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.
Visibility, Feb 4, 2012
A YEAR AGO MY REAR LEFT WINDOW HINGE BROKE. COST TO REPAIR $50 FOR PART. NOW THE RIGHT REAR WINDOW HINGE BROKE COST NOW HAS INCREASED TO $80 FOR REPAIR. REAR PANEL CRACKED WHEN HEAT WAVE OCCURRED. FORD SAYS NO RECALLS FOR EACH ISSUE. THIS SEEMS TO BE AN ISSUE ON THIS MODEL OF FORD. FORD HOLDS NO RECALL FOR BOTH ISSUES. *KB
Structure, Feb 1, 2012
WHEN WE HAD THE COLD SNAP A FEW WEEKS AGO, A PLASTIC PANEL, UNDER THE REAR WINDOW CRACKED. THE COST TO REPAIR THIS IS ABOUT $450 TO $550. SEARCHING ON LINE, THIS SEEMS TO BE A PROBLEM OVER A NUMBER OF MODEL YEARS, AS THERE ARE SEVERAL HUNDRED REPORTS. IN THE PAST WEEK, I HAVE SEEN 7 MORE EXPLORERS WITH A SIMILAR CRACK. FORD CUSTOMER SERVICE SAYS THERE IS NO RECALL. IT IS NOT A SAFETY ISSUE, BUT IT IS EXPENSIVE TO REPAIR. *TR
Power train, Jan 30, 2012
TRANSMISSION AND THROTTLE BODY FAILED. *TT
Structure, Jan 18, 2012
UPDATE ON REAR CRACKED PANEL: REAR BACK PANEL REPLACED TWICE. FORD SERVICE TOLD ME IT WOULD COST APPROX $800 TO REPLACE CRACKED PANEL AGAIN THEN SUGGESTED I TAKE MY '04 FORD EXPLORER TO A BODY SHOP FOR A REPAIR AT A COST OF APPROX $200 WHICH I DID. THAT REPAIR LASTED ABOUT 3 MONTHS...PANEL HAS CRACKED AGAIN. IF THE GLASS FALLS OUT SOMEONE IS GOING TO GET HURT. IT IS RIDICULOUS THAT FORD WILL NOT TAKE FULL RESPONSIBILITY FOR THIS DEFECTIVE PART.
Power train, Jan 17, 2012
WIFE AND KIDS WHERE DRIVING HOME AND THE TRANNY STARTED KICKING IN AND OUT OF GEAR (SLIPPING). IT JERKED INTO FIRST AT THE STOPLIGHT IN TOWN. *TR
Wheels, Jan 15, 2012
WAS DRIVING MY VEHICLE ON THE HIGHWAY AND GOT OFF WENT TO TURN. THE LUG NUTS SHEARD OFF, THOUGHT IT WAS A FLAT TIRE. THIS HAS HAPPENED THREE TIMES. THERE IS NO RECALL FOR THIS. I HAD MY KIDS IN THE VEHICLE ALL THREE TIMES. I WOULD LIKE TO HAVE THIS MATTER RESOLVED.
Structure, Jan 12, 2012
ABOUT A YEAR AGO I NOTICED THE PANEL BELOW THE REAR WINDOW START TO CRACK. AS TIME WENT ON THE CRACK CONTINUED DOWN THE ENTIRE PANEL NEXT TO THE FORD EMBLEM. THE REAR WINDOW NOW MAKES A RATTLING NOISE. I DON'T KNOW IF IT WILL LOOSEN ENOUGH FOR IT TO POP OUT IF I HIT A BUMP IN THE ROAD. IT HAS CERTAINLY REDUCED THE VALUE OF THE VEHICLE. I WENT ONLINE TO SEE IF ANYONE ELSE WAS HAVING THIS PROBLEM AND WAS SHOCKED TO SEE HUNDREDS OF COMMENTS. I CONTACTED FORD AND THEY SAID THERE WAS NO RECALL FROM YOU AND THAT UNTIL THERE WAS I SHOULD GO AHEAD AND HAVE IT FIXED. REPAIR COSTS SEEM TO BE AROUND $400. FOR THE PANEL PLUS PAINTING. I REALLY THINK A DESIGN FLAW SHOULD NOT BE MY PROBLEM. THEY KNOW IT WAS A FLAW SINCE THE NEWER MODELS ARE DESIGNED COMPLETELY DIFFERENT. *TR
Visibility, Structure, Jan 7, 2012
WHILE AT WORK MY REAR LIFT GATE WINDOW EXPLODED. AT FIRST SITE I THOUGHT IT WAS VANDALISM BUT NOTHING (CAR CHARGERS/CD'S/ ROAD SIDE KIT ETC) WAS TAKEN. AFTER FURTHER INVESTIGATING, THINGS JUST DIDN'T ADD UP NOR WERE CONSISTENT WITH THE SITE OF MY DESTRUCTIVE REAR WINDOW AND UPLIFTING OF THE PANEL UNDERNEATH THE SHATTERED GLASS (WHICH WAS MOSTLY ON THE GROUND AS OPPOSED TO BEING INSIDE MY VEHICLE.) *TR
Steering, Power train, Jan 4, 2012
I WAS TRYING TO PARK THE CAR WHEN I TOOK IT FROM DRIVE TO REVERSE THE WHOLE GEAR SHIFT CAME RIGHT OFF. IT WILL NO LONGER SWITCH GEARS NOR CAN I DRIVE IT. I SEARCHED ONLINE AND THERE ARE NUMEROUS OTHER 2004 EXPLORERS THAT THIS HAS HAPPENED TOO. THERE ARE 16 DIFFERENT COMPLAINTS WHICH ALL WERE EXACTLY LIKE MINE ON CARCOMPLAINTS.COM. THIS IS SUPER DANGEROUS, IMAGINE IF MY CHILDREN WERE IN THE CAR WHEN I WENT TO SWITCH GEARS AND IT BROKE OFF AND THE WERE NO WAY TO MOVE OR STOP IT FROM HITTING SOMEONE. THE EXPENSE TO FIX THIS 'LITTLE' PROBLEM OF FORDS IS COSTING ME MORE THAN I MAKE IN 2 MONTHS. *TR
Structure, Dec 29, 2011
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR LIFTGATE EXHIBITED A FRACTURE THAT STARTED FROM THE TOP OF THE MANUFACTURING EMBLEM AND DOWN TO THE BOTTOM OF THE LIFTGATE. THE CONTACT SPOKE WITH THE MANUFACTURER BUT WAS ADVISED THAT THERE WAS NOTHING THAT COULD BE DONE TO ASSIST. THE VEHICLE WAS NOT REPAIRED. THE CURRENT MILEAGE WAS 89,000 AND THE FAILURE MILEAGE WAS UNKNOWN.
Power train, Dec 22, 2011
THERE WAS A NOTICEABLY JERK AND THE O/T OFF LIGHT CAME ON WITH THE COMPUTER SAYING TO "CHECK TRANSMISSION". THE TRANSMISSION MECHANIC SAID REPLACE THE TRANSMISSION. *TR
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
Electrical system, Dec 11, 2011
CRUISE CONTROL IS INTERMITTENT, SOMETIMES ACCELERATES UNEXPECTEDLY ESPECIALLY WHEN PUSHING THE BUTTON TO TURN IT OFF. SO FAR HAVE BEEN ABLE TO STOP CAR, BUT IT IS A SCARY SITUATION. ALSO, REAR WARNING INDICATOR WORKS ONLY OCCASIONALLY. COULD RUN OVER OR INTO SOMEONE IF DEPENDING ON IT. *TR
Visibility, Structure, Dec 11, 2011
CRACKED PANEL BELOW REAR WINDOW. ALSO, REAR WINDOW APPEARS LOOSE. *TR
Power train, Dec 7, 2011
I PURCHASED A 2004 FORD EXPLORER BRAND NEW FROM THE DEALERSHIP. AT 70,000 MILES I STARTED TO NOTICE A CHANGE IN THE TRANSMISSION SLIPPING AND SUDDENLY KICKING WHEN GOING INTO GEAR. I TOOK THE VEHICLE TO THE DEALERSHIP AND THEY ADVISED THAT THE TRANSMISSION WOULD NEED TO BE REPLACED AT MY COST AND THERE IS NO RECALL AT THE PRESENT MOMENT. THIS IS A SAFETY CONCERN BECAUSE NO TRANSMISSION SHOULD START HAVING PROBLEMS WITH SUCH LITTLE MILEAGE. THIS MATTER REALLY NEEDS TO BE INVESTIGATED AND FORD NEEDS TO CORRECT THIS ISSUE PROMPTLY. *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, Nov 29, 2011
IN APRIL OF 2009 I BOUGHT A 2004 EXPLORER FROM CAR CONNECTIONS IN PALM BAY FLORIDA! THIS HAS BEEN NOTHING BUT A NIGHTMARE! BUT MY "MAIN" COMPLAINT 2 WEEKS AGO I TOOK THE TRUCK IN FOR REGULAR SERVICE TO FIND OUT THAT MY "OVER DRIVE" GEAR IS GONE. AAMCO EXPLAINED TO ME THAT FORD KNEW THAT AND IT IS A DEFECTIVE PART! SO, TO GET A 2ND OPINION I TOOK MY TRUCK TO MEINEKE, THEY ALSO MADE THE SAME COMMENT OF "THAT IS A DEFECTIVE PART FROM FORD" AND THEY WILL NOT RECALL THE PART! WELL, I AM BEING CHARGED FROM $3,400 TO THE LOWEST OF $2,800 FOR REPAIRS "EXCLUDING" TAX! WHY AM I AND THOUSANDS OF OTHERS PAYING FOR SOMETHING THAT FORD KNEW WAS GOING TO BE A COSTLY REPAIR FOR US CONSUMERS IN THIS HORRIBLE RECESSION! I FEEL THAT WE/I SHOULD BE COMPENSATED IN SOME SORT OF WAY JUST TO HELP FOR SOMETHING BAD THEY SENT OUT. I CAN'T EVEN TRADE THE TRUCK IN DUE TO THE VALUE HAS DECREASED TREMENDOUSLY! I AM STUCK WITH A VEHICLE THAT IS BASICALLY GOING TO RUST IN MY DRIVEWAY FOR BEING SO COSTLY! PLEASE LET FORD KNOW THAT THEY SHOULD HONOR WHAT THEY KNEW WAS WRONG! PLEASE HELP! *KB
Air bags, Nov 29, 2011
WITH NO WARNING OR ABNORMAL INSTRUMENT INDICATIONS, BOTH SIDE AIR BAGS INADVERTENTLY DEPLOYED DURING VEHICLE OPERATION. VEHICLE WAS ON A LEVEL PAVED STATE HIGHWAY, BETWEEN INTERSECTIONS, OPERATING BETWEEN 30-35MPH. *KB *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
Suspension, Tires, Nov 26, 2011
TIRES CUPPING AND WHINE AT ABOUT 40 MPH AND UP. *TR
Power train, Nov 26, 2011
MY VEHICLE FAILED TO ENGAGE IN PARK EVEN THOUGH I SHIFTED INTO PARK AND CONSOLE INDICATOR DISPLAYED PARK. I HAD SHIFTED INTO PARK ON A STEEP HILL. AS I EXITED THE VEHICLE, I RELEASED THE BRAKES AND ONE OF MY PASSENGERS ALERTED ME THAT THE VEHICLE WAS ROLLING BACKWARDS. I JUMPED BACK INTO THE VEHICLE, APPLIED THE BRAKES AND THE MOTION STOPPED. I VERIFIED THAT PARK WAS DISPLAYED ON THE CENTER CONSOLE, WHICH IT WAS. I THEN SHIFTED INTO REVERSE AND NEUTRAL AND BACK INTO PARK, AND THE SECOND TIME THE TRANSMISSION ENGAGED INTO PARK. WITHOUT MY PASSENGERS ALERTING ME TO THE VEHICLE MOTION, MY VEHICLE WOULD HAVE CRASHED AND POTENTIALLY INJURED THOSE IN THE VEHICLE. AFTER DETERMINING THE VEHICLE WAS IN PARK, I EXAMINED THE TIRE TRACKS IN THE SNOW TO SEE IF THERE WAS ANY CHANCE THAT THE VEHICLE SLID RATHER THAN ROLLED ON THE ROAD. THE TIRE TRACKS SHOWED CLEAR TIRE INDENTATIONS AND DID NOT INDICATE SLIDING, LEADING ME TO DETERMINE THAT THE VEHICLE DID NOT ENGAGE INTO PARK EVEN THOUGH THE CONSOLE INDICATED IT WAS IN PARK. *TR
Visibility, Nov 21, 2011
HTTP://WWW.CARCOMPLAINTS.COM/FORD/EXPLORER/2004/ACCESSORIES-INTERIOR/SUPPORTS_FOR_SUN_VISORS_CRACKED.SHTML THE SUN VISOR CLIP HAS BROKEN AND I AM UNABLE TO USE THE VISOR, IT JUST DANGLES. IT CAN CAUSE AN ACCIDENT. ONE NEEDS TO BE ABLE TO USE THE VISOR FOR SUN PROTECTION. I FEEL FORD SHOULD DO A RECALL BECAUSE SO THIS IS HAPPENING IN TOO MANY VEHICLES SO THERE HAS TO BE A MANUFACTURING PROBLEM. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
Visibility, Oct 31, 2011
THE HINGE ON THE GLASS HATCH BROKE AS I OPENED THE HATCH. THERE WAS NO DAMAGE TO THE HATCH HINGE PRIOR TO THIS. *TR
Visibility, Other or unspecified, Oct 25, 2011
I HAVE A 2004 FORD EXPLORER, ABOUT A MONTH AGO I NOTICED THE PLASTIC HINGE FOR THE BACK TAILGATE GLASS WAS BREAKING OFF. AFTER VISITING SEVERAL FORD USED CAR LOTS, I SEEN SEVERAL EXPLORERS WITH THE BROKEN HINGE AND REALIZED THIS IS A VERY COMMON PROBLEM. I HAVE CONTACTED FORD AND EXPRESSED MY CONCERNS, BUT THEY ARE STANDING BY THEIR PRODUCT. I RECIEVED AN ESTIMATE OF $360 TO REPAIR THE HINGES, BUT BEING A SINGLE PARENT OF FOUR THERE IS NO WAY I COULD AFFORD TO HAVE THIS REPAIR DONE. I HOPE THAT FORD WILL STEP UP AND RECALL THIS ISSUE BUT NO LUCK YET. *TT