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
Visibility, Structure, Dec 14, 2011
THE REAR PASSENGER WINDOW HINGE BROKE CAUSING THE GLASS TO FALL ON TOP OF ME AND HIT ME IN THE HEAD AND KNOCK ME DOWN TO THE GROUND. *TR
Visibility, Structure, Dec 11, 2011
CRACKED PANEL BELOW REAR WINDOW. ALSO, REAR WINDOW APPEARS LOOSE. *TR
Structure, Dec 5, 2011
TL* THE CONTACT OWNS A 2004 FORD EXPLORER LIMITED. THE CONTACT STATED THAT THE REAR LIFTGATE WAS FRACTURED AND THE CONTACT WAS CONCERNED THAT THE WINDOW WOULD POSSIBLY FALL OUT WHILE DRIVING. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THEY ADVISED HIM THAT THE FAILURE WAS NOT A SAFETY CONCERN AND OFFERED NO FURTHER ASSISTANCE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED AND THEY OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 58,000.
Structure, Dec 3, 2011
I HAVE THIS CRACK IN THE MIDDLE OF MY LIFTGATE AND I HAVE SEEN SOME OTHER FORD EXPLORERS AND FOUND ON INTERNET COMPLAINTS ABOUT IT. I CALLED FORD DEALER AND THEY SAID THERE WAS NO RECALL FOR THIS. AS I HAVE SAID. I HAVE SEEN OTHER FORDS WITH THE SAME CRACK ON THE MIDDLE OF THE LIFT GATE. *TR
Power train, Structure, Nov 28, 2011
TRANSMISSION WAS WORKING JUST FINE TILL ONE DAY IT WOULDN'T SHIFT INTO OVERDRIVE AND THEN IT WAS SHIFTING HARD FROM 2ND TO 3RD. REAR WINDOW HINGES BROKE. REAR TAIL GATE CRACKED RIGHT DOWN THE MIDDLE BY FORD SYMBOL. ALSO JUST THE OTHER DAY MY PASSENGER WINDOW STOPPED WORKING NO SIGNS NOTHING OF ANYTHING WRONG. I'M GOING TO START BUYING CHEVY THIS IS JUST UNACCEPTABLE. NO WONDER AMERICA IS NOT DOING GOOD OUR CAR COMPANY'S CAN'T MAKE GOOD PRODUCTS ANYMORE. *KB
Structure, Oct 24, 2011
REAR LIFTGATE GLASS HATCH FAILURE HINGE AND ATTACHMENTS BACK GLASS FAIL OFF. *TR
Structure, Oct 12, 2011
PAINT BUBBLES IN THE HOOD. THE DEALER JUST RESPONDED THAT IT WAS A MANUFACTURERS PROBLEM AND THAT I WOULD JUST NEED TO REPLACE THE ENTIRE HOOD AT A LARGE COST. *KB
Structure, Oct 11, 2011
I WENT TO INSTALL A PAIR OF STEP BARS ON MY TRUCK, AND NOTICED THAT MY BODY BUSHINGS LOOKED ODD. I TOUCHED ONE OF THEM AND IT CRUMBLED, AND UPON FURTHER INVESTIGATION I NOTICED AT LEAST 3 SETS ON EACH SIDE WERE IN THE SAME SHAPE. I CALLED FORD CUSTOMER SERVICE AND WAS TOLD TO TAKE IT TO THE DEALER TO HAVE IT CHECKED, AND THAT THERE WAS NO WARRANTY, CUSTOMER SATISFACTION PLAN, OR RECALL. I TOLD THEM I WAS A MECHANIC AND DID NOT NEED TO GO TO THE DEALER, BUT THEY DID REGISTER MY COMPLAINT. I HAVE NEVER SEEN BODY BUSHINGS IN SUCH STATE ON ANY NAME BRAND OR MODEL VEHICLE, EVEN AFTER THEY WERE 20 OR SO YEARS OLD. I HAVE SEEN THEM FLATTEN OUT, BUT NEVER DETERIORATE. I FEEL SURE THAT THE MATERIAL USED IS OF POOR QUALITY. BY NOT REPLACING THEM, THERE IS A RISK OF BODY CRACKING OR OTHER FAILURES. I FEEL THAT FORD SHOULD HAVE A RECALL ON THEM. AFTER SEARCHING THE INTERNET, I FIND THAT I AM NOT ALONE, AND FEEL THAT THERE ARE MANY MORE PEOPLE WITH THE SAME PROBLEM, THEY JUST DONT KNOW IT. *KB
Structure, Oct 10, 2011
THE REAR LIFT GLASS HINGES ON MY 2004 FORD EXPLORER BROKE DURING USE OF THE LIFT GLASS. THE PIN BROKE RIGHT THROUGH THE HINGE ON BOTH SIDES. THIS HAPPENED WHILE CAR WAS PARKED AND LIFT GATE WINDOW WAS OPEN. LEFT SIDE JUST FELL, AND THEN RIGHT ABOUT 1 MINUTE LATER, I JUST HAPPENED TO HAVE SOME 2X4'S IN THE BACK WHICH PREVENTED THE WINDOW FROM FALLING TO THE GROUND. THIS SEEMS LIKE A PRETTY DANGEROUS DEFECT. INTERNET RESEARCH HAS REVEALED THIS ISSUE WAS CAUSE FOR A RECALL ON THE '02 & '03 EXPLORER AND SEEMS TO BE WIDE SPREAD ON THE '04, YET NO RECALL FOR THE '04. *KB
Structure, Oct 10, 2011
I WAS AT A GROCERY STORE WITH MY YOUNG CHILDREN, CAME OUTSIDE, POPPED THE TAILGATE (TOP HALF OF THE TRUNK ON FORD EXPLORER) AND LOADED MY GROCERIES IN THE CAR. MY 12 YEAR OLD THEN WENT TO CLOSE THE TRUNK (TOP HALF ONLY) AND THE LEFT SIDE OF THE TAILGATE CAME OFF OF THE HINGES. THE WINDOW/TAILGATE WAS EXTREMELY HEAVY, SO I HAD TO RUN TO THE BACK OF THE CAR AND HELP HER TO HOLD THE WINDOW UP. THEN, AS WE WERE TRYING TO PUT THE WINDOW/TAILGATE BACK ONTO THE HINGE, THE OTHER HINGE BROKE AND THE WHOLE WINDOW CAME DOWN. THE WINDOW WAS ONLY CONNECTED BY THE WIRING AND THE SHOCKS THAT ARE INSIDE THE WINDOW. WE EASILY COULD HAVE BEEN INJURED BY THIS FALLING WINDOW/TAILGATE. MIND YOU I HAD NO WARNING THAT THESE WERE GOING TO FAIL...NO CRACKS, NO PROBLEMS CLOSING THE TAILGATE, NOTHING! MY DAUGHTER, A WOMAN WHO WAS IN THE PARKING LOT, AND I COULD NOT GET THE WINDOW BACK ON SO I COULD DRIVE IT HOME (45 MINUTES AWAY), SO I HAD TO CALL MY BROTHER IN LAW TO COME HELP ME BECAUSE HE WAS CLOSEBY. HE ENDED UP HAVING TO TAKE THE SHOCKS OF THE WINDOW/TAILGATE OFF COMPLETELY, SO THAT WE COULD PUT THE WINDOW/TAILGATE INTO THE CAR SO I COULD DRIVE IT HOME. THE WIRING WAS STILL CONNECTED. I HAVE CONTACTED FORD DIRECTLY, AND THEY WILL NOT TAKE RESPONSIBILITY FOR THIS FAILURE...EVEN THOUGH THEY HAVE DONE RECALLS ON THE 2002 AND 2003 FORD EXPLORER PLASTIC HINGES FOR THE TAILGATE. SAME PROBLEM, DIFFERENT YEAR. I HAVE RESEARCHED ONLINE LOOKING TO FIND IF MY 2004 EXPLORER HAD A RECALL, AND FOUND THAT MANY PEOPLE HAD THIS SAME THINGS HAPPEN TO THEM ON THEIR 2004 EXPLORER. I AM NOT THE ONLY ONE. *KB
Structure, Sep 18, 2011
REAR PANEL CRACKED UNDER WINDOW. THERE WAS NO DAMAGE TO VEHICLE, AN DI HAVE SEEN SEVERAL FORD EXPLORERS WITH THE SAME CRACK. *TT
Structure, Sep 9, 2011
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT WHEN OPENING THE REAR LIFT GATE, THE HINGE FRACTURED AND FELL BACK, STRIKING HIM IN THE HEAD. THE CONTACT RECEIVED A MINOR INJURY AS A RESULT. THE VEHICLE WAS NOT INSPECTED BY A DEALER NOR REPAIRED. THE MANUFACTURER WAS CONTACTED AND THEY OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 70,900.
Structure, Sep 7, 2011
TL* THE CONTACT OWNS A 2004 FORD EXPLORER XLT. THE CONTACT STATED THAT THE PANEL BELOW THE REAR WINDOW OF THE TAIL GATE DEVELOPED A CRACK. THE VEHICLE WAS TAKEN TO THE DEALER WHO STATED IT WAS A DESIGN FLAW AND THE PANEL NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE BUT DID NOT OFFER ANY ASSISTANCE SINCE THE WARRANTY HAD EXPIRED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 60,000 AND THE CURRENT MILEAGE WAS 75,000.
Structure, Aug 29, 2011
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR LIFTGATE GLASS WAS HANGING BESIDE THE STRUTS. THE DEALER WAS NOT NOTIFIED OF THE FAILURE. THE MANUFACTURER DENIED ANY ASSISTANCE WITH REPAIRING THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 180,000.
Structure, Aug 24, 2011
ONE OF THE REAR LIFT GATE HINGES HAS FAILED. THE PIN HAS PUSHED THROUGH THE HINGE. THE STRUCTURAL STRENGTH OF THE ALUMINUM USED AS SEEMED TO FAILED. THE OTHER HINGE SHOWS SIMILAR SIGNS OF FAILING BUT HAS NOT COMPLETELY FAILED. *TR
Structure, Aug 9, 2011
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THERE WAS A SMALL OBLIQUE ON THE REAR LIFTGATE WHICH FRACTURED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THEY ADVISED REPLACING THE OBLIQUE BUT THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED AND THEY OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 65,000.
Structure, Jul 19, 2011
THE LIFTGATE GLASS HINGE ON MY 2004 FORD EXPLORER (MODEL EXXLTSPNBX) BROKE WHILE CLOSING. THERE IS ONLY ONE BOLT HOLDING EACH OF THE TWO HINGES ONTO THE GLASS AND THE BOLT BROKE ON ONE OF THE HINGES. FORTUNATELY, I HELD THE GLASS AS TO NOT SLIP DOWN AND PULL THE OTHER HINGE CAUSING IT TO BREAK. THE WINDOW LIFT DID HOLD IT BUT WOULD NOT SLIDE BACK UP. THE LIFT HAD TO BE REMOVED IN ORDER TO SHUT AND LATCH THE WINDOW DOOR. THE BACK PANEL BELOW THE WINDOW WAS CRACKED WHEN I BOUGHT THE CAR AND THIS MAY HAVE LEAD TO SHIFTING IN THE WINDOW AND ADDITIONAL STRESS ADDED TO THE BOLT IN THE HINGE. THIS IS THE SAME PROBLEM THAT OCCURRED IN THE 2002 AND 2003 HATCH WINDOW HINGES. THERE ARE MANY EXAMPLES ONLINE OF THE BOLT BREAKING IN THE 2004 MODELS BUT A RECALL HAS NOT BEEN ISSUED YET AS HAS THE TWO PREVIOUS YEARS. *KB
Structure, Jul 19, 2011
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE HINGE ON THE REAR LIFT GATE WINDOW SEPARATED FROM THE VEHICLE AND THE GLASS SHATTERED ON THE GROUND. ONE PERSON WAS INJURED AS A RESULT. AN AUTHORIZED DEALER WAS NOTIFIED, BUT DID NOT OFFER ANY ASSISTANCE. THE MANUFACTRER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 129,990 AND THE CURRENT MILEAGE WAS 130,000.
Structure, Other or unspecified, Jul 14, 2011
THE PAINT ON THE ROOF OF MY 2004 FORD EXPLORER IS CHIPPING. I SPOKE WITH TWO AUTO BODY SHOPS AND 1 FORD DEALER, AND THEY ALL SAID THAT THE CHIPPING IS DUE TO THE FACT THAT THE PRIMER DID NOT ADHERE PROPERLY TO THE VEHICLE, SO THE PAINT IS CHIPPING. IN REVIEWING THIS ISSUE, I READ ONLINE THAT THERE IS A MULTITUDE OF PEOPLE EXPERIENCING THE SAME ISSUE. I SPOKE WITH FORD, AND THEY TOLD ME THAT THERE IS NO FINANCIAL ASSISTANCE AVAILABLE TO HELP ME, ALTHOUGH THEY ACKNOWLEDGED THAT THIS ISSUE IS THEIR FAULT. I WOULD LIKE THERE TO BE A RECALL SO THAT I CAN GET THIS ISSUE RESOLVED.
Structure, Jun 24, 2011
THE PAINT ON THE ROOF IS ALL PEELING OFF IT LOOKS LIKE CRAP I WAS TOLD THAT IT WOULD COST ABOUT 600.00 TO 1,500 TO REPAINT AND FIX IT CAR PAINT SHOULD NOT PEEL OFF THE ROOF I HAVE READ THAT OTHER PEOPLE HAVE HAD THE SAME TROUBLE WITH THE PAINT ON THERE EXPLORERS. *TR
Structure, Jun 14, 2011
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR HINGE LIFTGATE WAS FRACTURED. THE CONTACT REFERENCED NHTSA CAMPAIGN ID NUMBER: 04V44200(STRUCTURE: BODY: HATCHBACK/LIFTGATE: HINGE AND ATTACHMENTS)BUT THE DEALER INFORMED THE CONTACT THAT HIS VEHICLE WAS NOT INCLUDED IN THE RECALL. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE YET THE VEHICLE WAS NOT REPAIRED. THE CURRENT MILEAGE WAS 76,000 AND THE FAILURE MILEAGE WAS 76,000.MANUFACTURED NEAR THE CUTOFF DATE OF MENTIONED CAMPAIGN. SAME EXACT PROBLEM. PAID FOR REPLACEMENT HINGES. REPLACED MYSELF. UPDATED 09/14/2011 *LN UPDATED 12/13/11
Structure, Jun 13, 2011
2004 FORD EXPLORER. IN 2008 THE REAR BACK PANEL CRACKED AND WAS REPLACED BY FORD AT A COST OF $100 TO ME. IT IS NOW 2011 AND THE REAR BACK PANEL HAS CRACKED AGAIN BUT THIS TIME THE CRACK(S) APPEAR ON EITHER SIDE OF THE FORD EMBLEM. FORD NEEDS TO RECALL THESE BACK PANELS BECAUSE THEY ARE DEFECTIVE. *TR
Fuel system, Gasoline, Structure, Jun 12, 2011
1-"MILES TO E" HAVE ALWAYS REGISTERED AS DASHES AFTER A FILL UP SINCE 2004. DEALER SAYS NOTHING IS WRONG AND TO ADD GAS ADDITIVE (WHICH DOESN'T WORK) OR I CAN HAVE IT FIXED AT MY EXPENSE. DEALER HAS BEEN SOLD AND NEW DEALER NOW HAS "NO RECORD" OF MY PREVIOUS COMPLAINTS-- WHENEVER I HAD THE CAR IN FOR SERVICE I ASKED THEM TO CHECK IT. I SEE PLENTY OF OTHER COMPLAINTS FOR THIS SAME PROBLEM BUT FORD REFUSES TO FIX THIS AS WELL. 2-BACK HATCH BELOW WINDOW HAS CRACKED RECENTLY. HUSBAND HAD SAME VEHICLE DIFFERENT YEAR AND HIS CRACKED AS WELL. DEALER ACKNOWLEDGES MANY VEHICLES WITH SAME PROBLEM BUT SAYS THERE IS NO RECALL AND FORD WILL NOT FIX IT. I SEE THERE IS NOW A CLASS ACTION SUIT FOR THIS DEFECT. JUST WANTED TO GO "ON RECORD" AS ANOTHER UNHAPPY FORD OWNER (OF OVER 40 YRS).
Structure, Latches/locks/linkages, Jun 8, 2011
CONCERNING MY 2004 EXPLORER XLT. THE REAR HATCHBACK THAT OPENS THE BACK WINDOWS HAS A BROKEN LATCH. I AM VERY UPSET THAT THIS PART JUST SEEMED TO IMPLODE AND LEFT ME UNABLE TO CLOSE THE REAR BACK WINDOW. THE GARAGE I TOOK IT TO SAID FORD INFORMED THEM THE PART WAS ON BACK ORDER UNTIL 07-18-2011. I AM WONDERING IF THIS IS GOING TO BE A RECALLED ITEM FOR THE GARAGE INFORMED ME IT HAPPENS QUITE REGULARLY. PLEASE LET ME KNOW IF I HAVE ANY RECOURSE OR AM ENTITLED TO REIMBURSEMENT FOR THE NEEDED REPAIR. . *TR
Structure, Jun 8, 2011
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE VEHICLES HATCHBACK WAS CRACKED. THE VEHICLE WAS NOT TAKEN TO THE DEALER AND THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 77,000. UPDATED 08/10/11*LJ UPDATED 08/12/11.*JB