS ONLINE, THIS IS NOT AN ISOLATED INCIDENT FOR 2004 FORD EXPLORERS. *TR
Visibility, Structure, Apr 14, 2012
WHILE LOADING GROCERIES, I NOTICED THE HINGES TO MY REAR WINDOW WERE CRACKED. I QUIT USING THE WINDOW IN FEAR OF IT BREAKING. THE COST TO REPLACE THE PLASTIC HINGE IS COMPLETELY OUTRAGEOUS! I ALSO HAD A FRIEND CALL TODAY AND HIS HINGE BROKE, THANKFULLY THE GLASS DID NOT BREAK. FORD KNOWS THE HINGES ARE DEFECTIVE. WHY WOULD A MAJOR COMPANY LIKE FORD OVERLOOK THIS PROBLEM AND TAKE A CHANCE OF MANY LAW SUITS DUE TO THEIR NEGLIGENCE? THERE ARE OVER 1600 COMPLAINTS RECORDED. HOW MANY MORE IS NEEDED FOR A RECALL? FORD NEEDS TO STAND BEHIND THEIR PRODUCT. I HESITATED BUYING THIS FORD BECAUSE MY FIRST FORD CAUGHT FIRE WHILE I WAS DRIVING IT. THIRTY YEARS LATER I STILL THINK OF ALL THE BAD STORIES AND NOW, I WANT MY CHEVY BACK. *TR
Structure, Mar 19, 2012
TL* THE CONTACT OWNS A 2004 FORD EXPLORER SPORT. THE CONTACT STATED THAT THE VEHICLE WAS PARKED WHEN SHE NOTICED THAT THE HINGE ON THE REAR LIFTGATE WAS NOT PROPERLY HOLDING ONTO THE GLASS. AS A RESULT, THE GLASS WAS SLIDING DOWN INTO THE LIFT GATE PANEL. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND THEY WERE UNABLE TO DIAGNOSE THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS UNKNOWN.
Visibility, Structure, Mar 8, 2012
THE HINGES THAT HOLD ON THE REAR WINDOW ARE FAILING AND I CANNOT OPEN THE REAR WINDOW BECAUSE I AM AFRAID THAT IT WILL FALL OFF. OTHER YEAR EXPLORERS WERE RECALLED FOR THIS VERY REASON AND I CANNOT UNDERSTAND WHY THE 2004 MODEL WAS NOT RECALLED. THE PARTS ARE THE SAME AS THEY WERE IN OTHER YEARS. *TR
Structure, Feb 21, 2012
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THERE WAS A 6-INCH CRACK FROM THE BASE OF THE REAR WINDOW TO THE LICENSE PLATE. THE DEALER WAS NOT CONTACTED. THE MANUFACTURER WAS CONTACTED, BUT DENIED ANY ASSISTANCE WITH REPAIRS TO THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE AND CURRENT MILEAGE WAS 70,000. THE VIN WAS UNAVAILABLE.
Structure, Feb 21, 2012
AFTER A COLD SPELL IN JANUARY THE PANEL UNDER THE REAR WINDOW FRACTURED FROM THE WINDOW DOWN. WE TOOK THE CAR TO THE FORD DEALER AND WAS TOLD THIS IS VERY COMMON AND IT WOULD BE AROUND $400.00 DOLLARS TO FIX. IF THIS IS COMMON WHY IS FORD NOT CORRECTING THIS WITHOUT THE CUSTOMER HAVING TO PAY OUT OF POCKET. IT SEEMS THIS IS A MANUFACTURING PROBLEM NOT A CONSUMERS! *TR
Structure, Feb 7, 2012
REAR BODY PANEL APPLIQUE FORD SERIES PART #402A30. *TR
Structure, Feb 1, 2012
WHEN WE HAD THE COLD SNAP A FEW WEEKS AGO, A PLASTIC PANEL, UNDER THE REAR WINDOW CRACKED. THE COST TO REPAIR THIS IS ABOUT $450 TO $550. SEARCHING ON LINE, THIS SEEMS TO BE A PROBLEM OVER A NUMBER OF MODEL YEARS, AS THERE ARE SEVERAL HUNDRED REPORTS. IN THE PAST WEEK, I HAVE SEEN 7 MORE EXPLORERS WITH A SIMILAR CRACK. FORD CUSTOMER SERVICE SAYS THERE IS NO RECALL. IT IS NOT A SAFETY ISSUE, BUT IT IS EXPENSIVE TO REPAIR. *TR
Structure, Jan 18, 2012
UPDATE ON REAR CRACKED PANEL: REAR BACK PANEL REPLACED TWICE. FORD SERVICE TOLD ME IT WOULD COST APPROX $800 TO REPLACE CRACKED PANEL AGAIN THEN SUGGESTED I TAKE MY '04 FORD EXPLORER TO A BODY SHOP FOR A REPAIR AT A COST OF APPROX $200 WHICH I DID. THAT REPAIR LASTED ABOUT 3 MONTHS...PANEL HAS CRACKED AGAIN. IF THE GLASS FALLS OUT SOMEONE IS GOING TO GET HURT. IT IS RIDICULOUS THAT FORD WILL NOT TAKE FULL RESPONSIBILITY FOR THIS DEFECTIVE PART.
Structure, Jan 12, 2012
ABOUT A YEAR AGO I NOTICED THE PANEL BELOW THE REAR WINDOW START TO CRACK. AS TIME WENT ON THE CRACK CONTINUED DOWN THE ENTIRE PANEL NEXT TO THE FORD EMBLEM. THE REAR WINDOW NOW MAKES A RATTLING NOISE. I DON'T KNOW IF IT WILL LOOSEN ENOUGH FOR IT TO POP OUT IF I HIT A BUMP IN THE ROAD. IT HAS CERTAINLY REDUCED THE VALUE OF THE VEHICLE. I WENT ONLINE TO SEE IF ANYONE ELSE WAS HAVING THIS PROBLEM AND WAS SHOCKED TO SEE HUNDREDS OF COMMENTS. I CONTACTED FORD AND THEY SAID THERE WAS NO RECALL FROM YOU AND THAT UNTIL THERE WAS I SHOULD GO AHEAD AND HAVE IT FIXED. REPAIR COSTS SEEM TO BE AROUND $400. FOR THE PANEL PLUS PAINTING. I REALLY THINK A DESIGN FLAW SHOULD NOT BE MY PROBLEM. THEY KNOW IT WAS A FLAW SINCE THE NEWER MODELS ARE DESIGNED COMPLETELY DIFFERENT. *TR
Visibility, Structure, Jan 7, 2012
WHILE AT WORK MY REAR LIFT GATE WINDOW EXPLODED. AT FIRST SITE I THOUGHT IT WAS VANDALISM BUT NOTHING (CAR CHARGERS/CD'S/ ROAD SIDE KIT ETC) WAS TAKEN. AFTER FURTHER INVESTIGATING, THINGS JUST DIDN'T ADD UP NOR WERE CONSISTENT WITH THE SITE OF MY DESTRUCTIVE REAR WINDOW AND UPLIFTING OF THE PANEL UNDERNEATH THE SHATTERED GLASS (WHICH WAS MOSTLY ON THE GROUND AS OPPOSED TO BEING INSIDE MY VEHICLE.) *TR
Structure, Dec 29, 2011
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR LIFTGATE EXHIBITED A FRACTURE THAT STARTED FROM THE TOP OF THE MANUFACTURING EMBLEM AND DOWN TO THE BOTTOM OF THE LIFTGATE. THE CONTACT SPOKE WITH THE MANUFACTURER BUT WAS ADVISED THAT THERE WAS NOTHING THAT COULD BE DONE TO ASSIST. THE VEHICLE WAS NOT REPAIRED. THE CURRENT MILEAGE WAS 89,000 AND THE FAILURE MILEAGE WAS UNKNOWN.