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: visibility
115 reports, newest first. Show all
Engine and engine cooling, Visibility, Structure, Tires, Feb 28, 2011
I PURCHASED A 2004 FORD EXPLORER FROM A TOYOTA DEALERSHIP ON 1/28/11. THE CAR WAS A CERTIFIED / WARRANTED VEHICLE. I WAS ASSURED BY THE TOYOTA SALESMAN THAT ANY PROBLEM WITH THE CAR WOULD BE FIXED UNDER THE WARRANTY. SEVERAL PROBLEMS WHICH THE CAR HAS INCLUDE: MISMATCHED TIRES, INOPERABLE SUNROOF, LEAK IN THE DIFFERENTIAL SEAL & NOISE IN THE DIFFERENTIAL. I HAD THE CAR INSPECTED AT A FORD DEALERSHIP & WAS TOLD THESE PROBLEMS NEEDED REPAIR. THE TOYOTA DEALERSHIP HAS NOT RETURNED NUMEROUS PHONE CALLS, EMAILS & WHEN I BROUGHT THE CAR BACK TO THEM, I WAS TOLD ALL THESE REPAIRS HAD BEEN FIXED & LATER FOUND OUT THAT NOTHING WAS DONE. *TR
Electrical system, Exterior lighting, Visibility, Feb 14, 2011
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE VEHICLE WAS EXPERIENCING AN INTERMITTENT FAILURE IN WHICH THE HEADLIGHTS, RADIO AND WINDOWS STOPPED FUNCTIONING WHILE DRIVING AT ANY SPEED. THE FAILURES PERSISTED FOR A DURATION OF APPROXIMATELY 1-5 MINUTES. DURING THE FAILURES, THE POWER DOOR LOCKS AND INSTRUMENT PANEL LIGHTING ALSO DID NOT FUNCTION. THE VEHICLE WAS NOT TAKEN TO HAVE THE FAILURES DIAGNOSED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 97,000 AND THE CURRENT MILEAGE WAS 98,000.
Visibility, Jan 22, 2011
THE SUN VISOR ON THE 2004 FORD EXPLORER HAS A WEAK BRACKET THAT HOLDS THE VISOR. IF THE BRACKET FAILS, THAT CAN CAUSE THE DRIVER TO LOSE CONTROL AND HAVE AN ACCIDENT. *TR
Visibility, Structure, Jan 1, 2011
THE TAIL GATE ON THE 2004 EXPLORER SHOULD BE RECALLED,IT WILL ONLY GET WORSE AND LOTS OF PEOPLE WILL DIE WHEN THE BACK WINDOWS JUST START FALLING OUT. EVERY EXPLORER I SEE IT LIKE THIS! BUILT FORD TOUGH..LOL.....I GUESS IT'S OK FOR A FEW HUNDRED TO DIE UNTIL FORD MAYBE RECALL IT, IT'S THERE RESPONSIBILITY!!!!!!! I WILL NEVER BUY ANOTHER FORD TILL THIS GETS FIXED. THINK OF ALL THE LAWSUITS IN THE MAKING FORD..BAD BUSINESS!!! FIX MY FOUND ON ROAD...BEFORE YOU GET SUED...MY BACK WINDOW WILL FALL OUT SOON AND GUESS WHO`S GETTING SUED. FIX YOUR JUNK FORD YOU LIED TO ME QUALITY IS JOB 1000 MAKING MONEY AND LYING IS JOB 1..YOUR SICKLING BOYCOTT FORD I ALREADY HAVE 3000 PLUS WITH THIS PROBLEM JUST WAIT FORD YOU'LL GET YOURS... *TR
Visibility, Nov 30, 2010
I KNEW THE BACK REAR PANEL HAD A CRACK GOING DOWN IT, BUT THOUGHT NOTHING OF IT BECAUSE MOST EXPLORES HAVE THE SAME PROBLEM. IT WASN'T UNTIL I WAS DRIVING DOWN A VERY DARK ROAD AT 6 AM AND BOOM! THE BACK GLASS JUST POPPED. I THOUGHT IT HAD BEEN SHOT OUT. THE SHERIFF'S DEPARTMENT SHOWED UP AND HE THOUGHT THE SAME THING. BUT THE ONLY THING WE FOUND WAS BETWEEN THE HYDRAULICS ON THE WINDOW ITSELF, THE CRACK IN THE PANEL AND TEMPERATURE OUTSIDE IT IMPLODED. MY INSURANCE IN KY PAID FOR IT, BUT IT TOOK TWO WINDOWS AND IT STILL ISN'T RIGHT. *TR
Visibility, Structure, Nov 3, 2010
BACK GLASS HATCH FELL OFF IN MY HANDS COULD HAVE REALLY HURT SOMEONE. *TR
Visibility, Sep 17, 2010
DEFROSTER HEAT CONTROL FAILED, COULDN'T SEE THROUGH WINDSHIELD. *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
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
Visibility, Aug 31, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR WINDOW PANEL WAS FRACTURED. THE VEHICLE WAS TAKEN TO THREE REPAIR FACILITIES WHERE THE CONTACT WAS ADVISED THAT THE REAR WINDOW PANEL WOULD NEED REPLACING. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 28,000 AND THE CURRENT MILEAGE WAS 28,990. UPDATED 12/01/10. *LJ UPDATED 12/07/10
Visibility, Aug 22, 2010
SUN VISOR ANCHOR BASED OF 2004 FORD EXPLORER CRACKED AND FELL OUT, CAUSING PLASTIC PIECES TO FALL ON FACE, AND MAKING VISOR FALL IN FRONT OF LINE OF SIGHT WHILE DRIVING ON HIGHWAY . USING SUN VISOR IS NOW NOT POSSIBLE. *TR
Visibility, Latches/locks/linkages, Aug 22, 2010
DEFECTIVE REAR WINDOW HINGES ON MY 2004 FORD EXPLORER. I RARELY USE THE WINDOW HATCH AND TODAY I AM SORRY I DID. WHILE OPENING THE REAR WINDOW IT FELL ON TO MY HEAD. THE BRACKETS ON THE WINDOW BROKE. I AM WAITING FOR MY MECH. TO HELP ME REMOVE THE WINDOW SO I CAN BRING IT INTO TO GET REPAIRED. I OWN A 2002 FORD EXPLORER AND IT HAD A RECALL FOR THE SAME THING. SO WHY NOT THE 2004, IT IS THE SAME HINGE. *TR
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
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
Visibility, Jul 28, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THE DRIVER AND PASSENGER SUN VISORS WERE FRACTURED. THE DEALER ADVISED REPLACING THE VISORS AT HER EXPENSE. THE DRIVER SIDE SUN VISOR WAS REPLACED. THE CONTACT STATED THE FAILURE RECURRED ON THE DRIVER SIDE SUN VISOR. THE PASSENGER SIDE SUN VISOR WAS NEVER REPLACED. THE MANUFACTURER WAS NOT CONTACTED. THE FAILURE AND CURRENT MILEAGES WERE 96,607.
Visibility, Jul 3, 2010
DEFECTIVE CLIP/HINGE IN SUNVISOR ASSEMBLY OF 2004 FORD EXPLORERS, BREAKS AND CRACKS WITH NORMAL USE DUE TO FAULTY DESIGN. SAFETY HAZARD DUE TO THE FACT THAT ONCE IT BREAKS TO A CERTAIN POINT THE SUNVISOR WILL HANG IN DRIVERS VIEW AND IMPEDE VISION. A LARGE AMOUNT OF PEOPLE ARE HAVING THE SAME PROBLEM I AM HAVING. SOME OF THEIR COMMENTS CAN BE VIEWED AT HTTP://WWW.CARCOMPLAINTS.COM/FORD/EXPLORER/2004/ACCESSORIES-INTERIOR/SUPPORTS_FOR_SUN_VISORS_CRACKED.SHTML TO BEGIN YOUR INVESTIGATION. LUCKILY OURS CAME APART WHEN THE CAR WAS STOPPED, BUT SOMEONE USING THE VISOR TO INCREASE VISIBILITY MAY NOT BE SO FORTUNATE. *TR
Visibility, Jun 6, 2010
WHILE ATTEMPTING TO CLOSE THE WINDOW ON HATCHBACK, THE WINDOW HINGES BROKE. *TR
Visibility, May 19, 2010
REAR WINDOW HINGES ON 2004 FORD EXPLORER BROKE. *TR
Visibility, May 3, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE FIBER GLASS FITTING UNDER THE WINDOW NEXT TO THE TAILGATE BEGAN CRACKING AND WAS BECOMING PROGRESSIVELY WORSE. THE OWNER HAD NOT CONTACTED THE DEALER. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 57,000.
Visibility, Jan 1, 2010
PLASTIC PIN SECURING BLEND DOOR ACTUATOR BREAKS, FREEZING BLEND DOOR IN POSITION.(COOL) UNABLE TO GET HEAT FROM VEHICLE HVAC SYSTEM. CAN NOT DEFROST/DEFOG WINDOWS IN COLD/WET WEATHER. VISIBILITY IS LIMITED DURING COLD/WET WEATHER. THE REDUCED VISIBILITY CAUSED ME TO VEER OFF OF PAVEMENT IN A RURAL AREA NEAR MY HOME BECAUSE I COULD NOT SEE THE LANE MARKERS. RESEARCH ON THE INTERNET SHOWS THIS IS A RECURRING, COMMON PROBLEM. FORD MOTOR CO. IS AWARE OF THE ISSUE BUT HAS NOT TAKEN STEPS TO RESOLVE THIS DANGEROUS SITUATION. *TR
Visibility, Dec 16, 2009
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE REAR WINDOW PANEL HAD DEVELOPED CRACKS. THE VEHICLE HAS NOT BEEN DIAGNOSED BY THE DEALERSHIP . THE CURRENT AND FAILURE MILEAGES WERE 53000.
Visibility, Structure, Dec 10, 2009
CRACKS APPEARED BELOW THE REAR WINDOW OF MY FORD EXPLORER. THERE WAS NO ACCIDENT. *TR
Visibility, Oct 23, 2009
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE GLASS FOR THE REAR LIFT GATE HAS DEVELOPED CRACKS IN IT. THE REAR DEFROSTER WAS ALSO INOPERATIVE. HE NOTIFIED THE DEALER, AND A TECHNICIAN STATED THAT IT WOULD COST $500.00 TO REPLACE THE COMPONENT. THE TECHNICIAN ALSO ADDED THAT THEY WERE AWARE OF THE FAILURE. NO REPAIRS WERE MADE. THE MANUFACTURER WAS NOTIFIED, BUT NO ASSISTANCE WAS PROVIDED. HE HAS PICTURES OF MULTIPLE VEHICLES WITH THE SAME MODEL TYPE, INCLUDING HIS VEHICLE, WITH IDENTICAL FAILURES. THE FAILURE MILEAGE WAS 55,000. THE CURRENT MILEAGE WAS 65,000.
Visibility, Oct 10, 2009
BLEND DOOR ACTUATOR PIN IS DEFECTIVE. I HAVE RESEARCHED THIS PROBLEM ONLINE AND IT IS A WIDESPREAD ISSUE. HEAT / DEFROST WILL NOT WORK. IN THE WINTERTIME THIS MAKES DRIVING EXTREMELY HAZARDOUS. *TR
Visibility, Structure, Oct 8, 2009
FORD DESIGNED A PLASTIC PIECE OF MOLDING THAT IS GLUED TO THE BACK GLASS OF EVERY EXPLORER. THIS HAS CRACKED ON EVERY EXPLORER I HAVE SEEN. IT HAS BEEN FIXED ONCE BY FORD, BUT IT HAS BROKE AGAIN. I ASSUME THAT IF IT HAS BROKE EVERY TWO YEARS SO FAR, IT WILL CONTINUE TO BREAK. FORD HAS REFUSED TO FIX THIS DEFECT. *TR