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
Seat belts, Structure, Oct 12, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER SPORT. WHILE THE VEHICLE WAS PARKED, THE CONTACT NOTICED A CRACK NEAR THE EMBLEM IN THE CENTER OF REAR LIFTGATE. THE VEHICLE WAS TAKEN TO A BODY SHOP AND REPAIRED. THE CONTACT ALSO STATED THAT THE DRIVER AND FRONT PASSENGER SEAT BELTS DID NOT RETRACT AT TIMES. SHE HAD TO REPEATEDLY PULL THE SEAT BELTS SO THAT THEY WOULD RETRACT. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 50,000 AND THE CURRENT MILEAGE WAS APPROXIMATELY 70,000.
Structure, Oct 7, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE PANEL IN THE REAR LIFTGATE WAS SPLIT. THE CONTACT CALLED THE DEALER WHO STATED THAT THE FAILURE WAS COMMON. THE CONTACT CALLED THE MANUFACTURER WHO STATED THAT THERE WERE NO RECALLS AND REPAIRS WOULD BE AT HIS EXPENSE. THE FAILURE MILEAGE WAS APPROXIMATELY 62,000.
Structure, Oct 6, 2010
A CRACK HAS FORMED IN THE REAR LIFT GATE PANEL. IT OCCURRED OVERNIGHT WHILE NOT IN USE ABOUT 2 WEEKS AGO. I DIDN'T THINK MUCH OF IT UNTIL I BEGAN NOTICING MANY OTHER EXPLORERS AND MERCURY MOUNTAINEERS OF ABOUT THE SAME YEAR (2002-2004) WITH THE SAME DEFECT. I DECIDED TO SEE IF THERE WAS A RECALL, BUT ALL I COULD FIND WAS A LOT OF PEOPLE COMPLAINING AND NO ACTION FROM FORD. I DON'T KNOW HOW MANY OTHERS HAVE FILED A COMPLAINT WITH YOU, BUT AT ONE WEBSITE THERE ARE AT LEAST 290 OTHER OWNERS WHO HAVE POSTED A COMPLAINT. IF YOUR INTERESTED, HERE IS THE LINK: HTTP://WWW.CARCOMPLAINTS.COM/FORD/EXPLORER/2004/BODY_PAINT/CRACKED_PANEL_BELOW_THE_REAR_WINDOW.SHTML. *TR
Structure, Latches/locks/linkages, Oct 1, 2010
2004 EXPLORER WITH 110K MILES - DEVELOPED CRACK IN LIFTGATE PANEL APP DEC 2008. FORD COVERED 80% OF REPAIR COST OF $750 SINCE VEHICLE WAS UNDER 75K MILES, EVEN THOUGH AN OBVIOUS DESIGN FLAW. SEPT 29, 2010 REAR HATCH WINDOW HINGE BREAKS CAUSING DOOR TO FALL ONTO MY HANDS AND LEGS...SORE BUT NOT PERMANENT. TWO CO-WORKERS HAD TO HELP ME RAISE IT UP ENOUGH TO LOCK IT IN PLACE. DEALER REPAIRED FOR $65 PARTS IN $170 LABOR. DANGEROUS AND UNSAFE. *TR
Visibility, Structure, Sep 16, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE EXAMINING THE VEHICLE THE CONTACT NOTICED A CRACK ON THE PANEL BELOW THE REAR WINDOW. THE VEHICLE HAS NOT BEEN DIAGNOSED AND THERE WERE NO PRIOR WARNINGS. THE CURRENT AND FAILURE MILEAGES WERE 89000. UPDATED 01/03/11
Structure, Sep 14, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE LIFTGATE WAS FRACTURED DOWN THE CENTER. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE CONTACT WAS INFORMED THAT HE WOULD BE RESPONSIBLE FOR REPLACING THE ENTIRE LIFTGATE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 45,000 AND THE CURRENT MILEAGE WAS APPROXIMATELY 48,000. UPDATED 12/21/10*BF THE CONSUMER STATED NO REPAIRS WERE MADE. HE BELIEVED THE INTEGRITY OF THE REAR WINDOW LIFTGATE HAS BEEN COMPROMISED. UPDATED 12/29/10
Structure, Sep 13, 2010
THERE IS A CRACK IN THE REAR PANEL UNDER THE WINDSHIELD OF MY 2004 FORD EXPLORER XLT. ASIDE FROM BEING UNSIGHTLY, I'M AFRAID THAT THIS CRACK WILL WEAKEN THE PANEL WHICH IS INTEGRAL TO KEEPING THE REAR WINDSHIELD SEATED PROPERLY. *TR
Structure, Latches/locks/linkages, Sep 13, 2010
IN JULY 2010, I NOTICED A CRACK IN THE PANEL PORTION OF THE BACK WINDOW HATCH OF MY 2004 FORD EXPLORER. I REPORTED THIS TO MY DEALER, WHO MORE OR LESS SAID WELCOME TO THE CLUB, AND TOLD ME TO CONTACT THE BODY SHOP. THE COST OF $500-600 WOULD HAVE TO BE PAID BY ME AND THERE IS NO REASON TO THINK THAT IT WON'T HAPPEN AGAIN. I AM SO DISAPPOINTED IN FORD MOTOR CO., I THOUGHT I COULD EXPECT MORE FROM A LOCAL MANUFACTURER. IT SEEMS TO ME THAT THIS IS SOMETHING THAT SHOULD HAVE BEEN DISCOVERED IN PRODUCT TESTS AND/OR TRIALS. WHY DIDN'T FORD KNOW THAT THE MATERIAL THEY USED WAS NOT CAPABLE OF STANDING UP TO THE USE IN THE AREA THEY PLACED IT? *TR
Structure, Sep 9, 2010
PANEL BENEATH REAR GLASS CRACKS ON FORD EXPLORERS. SEVERAL REPORTS OF SAME OCCURRENCE ON INTERNET AND 3 (INCLUDING MYSELF) WHERE I WORK. ALMOST ALL SAME DESCRIPTION, "PANEL BREAKS NEAR FORD EMBLEM". *TR
Structure, Sep 6, 2010
CRACKED REAR PANEL IN TAILGATE BELOW WINDOW. *TR
Visibility, Structure, Sep 4, 2010
1. PANEL BELOW REAR WINDOW CRACKED NOV 2009; CRACK IS LOCATED TO THE LEFT OF FORD EMBLEM AND IS THE LENGTH OF THE PANEL. FORD REFUSED TO REPAIR FREE OF CHARGE; WE DID NOT REPAIR IT. 2. THIS MORNING TAILGATE GLASS BLEW OUT WHILE CAR WAS PARKED IN OUR GARAGE AND THANKFULLY NO ONE WAS NEAR IT WHEN IT HAPPENED AS GLASS FLEW EVERYWHERE. CAR HAD NOT BEEN DRIVEN FOR OVER 24 HRS. *TR
Structure, Aug 30, 2010
CRACKED REAR PANEL ON 2004 FORD EXPLORER. DROVE IT THROUGH A CAR WASH AND IT SHATTERED. IT CAN FLY OFF AND HIT SOMEONE. *TR
Structure, Aug 19, 2010
I DISCOVERED A CRACK IN THE PLASTIC PANEL BELOW THE REAR WINDOW OF MY 2004 FORD EXPLORER LAST NIGHT WHILE UNLOADING GROCERIES. THERE HAD BEEN NO IMPACT TO THIS AREA OF THE VEHICLE SO I HAD NO IDEA WHERE IT CAME FROM. I CHECKED WITH A LOCAL BODY SHOP AND THE ESTIMATOR TOLD ME THIS IS A VERY COMMON ISSUE WITH FORD EXPLORERS AND MERCURY MOUNTAINEERS. IT WAS APPARENTLY A MANUFACTURING DEFECT AND THAT I SHOULD CHECK WITH FORD. I STOPPED BY THE LOCAL FORD DEALERSHIP BUT THE SERVICE MANAGER WAS OUT TO LUNCH. THE SALESMAN I TALKED TO SAID HE SAW THE PROBLEM A NUMBER OF TIME WHEN HE WORKED AT THE LINCOLN MERCURY DEALER. WAITING FOR THE SERVICE MANAGER TO CALL ME. *TR
Structure, Aug 19, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT ATTEMPTED TO CLOSE THE REAR LIFT GATE WINDOW AND THE HINGES FRACTURED CAUSING THE GLASS TO FALL AND SHATTER OVER HER HEAD. SHE SUFFERED MINOR INJURIES AS A RESULT. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE SHE WAS AWAITING A DIAGNOSIS OF THE FAILURE AND REPAIRS. THE FAILURE AND CURRENT MILEAGE WAS 80,000.
Structure, Aug 17, 2010
TAILGATE/DOOR WITH GLASS CRACKED AND BROKE. FIBERGLASS WAS MADE FAR TOO WEAK AND CRACKED. THIS IS A COMMON PROBLEM WITH THIS VEHICLE. *TR
Structure, Aug 16, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THERE WAS A CRACK ON THE REAR LIFT GATE FROM THE VEHICLE LOGO TOWARD THE REAR DOOR. THE CONTACT STATED IN COLD TEMPERATURES, THE CRACK WAS BARELY VISIBLE YET IN WARMER TEMPERATURES, THE CRACK WOULD EXPAND. THE DEALER ADVISED THE FAILURE WAS COMMON IN HIS YEAR, MAKE AND MODEL BUT WAS NOT UNDER RECALL. THE FAILURE MILEAGE WAS 78,000 AND THE CURRENT MILEAGE 78,500.
Power train, Structure, Aug 9, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE THE VEHICLE WAS PARKED, SHE OPENED THE REAR GLASS WINDOW LOCATED ON THE LIFT GATE. THE WINDOW WAS OPEN FOR A FEW MOMENTS UNTIL ONE OF THE TWO HINGES BROKE RESULTING IN THE WINDOW HANGING BY ONE HINGE. UPON EXAMINING THE BROKEN HINGE SHE NOTICED THAT THE SCREW HOLDING THE HINGE IN PLACE ALSO BROKE IN HALF. THE FAILURE WAS NOT DIAGNOSED. THE VEHICLE WAS NOT REPAIRED. SHE ALSO STATED THAT THE VEHICLE HESITATED TO SHIFT INTO REVERSE AND WOULD LUNGE FORWARD BEFORE MOVING IN REVERSE. WHEN SHIFTING FROM REVERSE TO DRIVE, THE FAILURE RECURRED AND SHE HEARD A POPPING NOISE WHEN THE VEHICLE FINALLY SHIFTS INTO GEAR. THE FAILURES HAVE OCCURRED INTERMITTENTLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO WAS UNABLE TO DIAGNOSE THE FAILURE. THE VEHICLE WAS NOT REPAIRED AND THE FAILURE CONTINUED TO RECUR INTERMITTENTLY. THE FAILURE AND CURRENT MILEAGES WERE 160,000.
Visibility, Structure, Aug 5, 2010
I HAVE A 2004 EXPLORER AND I LIFTED THE GLASS HATCH TODAY AND IT BROKE AND BEGAN TO FALL ON MY HEAD, LUCKILY I REACTED AND GRABBED IT BEFORE IT KNOCKED ME OUT. I HAD TO GET HELP BECAUSE IT WAS TO HEAVY FOR ME BECAUSE I HAVE A BAD BACK, HAD SURGERY AND WAS AFRAID THAT I WAS GOING TO RE DAMAGE. I HAD TO HAVE MY HUSBAND COME UP THERE WHILE WE HELD IT BECAUSE STRUTS WOULD NOT FOLD IT IN. TOOK IT TO FORD AND AM BEING CHARGED A DIAGNOSTIC CHARGE TO DIAGNOSIS IT I AM NOT SURE THAT IS NEEDED, AND PARTS ARE GOING TO BE $155, AND I WAS TOLD THAT THEY ARE NOT RESPONSIBLE FOR THE WINDOW IF IT BREAKS! PARTS ARE NOT AVAILABLE THEY SAID THEY WILL ORDER. I HAVE NO CAR, NO WARRANTY, AND A SORE BACK FROM ANOTHER PROBLEM FORD IS AWARE OF BUT REFUSES TO ACCEPT RESPONSIBILITY FOR. THANK GOD IT DID NOT HIT MY 11 YEAR OLD IN THE HEAD OR NECK THIS COULD BE VERY DANGEROUS EVEN DEADLY. *TR
Structure, Aug 5, 2010
I NOTICED A CRACK IN THE PANEL BENEATH MY REAR WINDOW IN MY 2004 FORD EXPLORER. THE CRACK HAS CONTINUED TO GET LARGER SINCE I NOTICED IT A COUPLE MONTHS AGO. *TR
Visibility, Structure, Jul 30, 2010
HAVE A 2004 FORD EXPLORER I BOUGHT NEW. IT NOW HAS APPROXIMATELY 95250 MILES. AFTER WASHING CAR 2-5-10, A MILD DAY HERE IN CT THOUGH WINTERTIME, I NOTICED TRIM PANEL UNDER REAR WINDOW SHOWED VERTICAL CRACK MOST ALL THE WAY THROUGH. SEVERAL DAYS LATER CRACK HAD MIGRATED ALL THE WAY THROUGH TO BOTTOM OF PANEL. CONTACTED FORD CUSTOMER SERVICE ONLINE 2-17-10 ASKING IF THIS WAS A SAFETY CONCERN AS HAD READ OTHERS HAD IT HAPPEN TO THEM AS WELL ON VARIOUS AUTOMOBILE WEBSITES LIKE EDMUNDS. UNDERSTOOD BEFORE WRITING IT WAS NOT A RECALL AT THAT TIME. GOT A POLITE RESPONSE 2-18-10 THAT THOUGH SORRY FOR THE INCONVENIENCE, I SHOULD BRING IT TO THE DEALER FOR ASSESSMENT. I NEVER THOUGHT IT WAS BAD ENOUGH TO WARRANT SUCH A TRIP. HOWEVER, I AM NOTICING THAT THE WINDOW HOW SEEMS TO RATTLE WHEN CLOSING IF ONLY THE WINDOW PORTION IS OPENED RATHER THAN THE ENTIRE REAR DOOR. I REALLY WANT TO BELIEVE THAT THE WINDOW IS NOT IN JEOPARDY OF SEPARATING FROM THE FRAME WHEN I'M DRIVING DOWN THE ROAD. CAN YOU CONFIRM THAT OTHER EXPLORER OWNERS OF THIS VINTAGE HAVE IN FACT REGISTERED COMPLAINTS WITH NHTSA AS I AM DOING TONIGHT. WILL FORD BE ASKED TO MAKE REPAIRS TO OWNER'S VEHICLES FOR THIS DEFECT? THANK YOU IN ADVANCE FOR YOUR FEEDBACK. *TR
Power train, Structure, Jul 27, 2010
2004 FORD EXPLORER TRANSMISSION CLUNKING AND SHIFTING ROUGHLY, TAKING LONG TIME TO ENGAGE CAUSE VEHICLE TO ROLL BACK, DOES NOT SEEM TO ENGAGE FOR A PERIOD OF TIME. ALSO WHINES SO LOUD FOLKS IN BACK SEAT CAN'T HEAR FRONT SEAT PEOPLE TALKING. APPEARS EACH TIME DRIVEN. WAS THAT WAY WHEN PURCHASED NEW AND DEALER FIXED IT, NOW ONCE AGAIN SAME ISSUE. *TR
Structure, Jul 27, 2010
REAR PANEL ON 2004 FORD EXPLORER IS CRACKED. THIS HAPPENED IN FEBRUARY OF 2009. NOTHING HAS BEEN DONE TO REPAIR THIS DUE TO THE COST. THIS IS A DEFECT COMMON TO THIS MODEL AND SHOULD BE REPAIRED BY FORD. THIS COULD CAUSE SHATTERING OF GLASS WINDOW IF IT BECOMES LOOSE. *TR
Structure, Jul 23, 2010
DEFECT IN HATCH AREA OF FORD EXPLORER CAUSING A CRACK NEAR THE FORD EMBLEM. HAPPENED WHEN VEHICLE HAD LESS THAN 60K MILES. CALLED FORD DEALER WHO SAID NOT COVERED UNDER WARRANTY. *TR
Structure, Jul 19, 2010
THE PANEL UNDER THE REAR HATCH WINDOW HAS CRACKED AND KEEPS GETTING WIDER. *TR
Structure, Jul 16, 2010
2004 FORD EXPLORER LIFT GATE GLASS FELL OFF AFTER UPPER LEFT HAND HINGE SNAPPED. SECONDARY FAILURE OF LEFT HAND GAS SHOCK SHEARING NEAR MOUNTING BOSS ON GATE. *TR 1) THE GLASS LIFT GATE WAS GETTING HARDER TO CLOSE. I BELIEVE CORROSION LOOSENED THE HINGE JOINT TO THE GLASS. 2) THE FAILURE WAS IMMEDIATE AND WITHOUT WARNING. THE BACK GATE CAME CRASHING DOWN AND THE RIGHT HAND SIDE CAME FLYING UP. 3) SHORT TERM FIX - VISQUEEN AND DUCT TAPE. LONG TERM FIX - WILL BE TO DISASSEMBLE AND REPLACE THE HINGE/SHOCK ASSEMBLY.