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, Equipment, Jan 26, 2011
THE PROBLEM THAT I'M CONCERNED ABOUT IS THE TRANSMISSION AND REAR END. FOR THE TRANSMISSION-THIS IS THE THIRD TIME FOR THIS PROBLEM WITH OUR TRUCK. HAD IT AT THE DEALER SHIP JUST AFTER THE WARRANTY WENT OUT AROUND 37,000 AN PAID A LITTLE OVER $600.00 TO FIX IT . LASTED TILL 80,000 THEM TOOK IT BACK AND PAID AROUND $200.00 TO FIX. NOW AT 136,000 AND THE TRUCK WILL NOT MOVE AT ALL. DEALER SHIP WANTS ANOTHER $3,306.00 TO FIX IT AGAIN. THE REAR END IS MAKING A LOUD WINE NOISE. *TR
Structure, Jan 25, 2011
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR LIFTGATE EXHIBITED A FRACTURE DOWN THE MIDDLE OF THE HATCH. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSIS OR REPAIRS. THE MANUFACTURER WAS NOT CONTACTED AND THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 72,000 AND THE CURRENT MILEAGE WAS 78,000.
Fuel system, Gasoline, Vehicle speed control, Jan 25, 2011
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT WAS DRIVING APPROXIMATELY 5 MPH WHEN THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TOWED TO THE DEALER WHERE THE TECHNICIAN REPLACED THE FUEL PUMP, THROTTLE BODY AND SEVERAL UNKNOWN SENSORS IN THE VEHICLE. THE FAILURE RECURRED AND THE VEHICLE WAS TOWED TO THE DEALER. THE TECHNICIAN ADVISED THAT THEY WOULD PERFORM EXTENSIVE DIAGNOSTIC TESTING ON THE VEHICLE. THE VEHICLE WAS NOT REPAIRED. THE CONTACT STATED THAT THE FAILURE WOULD OCCUR INTERMITTENTLY IN COLD TEMPERATURES LESS THAN TWENTY DEGREES. THE APPROXIMATE FAILURE MILEAGE WAS 45,000.
Structure, Jan 24, 2011
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT NOTICED THAT THE REAR PLASTIC TAILGATE STRIP WAS CRACKED IN THE CENTER. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR INSPECTION. THE TECHNICIAN INFORMED THAT THE MANUFACTURER WOULD BE RESPONSIBLE FOR THE EXPENSE OF REPLACING THE PLASTIC STRIP FOR VEHICLES THAT DO NOT EXCEED 36,000 MILED. THE VEHICLE WAS NOT REPAIRED BECAUSE THE CONTACT EXCEEDED THE REQUIRED MILEAGE. THE FAILURE MILEAGE WAS APPROXIMATELY 40,000. THE VIN WAS UNAVAILABLE.
Power train, Jan 24, 2011
TRANSMISSION FAILURE ON 2004 FORD EXPLORER AT ~109K MILES. CRASH/BANG NOISE HEARD JUST BEFORE FAILURE: HIGH ENGINE RPMS AND NO FORWARD PROPULSION, FLASHING OD LAMP AND ILLUMINATED SERVICE ENGINE SOON LAMP. PROBLEM PRECEDED BY INTERMITTENT FAILURE TO ENGAGE REVERSE GEAR, OR SUDDEN JERKING/ROUGH ENGAGEMENT, OCCASIONAL SLIPPING OF GEARS ON ACCELERATION. UPON TOTAL FAILURE, DEALERSHIP INVESTIGATED, SAYS "KNOWN PROBLEM WITH THIS VEHICLE", RECOMMENDED COMPLETE TRANSMISSION REPLACEMENT AT $4000. VEHICLE IS ONE OF THOSE RECALLED IN 2005 FOR BAD TRANSMISSION FLUID FORMULA INSTALLED AT FACTORY. THIS VEHICLE HAS ALWAYS HAD PECULIAR SHIFT BEHAVIOR WHICH FORD CONSISTENTLY SAID WAS NORMAL FOR THE VEHICLE. APPARENTLY, AS MANY OTHER OWNERS HAVE SINCE EXPERIENCED, THE ROUGH SHIFTING (PERHAPS PRECIPITATED BY BAD FORMULA FLUID AND/OR DAMAGE THIS MAY HAVE DONE TO OTHER COMPONENTS) WAS INDICATIVE OF EVENTUAL TOTAL FAILURE. *TR
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
Structure, Jan 22, 2011
I AM THE OWNER OF A 2004 FORD EXPLORER, WITH APPRX. 50,000 HIGHWAY MILES. IN 2007 I WALKED OUTSIDE TO FIND THE REAR BACK PANEL UNDER THE WINDOW WITH THE FORD EMBLEM WAS CRACKED. I TOOK IT TO THE FORD DEALERSHIP , IT WAS STILL UNDER WARRANTY. THE TOTAL COST FOR REPAIR WAS 403.47, I HAD TO PAY 250.00 & THE WARRANTY COVERED THE DIFFERENCE OF 153.47. HERE IT IS 2011, I WALK OUTSIDE TO FIND THE REAR PANEL UNDER THE WINDOW WITH THE FORD EMBLEM CRACKED AGAIN, THE ONLY DIFFERENCE THIS TIME IS , I HAVE NO WARRANTY. THIS APPARENTLY IS A DEFECT ON FORDS PART, THE SAME CRACK 2 TIMES ON THE SAME VEHICLE AFTER BEING REPLACED AND FORD HAS NOT RECALLED YET. THEIR IS NOT ONE DAY YOU DRIVE AND NOT FIND FORD EXPLORER OWNERS DRIVING AROUND WITH CRACKS ON THE REAR PANEL. COME ON FORD OWN UP OR LOSE CONSUMERS. *TR
Structure, Jan 17, 2011
CRACK IN REAR UPPER TAILGATE. *TR
Engine and engine cooling, Jan 13, 2011
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE DRIVING APPROXIMATELY 35 MPH HE HEARD A NOISE AND THE VEHICLE STALLED. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER. HE WAS ADVISED BY THE DEALER THAT THE NUMBER THREE PISTON BROKE AND CEASED THE ENGINE. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS UNAVAILABLE. HE CALLED THE MANUFACTURER FOR ASSISTANCE AND HE WAS ADVISED THAT THE VEHICLE WAS NO LONGER UNDER WARRANTY. THE APPROXIMATE FAILURE AND CURRENT MILEAGES WERE 67,800.
Power train, Jan 11, 2011
I HAVE A 2004 FORD EXPLORER AND IT RECENTLY STARTED MAKING A RUMBLING NOISE. I BROUGHT IT TO MY MECHANIC AND HE LOOKED AT IT AND SAID IT WAS MY TRANSMISSION. HE ALSO SAID THAT IT WAS AN EXTREMLY COMMON PROBLEM FOR 2004 EXPLORERS. IF YOU GOOGLE "2004 EXPLORER PROBLEMS" AND CLICK ON ANY OF THE LINKS THE FIRST PROBLEM IS TRANSMISSION ISSUES. I HAVE OWNED THIS CAR SINCE IT WAS NEW IN 2004 AND HAVE NOT ABUSED THE CAR. FOR A 2004 CAR WITH ONLY 75000 MILES ON IT TO HAVE A TRANSMISSION GO IT IS A PROBLEM. I HAVE BEEN QUOTED $3000 TO FIX THIS PROBLEM THE FIX BEING A NEW TRANSMISSION. WHEN FORD KNOWS ABOUT THIS PROBLEM THEY SHOULD DO SOMETHING ABOUT IT. *TR
Structure, Jan 11, 2011
CRACK APPEARED ON PLASTIC PANEL JUST TO THE LEFT OF FORD EMBLEM THE CAR HAD 92K MILES WHEN OCCURRED. BODY SHOP ESTIMATE $500.00 TO REPAIR. *TR
Wheels, Jan 11, 2011
3 OUT OF 4 WHEEL BEARINGS HAVE HAD TO BE REPLACED ON 2004 FORD EXPLORER BETWEEN 71,000 AND 82,000 MILES. DRIVERS SIDE FRONT WAS REPLACED BETWEEN 71,000 AND 72,000 MILES, DRIVERS SIDE REAR REPLACED SHORTLY AFTER AND NOW THE PASSENGER FRONT NEEDS REPLACING AT 82,000 MILES. SEVERAL POSTS ON THE INTERNET WITH THE SAME COMPLAINT FOR THE SAME MAKE/MODEL/YEAR OF THIS VEHICLE. I WAS TOLD BY THE FORD DEALER THAT IF I DIDN'T FIX THEM THE TIRE COULD FALL OFF AT ANY TIME WITH OUT WARNING. *TR
Steering, Jan 10, 2011
NOISE IN FRONT END, PREMATURE FAILURE OF TIE ROD ENDS. *TR
Power train, Jan 8, 2011
TRANSMISSION WENT OUT ON MY 2004 FORD EXPLORER ONLY A DAY AFTER I BOUGHT IT FROM A DEALERSHIP. THE REPLACEMENT TRANSMISSION WILL COST ME $3400 PLUS THE $10550 THAT I PAID FOR THE VEHICLE THE DAY BEFORE. WHAT A BIG MESS THIS IS. *LN
Power train, Jan 5, 2011
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE DRIVING IN REVERSE APPROXIMATELY 2 MPH, THE TRANSMISSION EXHIBITED A DELAY RESPONSE AND WOULD SLIP VIOLENTLY INTO GEAR. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THEY INFORMED HER THAT THE TRANSMISSION NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. ONE YEAR AND SIX MONTHS LATER, AFTER THE NEW TRANSMISSION WAS INSTALLED, THE VEHICLE FAILED TO ACCELERATE OVER 30 MPH. THE FAILURE WAS DIAGNOSED BY THE DEALER WHO STATED THAT THE TRANSMISSION NEEDED TO BE REPLACED FOR THE SECOND TIME. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 27,000. THE VIN WAS UNAVAILABLE.
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
Structure, Jan 1, 2011
NOTICED A NUMBER OF CRACKED REAR PANELS ON LATE MODEL FORD EXPLORERS (2004-2006)- THIS PROBLEM IS WIDESPREAD ON THE FORD EXPLORER- FORD HAS FAILED TO ACKNOWLEDGE THAT THIS DEFECT IN WORKMANSHIP EXIST- FORD SHOULD RECALL THESE VEHICLES OR OFFER A GOODWILL REPAIR THESE FORD EXPLORER OWNERS. *TR
Power train, Dec 31, 2010
THE TRANSMISSION ON MY 2004 FORD EXPLORER IS FAILING; IS WILL SLIP OUT OF GEAR, AND THEN SHIFT BACK INTO GEAR HARD ENOUGH THAT IT MAKES THE ENTIRE VEHICLE SHAKE AND LURCH FORWARD. THE VEHICLE ONLY HAS 68K MILES ON IT, AND IS ONLY USED AS A COMMUTER VEHICLE. IT HAS NEVER BEEN TAKEN OFF ROAD, AND I HAVE NEVER USED IT TO TOW ANYTHING. *TR
Structure, Dec 30, 2010
VERTICAL CRACK IN THE PLASTIC TAILGATE ATTACHED TO THE REAR WINDOW LEFT OF THE FORD EMBLEM. FORD DEALER SAID THEY HAVE SEEN MANY OF THESE, SO I FEEL THIS IS A DESIGN FLAW & FORD SHOULD FIX FOR FREE. FORD GIVING ME RUN A ROUND. SO MUCH FOR FORD TOUGH. WHO SHOULD I CONTACT TO GET THIS FIXED FOR FREE? OR SHOULD I TAKE IT TO THE NEWS STATION ABOUT JUST HOW TOUGH FORD TRUCKS ARE.... THEY CRACK LIKE EASTER EGGS....... I HAVE NEVER HAD THIS OFF ROAD AND KEEP IT IN A GARAGE.
Power train, Dec 30, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER XLT. WHEN THE CONTACT SHIFTED INTO REVERSE GEAR THE VEHICLE WOULD NOT MOVE FOR APPROXIMATELY FOUR TO FIVE MINUTES. THE VEHICLE ALSO MADE A LOUD NOISE AND THEN MOVED IN REVERSE. THE VEHICLE WAS PREVIOUSLY TAKEN TO THE DEALER IN 2007 AND THE SOLENOID WAS REPLACED PER THE WARRANTY. THE DEALER WANTED TO REPLACE THE SOLENOID A SECOND TIME FOR $1000 AT THE OWNERS EXPENSE. THE MANUFACTURER WAS NOT CONTACTED. THE FAILURE MILEAGE WAS 42,000.
Tires, Dec 29, 2010
I OWN A 2004 FORD EXPLORER SPORTTRAC THAT CAME WITH MICHELIN CROSS TERRAIN TIRES. AS I WAS DRIVING HOME FOR THE HOLIDAYS MY FRONT DRIVER SIDE TIRE CAME APART, RUBBER STARTED TO FLY EVERYWHERE, BEATING MY TRUCK UP PRETTY BAD. THE TIRE WAS STILL HOLDING AIR WHEN I MADE IT TO THE SHOULDER, THE TIRE HELD ITS AIR PRESSURE FOR 2 DAYS AFTER I HAD TAKEN IT OFF. JUST THOUGHT I SHOULD LET SOMEONE KNOW. *TR
Power train, Dec 26, 2010
MY WIFE OWNS A 2004 FORD EXPLORER XLT WITH WHAT I'VE FOUND TO BE A COMMON PROBLEM. THE OVERDRIVE LIGHT FLASHES ON THE DASH BOARD. IT USUALLY IS A TRANSMISSION PROBLEM THAT IS A VERY EXPENSIVE REPAIR. THIS ISSUE WITH THE EXPLORER HAS BEEN GOING ON FOR OVER A DECADE. I THINK THAT FORD SHOULD BE HELD ACCOUNTABLE. AFTER ALL FORD DID TAKE BAIL OUT MONEY. I THINK THAT A RECALL WOULD BE THE PROPER ACTION FOR THE FORD. MOTOR COMPANY. I AM ONE OF THOUSANDS OF CONSUMERS WHO HAVE BEEN ABANDONED BY ANOTHER BIG COMPANY. *TR
Structure, Dec 21, 2010
REAR PANEL VERTICAL CRACK BELOW WINDOW. *TR
Power train, Dec 21, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 30 MPH, HE COULD FEEL A SLIP IN THE GEARS. HE ALSO STATED THAT WHEN SHIFTING INTO REVERSE, THERE WAS A VIOLENT SHIFT IN THE VEHICLE. THE VEHICLE WAS INSPECTED BY A DEALER WHO INFORMED THE CONTACT THAT HE NEEDED TO REPLACE THE TRANSMISSION. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 10,000. UPDATED 12/14/2011 *CN UPDATED 02/23/11
Engine and engine cooling, Dec 19, 2010, fire
MY WIFE WAS DRIVING OUR 2004 FORD EXPLORER EDDIE BAUER UPHILL ON A MOUNTAIN ROAD WHEN SHE FELT LIKE THE ENGINE IS LOOSING POWER. SHE STOPPED, EXITED THE VEHICLE AND SAW SMOKE COMING FROM UNDER THE CAR IN THE ENGINE AREA. THEN SOME PEOPLE STOPPED AND PULLED HER AWAY BECAUSE FROM THE POINT MY WIFE WAS STANDING SHE COULD NOT SEE THE ACTUAL FIRE. AS A RESULT THE ENGINE COMPARTMENT BURNED DOWN COMPLETELY CREATING A BIG HOLE IN THE HOOD. THE CAR HAD ABOUT 120K MILES ON ODOMETER AND WE HAVE NOT MISSED ANY SERVICE MAINTENANCE POINTS. SHE SAID BESIDES THAT POWER LOSS THERE WAS NO INDICATION THAT THERE IS SOMETHING WRONG WITH THE VEHICLE. *TR