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, May 2, 2012
VEHICLE'S TRANSMISSION STARTED TO SLIP, AS WE WERE DRIVING WE WOULD HIT THE GAS HARDER TO COMPENSATE AND THEN THE TRANSMISSION WOULD CATCH CAUSING THE VEHICLE TO SURGE FORWARD UNEXPECTEDLY. *JS
Engine and engine cooling, May 2, 2012
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE ENGINE TRANSITIONED INTO SAFE MODE AND STALLED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER, WHERE THE PCM, THROTTLE, JACK SHAFT CHAIN, AND BEARINGS WERE REPLACED. THE FAILURE CONTINUED. BOTH THE DEALER AND MANUFACTURER STATED THAT THE FAILURE COULD NOT BE DIAGNOSED. THEY RECOMMENDED ATTEMPTING VARIOUS TRIAL AND ERROR REMEDIES. THE CONTACT STATED THAT THE PCM AND THROTTLE AGAIN NEEDED TO BE REPLACED. THE FAILURES CONTINUED. THE FAILURE MILEAGE WAS 100,000 AND THE CURRENT MILEAGE WAS 118,861.
Engine and engine cooling, Apr 26, 2012, fire
ON 1/17/12 DRIVING ON HIGHWAY AND NOTICED A BURNING SMELL. IT WAS A STRONG SMELL. NOTICED A GLOW UNDER THE DASHBOARD AND PULLED INTO A EMPTY PARKING LOT. THE TRUCK WENT UP IN FLAMES. CALLED FORD AND THEY SAID PROVE WHAT HAPPENED. NOT SURE BUT THE VEHICLE WAS IN VERY GOOD CONDITION WITH NO PROBLEMS THAT I KNEW OF BEFORE THIS FIRE. NO ONE WAS HURT. *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
Engine and engine cooling, Power train, Apr 9, 2012
TRANSMISSION FAILURE, SLIPS BETWEEN GEARS, REPLACEMENT REQUIRED. *TR
Power train, Apr 2, 2012
FIRST HAD MY TRANSMISSION LOOKED AT IN MAY 2008 WHERE IT WAS SLIPPING INTO REVERSE AND JOLTING THE VEHICLE, WHICH HAD ONLY 44133 MILES. HAD IT LOOKED AT MY A FORD DEALER THAT TOLD ME THERE WAS NOTHING WRONG. NOW IN MAY 2012 AT 110,000 MILES MY TRANSMISSION WAS RE-LOOKED AT FOR SLIPPING INTO FIRST AND SECOND GEAR. WHICH AT THIS TIME I WAS TOLD THAT I NEEDED A NEW TRANSMISSION AND YET I AM STILL MAKING PAYMENTS. FORD COMPLAINT LINE TELLS ME THEY ARE NOT DOING ANYTHING TO RESOLVE THIS PROBLEM AT THIS TIME AND NOW ME AND MY 3 CHILDREN ARE WITHOUT A VEHICLE BECAUSE MY TRANSMISSION HAD NOW COMPLETELY FAILED AND THE VEHICLE REMAINS IN A STORE PARKING LOT BROKE DOWN. THANKS FORD! *TR
Visibility, Mar 30, 2012
REAR WINDOW HINGE FRACTURED CAUSING GLASS TO FALL OFF OF REAR DOOR. THIS IS THE SAME PROBLEM AS THE 2002-2003 FORD RECALL #04S20. REF NHTSA CAMPAIGN ID NUMBER 04V442000. FORD DOES NOT INCLUDE THE 2004 EXPLORER IN THEIR RECALL BUT THE PROBLEM IS THE SAME. I HAVE HEARD OF OTHER 2004 EXPLORER OWNERS HAVING THE SAME PROBLEM AND THE SERVICE MANAGER AT THE DEALER WHO REPLACED THE HINGE SAID IT IS A COMMON PROBLEM ON THE 2004 MODEL YEAR. I FEEL THAT THE PROBLEM EXTENDED INTO THE 2004 MODELS AND SHOULD HAVE BEEN INCLUDED IN THE RECALL OF THE 2002-2003 MODELS. *JS
Wheels, Mar 28, 2012
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 30 MPH, HE HEARD A LOUD NOISE. AFTER INSPECTING THE VEHICLE HE NOTICED THAT THE BOLT TO THE LUG NUTS WERE SEPARATED FROM THE REAR DRIVER AND PASSENGER TIRES. THE VEHICLE WAS TAKEN TO A TIRE SPECIALIST WHERE THE LUG NUTS WERE REPLACED. THE MANUFACTURER WAS CONTACTED AND THEY OFFERED NO ASSISTANCE. THE FAILURE AND THE CURRENT MILEAGES WERE UNKNOWN. THE VIN WAS UNAVAILABLE.
Power train, Mar 26, 2012
THE O/D OFF LIGHT BEGAN BLINKING AND THERE WAS UNCONTROLLED DECELERATION AND WHEN ACCELERATING FROM A STOP THERE IS HIGHER THAN THE USUAL RPM'S NEEDED TO SHIFT FROM FIRST TO SECOND GEAR. MY INVESTIGATION REVEALED THIS IS A KNOWN PROBLEM WITH THIS PARTICULAR YEAR OF FORD EXPLORER AND THERE WAS AN ARTICLE IN APRIL, 21, 2009, ATLANTA CONSTITUTION-JOURNAL REPORTS REGARDING AN ANNOUNCEMENT BY THE NHTSA REGARDING THE FAULTY TRANSMISSION PROBLEMS. AT THIS TIME THERE IS NO CURRENT RECALL FOR THIS ISSUE, HOWEVER, IT IS A COSTLY REPAIR TO CONSUMERS FOR AN ISSUE WHICH FORD AND THE NHTSA IS AWARE OF. *TR
Power train, Mar 20, 2012
SHORTLY AFTER I FIRST PURCHASED THE VEHICLE AFTER ABOUT 2-3 YEARS AGO. I NOTICED IT WOULD JERK & WAS HARD TO SHIFT GEARS. IT WOULD SOMETIMES BE IN GEAR & NOT GAS. AFTER I TOOK IT TO A SHOP TO HAVE IT LOOKED AT IT WAS A WIRE OR CABLE LOOSE TO THE TRANS. EVERYTHING SEEMED OK FOR AWHILE THEREAFTER BUT THEN IT STARTED AGAIN. JUST RECENTLY AS I WAS ON THE EXPRESSWAY THE TRANSMISSION OVERHEATED LIGHT SENSOR CAME ON & THEN THE CHECK TRANSMISSION SENSOR FOLLOWED. I RESEARCHED AND FOUND THAT 1 OUT OF EVERY 10 CUSTOMERS WITH A FORD EXPLORER BETWEEN 2000-2004 HAVE TRANSMISSIONS ISSUES. ALSO I CALLED TO FORD CUSTOMER SERVICE AND WAS ADVISED THAT THERE IS NO RECALL EVEN WITH SEVERAL COMPLAINTS AND THAT NO GOODWILL OR FINANCIAL SERVICES COULD BE OFFERED TO ASSIST ME WITH THE REPAIRING OF MY VEHICLE, EVEN AFTER I STRESSED MY COMPLETE DISSATISFACTION WITH THE OUTCOME. *KB
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.
Steering, Power train, Electrical system, Mar 17, 2012
AFTER STARTING VEHICLE AND MOVING SHIFT LEVER FROM PARK TO REVERSE - ROTATING SHIFT HANDLE MOUNT BROKE OFF- REQUIRED TOWING AND $1800 REPAIR COST. HAVE SEEN SIMILAR INSTANCES ON CONSUMER COMPLAINT BOARDS - FORD FAILS TO RECOGNIZE AS BEING A SAFETY MANUFACTURING DEFECT. *TR
Power train, Mar 12, 2012
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT WHILE DRIVING 40 MPH AND WITHOUT WARNING, THE VEHICLE SLIPPED INTO VARIOUS GEARS. THE CONTACT ALSO STATED THAT THE ONLY WAY THE FIRST GEAR COULD BE DISENGAGED WAS TO APPLY PRESSURE ON THE ACCELERATOR PEDAL. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. IN ADDITION, THE CONTACT STATED THAT THE TRANSMISSION HAD TO BE REPLACED TWICE. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 75,000 AND THE CURRENT MILEAGE WAS 85,000.
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
Power train, Mar 7, 2012
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE TRANSMISSION FAILED WITHOUT WARNING. THE CONTACT TOOK THE VEHICLE TO THE DEALER AND WAS TOLD THAT THE TRANSMISSION OVERHEATED, THE FIFTH GEAR FAILED AND THE HOUSING ROD WAS FRACTURED. THE DEALER ALSO STATED THAT THE FAILURE WAS COMMON IN THE PARTICULAR YEAR, MAKE AND MODEL VEHICLE. THE FAILURE AND THE CURRENT MILEAGE WAS 153,435. UPDATED 04/19/12*LJ UPDATED 04/30/12
Vehicle speed control, Mar 1, 2012
THE ENGINE SHUTS OFF WHILE USING THE CRUISE CONTROL. *TR
Engine and engine cooling, Mar 1, 2012
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT WHEN DRIVING ANYWHERE FROM 30-50 MPH WITH THE CRUISE CONTROL ACTIVATED, THE VEHICLE WOULD STALL. THE VEHICLE WOULD HAVE TO BE PLACED IN NEUTRAL IN ORDER TO BE RESTARTED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE THEY ADVISED THE CONTACT THAT THEY WERE UNABLE TO DIAGNOSE THE FAILURE. THE MANUFACTURER WAS CONTACTED AND THEY OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 100,000. THE VIN WAS UNAVAILABLE.
Vehicle speed control, Feb 26, 2012
THERE IS A LONG HESITATION WHILE ATTEMPTING TO ACCELERATE EITHER FROM A COMPLETE STOP OR WHILE THE VEHICLE IS ROLLING. *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
Wheels, Feb 17, 2012, fire
ON THE HIGHWAY, PASSING A TRACTOR TRAILER AND THE RIGHT REAR WHEEL BEARINGS GAVE OUT. WHEEL FROZE AND CAUGHT ON FIRE. PULLED OVER AND FORTUNATELY OTHERS HAD STOPPED AND ASSISTED IN PUTTING FIRE OUT. WAS TERRIFYING - OUR CHILDREN WERE SITTING IN THE BACK! WE THEN ENDED UP STRANDED AWAY FROM HOME AS WE WERE ON A FAMILY TRIP. *TR
Visibility, Feb 9, 2012
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT HEAT NO LONGER FLOWED THROUGH THE VENTS AND SHE WAS UNABLE TO DEFROST THE WINDSHIELD. AS A RESULT, HER VISION WAS OBSTRUCTED WHILE DRIVING. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC AND THEY INFORMED HER THAT THE BLEND DOOR NEEDED TO BE REPLACED. THE VEHICLE HAD NOT BEEN REPAIRED. THE MANUFACTURER WAS NOTIFIED AND THEY OFFERED NO ASSISTANCE. THE FAILURE AND CURRENT MILEAGES WERE APPROXIMATELY 36,000. THE VIN WAS UNAVAILABLE.
Structure, Feb 7, 2012
REAR BODY PANEL APPLIQUE FORD SERIES PART #402A30. *TR