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
1,408 reports, newest first.
Power train, Apr 7, 2013
WE WAS DRIVE THE STREET DOING 30 MPH UNTIL WE CAME UNTIL A STOP LIGHT . WHEN THE LIGHT TURN GREEN THE TRANSMISSION STARTED TO ACT LIKE IN DIDN'T WONT TO GO INTO GEAR . WHEN ONLY HAD THE CAR FOR A YEAR IN ONLY PUT ALMOST LESS THEN 9 TO 8 THOUSAND MILE ON IT. WHEN THE CAR FULL SERVICE EVERY TIME... DON'T KNOW WHAT TO DO ANY MORE. *TR
Structure, Apr 5, 2013
I WAS CLOSING THE UPPER DOOR ON THE BACK OF MY SUV WHEN THE RIGHT HINGE BROKE AND THE DOOR ALMOST DROPPED TO THE GROUND. I MANAGED TO WRESTLE IT BACK UP BUT THE HYDRAULIC SHOCK ON THE DOOR BROKE AND LEAKED FLUID ALL OVER THE CAR. I CANNOT GET IT BACK INTO THE WINDOW OPENING PROPERLY IT IS OPEN ABOUT AN INCH. I AM AFRAID TO DRIVE THE CAR IN CASE THE WINDOW FALLS OUT. *TR
Engine, Apr 2, 2013
AT ABOUT 65,000 MILES, MY TRANSMISSION BEGAN SLOWLY ACTING UP; IT VWAS DIFFICULT TO PUT INTO GEAR AND CLUNKS WHILE DRIVING. IT IS GETTING WORSE, AND FORD WILL NOT HELP WITH REPAIRS BECAUSE IT IS OUT OF WARRANTY. *TR
Power train, Apr 1, 2013
TRANSMISSION SEEMS TO SLIP AND ENGINE REVS ALSO WHEN PUT IN REVERSE TRANSMISSION SEEMS TO JUMP. *TR
Structure, Other or unspecified, Apr 1, 2013
REAR BODY PANEL AROUND BACK WINDOW SPLIT
Steering, Service brakes, Engine, Apr 1, 2013
WHILE DRIVING, THE VEHICLE JUST SHUT OFF. I HAD NO CONTROL OF THE VEHICLE ONCE IT SHUT OFF, EXCEPT TO UTILIZE THE EMERGENCY BRAKE TO GET ME STOPPED. ONCE STOPPED, I PUT IT IN PARK AND IT STARTED UP FIRST TRY. NO CHECK ENGINE LIGHT CAME ON. SAME THING HAPPENS ON A REGULAR BASES. USUALLY HAPPENS WHILE BRAKING OR TURNING AT SPEEDS LOWER THAN 30MPH, THEN ENGINE JUST STALLS AND EVERYTHING TURNS OFF. THIS TO ME IS A MAJOR SAFETY CONCERN, BECAUSE WITHOUT TOTAL CONTROL OF THE VEHICLE AND VEHICLE LIGHTING AT NIGHT, IT COULD SERIOUSLY INJURE OR KILL SOMEONE. I HIGHLY RECOMMEND INVESTIGATING THIS FURTHER SO WE CAN ALL CONTINUE TO BE SAFE. THANKS! *TR
Power train, Electrical system, Mar 18, 2013
MY CAR WON'T SHIFT IN TO GEAR ANY MORE. *TR
Power train, Mar 11, 2013
GOING 55 MILES AN HOUR TRUCK SLIP OUT OF GEAR. *TR
Structure, Feb 22, 2013
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT AS SHE APPROACHED THE VEHICLE, SHE NOTICED THAT THE HORIZONTAL PANEL UNDER THE REAR LIFT GATE WAS FRACTURED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THEY ADVISED HER THAT THE PANEL NEEDED TO BE REPLACED. THE VEHICLE WAS REPLACED FOR THE HORIZONTAL PANEL AND EMBLEM. THE MANUFACTURER WAS CONTACTED AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 21,652. THE CURRENT MILEAGE WAS APPROXIMATELY 36,000. *TR
Structure, Feb 15, 2013
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THERE WAS AN EXCESSIVELY LONG FRACTURE IN THE REAR LIFTGATE NEAR THE MANUFACTURING EMBLEM BELOW THE REARVIEW WINDOW. THE VEHICLE WAS NOT INSPECTED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 50,000.
Structure, Feb 11, 2013
THE REAR PANEL CRACKED FOR NO APPARENT REASON. *TR
Power train, Structure, Jan 30, 2013
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR LIFTGATE BODY PANEL WAS CRACKED. THE VEHICLE WAS TAKEN TO THE DEALER WHO DIAGNOSED THAT THE BODY PANEL NEEDED TO BE REPLACED. THE CONTACT ALSO STATED THAT WHILE DRIVING APPROXIMATELY 25-35 MPH, A NOISE WAS HEARD COMING FROM THE REAR DIFFERENTIAL. THE VEHICLE WAS TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING. THE TECHNICIAN STATED THAT THE REAR DIFFERENTIAL NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND STATED THE VEHICLE WAS NOT INCLUDED IN ANY RECALLS. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS UNKNOWN AND THE CURRENT MILEAGE WAS 80,000. THE VIN NUMBER WAS NOT AVAILABLE.
Vehicle speed control, Service brakes, Jan 20, 2013
WHILE DRIVING, THE CRUISE CONTROL STOPPED WORKING AND CAR STALLED. AT THE SAME TIME THE ABS LIGHT COMES OFF AND ON. *TR
Seat belts, Jan 17, 2013, crash
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT WHILE DRIVING 60 MPH AROUND A CURVE AND OVER A POTHOLE, THE DRIVER LOST CONTROL OF THE VEHICLE. THE VEHICLE THEN BEGAN JERKING AND THE VEHICLE FLIPPED OVER FIVE TIMES WHILE THE DRIVER WAS ATTEMPTING TO COMPLETE THE TURN. THE CONTACT WAS A REAR PASSENGER IN THE VEHICLE. THE CONTACT STATED THAT THE REAR SEAT BELTS FAILED TO SECURE THE PASSENGER'S PROPERLY. AS A RESULT, THE CONTACT'S HEAD WAS THROWN THROUGH THE WINDOW AND STUCK THE GROUND EACH TIME THE VEHICLE ROLLED OVER ON THE ROOF. THE CONTACT AND ONE OTHER PASSENGER WERE INJURED. THE VEHICLE WAS DESTROYED. THE VIN WAS NOT AVAILABLE. THE FAILURE AND CURRENT MILEAGES WERE UNKNOWN.
Structure, Jan 17, 2013
WHILE THE VEHICLE WAS PARKED FOR 2 OR 3 DAYS UNDER THE CARPORT IN THE DRIVEWAY, THE BACK PANEL UNDER THE WINDOW CRACKED FOR ABSOLUTELY NO REASON. *TR
Service brakes, Hydraulic, Jan 3, 2013
TL* THE CONTACT OWNS A 2008 VOLVO VNL. THE CONTACT STATED THAT THE VEHICLE WAS PARKED ON AN INCLINE WHEN HE APPLIED THE PARKING BRAKE AND THE VEHICLE UNEXPECTEDLY ROLLED AWAY. THE FAILURE RECURRED THREE TIMES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT AUTO SHOP FOR DIAGNOSIS. THE TECHNICIAN DETERMINED THAT THE BRAKE SLACK ADJUSTER ON THE SECOND AXLE WAS FAULTY. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 415,000.
Vehicle speed control, Dec 31, 2012
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT WHILE STOPPED, THE VEHICLE ACCELERATED INDEPENDENTLY AND WITHOUT WARNING. THE FAILURE RECURRED NUMEROUS TIMES. THE VEHICLE WAS TAKEN TO A DEALER FOR DIAGNOSIS WHERE THE THROTTLE BODY SENSOR UNIT WAS REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED BUT OFFERED NO ASSISTANCE. THE FAILURE AND CURRENT MILEAGE WAS 74,000.
Visibility, Structure, Dec 21, 2012
THE REAR WINDOW HINGE PIN (PASSENGER SIDE) HAS CORRODED AND BROKEN ALLOWING THE WINDOW TO FALL OFF OF THE REAR TAIL GATE. I NOTICED THE BROKEN HINGE BEFORE USING THE LIFT GATE WHICH HAS PREVENTED IT FROM FALLING OFF THUS FAR. I HAVE READ THAT THIS IS A VERY COMMON PROBLEM ON THIS VEHICLE AND FORD WILL NOT OWN UP TO THE PROBLEM. *TR
Structure, Dec 18, 2012
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR LIFTGATE HATCHBACK HINGE WAS CORRODED AND CRACKED, CAUSING THE GLASS TO SEPARATE FROM THE FRAME. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION. THE MANUFACTURER ADVISED THE CONTACT THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER: 04V442000 (RECASTRUCTURE: BODY: HATCHBACK/LIFTGATE: HINGE AND ATTACHMENTS). THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 80,000.
Structure, Dec 8, 2012
THERE IS A CRACK TO THE LEFT OF THE FORD ISIGNIA ON THE REAR LIFT TAIL GATE. THE CRACK RUNS FROM THE BOTTOM OF THE REAR PANEL JUST BELOW THE REAR WINDOW TO THE BOTTOM OF THAT PANEL. THE PANEL IS THE TOP HALF OF THE LIFT GATE WHERE THE GATE OPENS TO ENTER ITEMS WITHOUT OPENING THE ENTIRE TAIL GATE. I UNDERSTAND FROM OTHER FORD EXPLORER OWNERS THAT THIS CAN CAUSE THE REAR WINDOW TO BLOW OUT BECAUSE THE PANEL IS NO LONGER SECURE DUE TO THE CRACK. OBI# 10487645 *TR
Structure, Dec 7, 2012
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT AFTER EXITING THE VEHICLE, SHE NOTICED THAT THE REAR HATCHBACK WINDOW PANEL WAS FRACTURED. THE VEHICLE WAS NOT TAKEN TO A MECHANIC. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED ABOUT THE FAILURE AND ADVISED THE CONTACT THAT THEY WERE UNAWARE OF THE ISSUE. THE FAILURE AND CURRENT MILEAGES WERE APPROXIMATELY 92,000.
Engine and engine cooling, Power train, Nov 26, 2012
FIRST ISSUE WAS WITH THE SOLENOIDS NOW THE ISSUE IS WITH 1-2 SHIFT RATIO. SHIFTING INTO NEUTRAL. *TR
Structure, Nov 23, 2012
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE PANEL ON THE EXTERIOR OF THE REAR LIFT GATE WAS FRACTURED. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 160,000.
Power train, Service brakes, Fuel/propulsion system, Nov 22, 2012
ON APRIL 6TH OF THIS YEAR I PURCHASED A 2004 FORD EXPLORER. THE NEXT DAY I TOOK THE CAR FOR CITY INSPECTION...IT PASSED. THE VERY NEXT DAY (SUNDAY) THE CHECK ENGINE LIGHT CAME ON. THE ABS LIGHT WOULD ALSO ILLUMINATE. I TOOK THE CAR TO AUTOZONE TO HAVE IT DIAGNOSED (EGR VALVE). ONLY THE CHECK ENGINE LIGHT COULD BE DIAGNOSED BECAUSE THE ABS LIGHT CAME ON AT RANDOM WHILE I WAS DRIVING. THE CAR WAS STILL UNDER THE 1000 MILE WARRANTY SO THE EGR VALVE WAS REPLACED AND A SPEED SENSOR BELIEVED TO BE THE PROBLEM WITH THE ABS LIGHT. I PURCHASED AN INDEPENDENT EXTENDED WARRANTY SO I WOULD BE COVERED FOR ANY SURPRISE EXPENSES. I HAD MY CHANCE TO USE IT IN JUST A FEW MONTHS LATER WHEN THE CAR RAN HOT. THE REPAIR WAS NOT COVERED. THIS HAPPENED IN JULY, JUST A FEW MONTHS AFTER BUYING THE CAR. EARLIER THIS MONTH (NOVEMBER 2012) THE SERVICE ENGINE LIGHT CAME ON AGAIN BUT IT DIDN'T STAY ON SO I COULDN'T GET IT DIAGNOSED. NO NEED TO HAVE IT DIAGNOSED BECAUSE THE BATTERY LIGHT CAME ON TOO. I TOOK IT TO AUTOZONE ONCE AGAIN AND THE BATTERY TESTED BAD. IT WOULDN'T START AT THE STORE. I BOUGHT THE BATTERY, IT WAS INSTALLED AND CHECKED AGAIN. THE ALTERNATOR SHOWED IT WASN'T CHARGING. I HAD TO HAVE THE ALTERNATOR REPLACED. WITH THE COLD WEATHER, I DISCOVERED THE DEFROST VENTS DON'T WORK. AIR ONLY BLOWS FROM FRONT VENTS. ON THE MORNING OF NOVEMBER 19TH, I WAS TAKING MY SON TO SCHOOL AND THE OVERDRIVE LIGHT STARTED FLASHING. IT HAPPENED AGAIN WHILE ON MY WAY HOME FROM WORK ON NOVEMBER 21ST. SO NOW I SUPPOSE I HAVE TRANSMISSION PROBLEMS. FORD NEEDS TO ANSWER FOR THEIR HORRIBLE ENGINEERING. *TR
Structure, Nov 20, 2012
VEHICLE WAS PARKED. OPERATOR OPENED REAR HATCH GLASS, AT WHICH TIME THE RIGHT HINGE SEPARATED. THIS CAUSED THE GLASS TO SLAM DOWN. FORTUNATELY, THE OPERATOR WAS ABLE TO JUMP OUT OF THE WAY TO AVOID INJURY. THE GLASS DID NOT BREAK, BUT THE STRUTS ARE BENT. BOTH THE RIGHT AND LEFT HINGES APPEAR TO BE DEFECTIVE AND IN NEED OF REPLACEMENT. THE REAR HATCH IS NOT USABLE UNTIL THE HINGES AND STRUTS ARE REPLACED. *TR