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, Dec 15, 2010
1) 2004 EXPLORER EDDIE BAUER TRANSMISSION BADLY SLIPPING AND DELAY IN ENGAGING RESULTING IN VEHICLE LUNGING FORWARD ONCE IT ENGAGES. 2) HAS BEEN HAPPENING FOR ABOUT 3-4 YEARS INTERMITTENTLY. DEALER SAID THIS WAS NORMAL IN FIRST TIME I COMPLAINED. NOW IT HAPPENS EVERY DAY. 3) HAD TO HAVE THE TRANS REBUILT AT A COST OF $2328.25. *TR
Suspension, Electrical system, Interior lighting, Equipment, Dec 14, 2010
I HAVE A 2004 FORD EXPLORER WHICH WHILE DRIVING LAST YEAR I WAS TOLD THAT MY HUB ASSEMBLY ON MY DRIVER'S SIDE WAS BAD AND THAT I NEEDED TO REPLACE IT. I REPLACED IT WITH A HUB ASSEMBLY FROM ADVANCE AUTO PARTS IN JAN 2010. I JUST HAD TO REPLACE THIS PART AGAIN IN DEC 2010. I LOST BREAKS. I ALSO HAVE A HORRIBLE JERKING WHEN I AM BACKING UP FROM A TIGHT SPOT AND THE WHEELS ARE TURNED SHARPLY. MY DOOR AJAR LIGHT AND ALL INTERIOR LIGHTS DO NOT GO OFF WHEN THE DOOR IS OPENED OR THE VEHICLE IS CRANKED UNLESS I TURN THE INTERIOR LIGHT SWITCH TO THE OFF POSITION AND BACK TO THE ON WHEN THE DOORS OPEN POSITION. I HAVE HAD THE ELECTRICAL ISSUE REVIEWED TWICE IN THE PAST. I HAVE HAD THE JERKING LOOKED AT WITH NO REASON GIVEN MORE THAN ONCE. I HAD MY VEHICLE INSPECTED ON NOV 30TH AND NOTHING WAS MENTIONED ABOUT THE TERRIBLE CONDITION THE HUB ASSEMBLY WAS IN NOR THE BEARINGS THAT A MOBILE MECHANIC SHOWED ME WERE TERRIBLY WORN. I AM REPLACING THEM SOON. IT SEEMS TO ME THAT FORD MUST KNOW ABOUT ALL OF THESE PROBLEMS AND IT SHOULD BE SOMETHING THAT THEY ARE WILLING TO HELP THE CONSUMER IN FIXING SINCE MOST FORD BUYERS ARE DIEHARD FORD OWNERS LIKE MYSELF. *TR
Structure, Dec 11, 2010
I AWOKE ONE MORNING AND I FOUND A LARGE CRACK IN THE REAR HATCH OF MY 04 FORD EXPLORER. IT WAS NOT LIKE THAT THE PREVIOUS EVENING WHEN I GOT HOME. I RESEARCHED THE PROBLEM ONLINE AND FOUND MANY SIMILAR STORIES. I ALSO FOUND THAT THERE IS CURRENTLY NO MANUFACTURER RECALL TO REMEDY THE SITUATION. PLASTIC REAR HATCH CRACKED UNDER EXTREME TEMPERATURE. REAR GLASS MAY BREAK WHILE DRIVING AND POSE HAZARD TO OTHER DRIVERS. PLAN ON REPLACING, HOWEVER I DON'T BELIEVE I SHOULD PAY FOR IT BECAUSE OF THE POOR QUALITY OF THE ORIGINAL PART. *TR
Vehicle speed control, Dec 10, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT WHEN THE VEHICLE WAS IN PARK WITH THE EMERGENCY BRAKE ENGAGED, THE VEHICLE WOULD ABNORMALLY ACCELERATE WITHOUT WARNING. THE DEALER WAS NOT NOTIFIED OF THE FAILURE. THE MANUFACTURER WAS CONTACTED WHO ADVISED THE CONTACT TO TAKE THE VEHICLE TO A DEALER FOR A DIAGNOSTIC TEST. THE VEHICLE WAS NOT REPAIRED OR DIAGNOSED. THE CURRENT MILEAGE WAS APPROXIMATELY 60,000 AND THE FAILURE MILEAGE WAS APPROXIMATELY 59,500.
Engine and engine cooling, Dec 9, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 55 MPH, THE VEHICLE SUDDENLY STALLED AND ALL THE WARNING LIGHTS ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE WAS ABLE TO BE RESTARTED. THE FAILURE OCCURRED THREE DIFFERENT TIMES. THE VEHICLE WAS INSPECTED BY AN AUTHORIZED DEALER WHO COULD NOT DUPLICATE THE FAILURE. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 67,100. UPDATED 02/23/11*LJ UPDATED 05/04/11
Power train, Dec 9, 2010, crash
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE THE VEHICLE WAS PARKED, THE CONTACT TRIED TO SHIFT TO DRIVE WHEN THE GEAR SHIFT BROKE OFF. THE VEHICLE WAS TOWED TO THE DEALER. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 55,242.
Structure, Latches/locks/linkages, Dec 5, 2010
I HAVE HAD MY 2004 FORD EXPLORER FOR 3 YEARS NOW. TODAY I WENT TO OPEN MY REAR HATCH AND THE WINDOW HINGES JUST BROKE. NOW MY WINDOW IS HANGING THEREAND I DON'T KNOW HOW I AM GOING TO GET THEM FIXED SINCE I DON'T HAVE ANY EXTRA MONEY. I THINK THIS SHOULD BE A RECALL SINCE THERE HAS BEEN A LOT OF COMPLAINTS ABOUT THIS PROBLEM. *TR
Structure, Dec 4, 2010
THE HATCH BELOW MY REAR WINDOW HAS CRACKED ON BOTH SIDES OF THE FORD LOGO ON MY EXPLORER. IT SEEMED TO HAVE HAPPENED OVER NIGHT. I AM CONCERNED THAT IT MAY NOT BE STRONG ENOUGH TO HOLD THE WINDOW IN WHILE DRIVING. FORD HAS HAD THREE YEARS OF MODELS WITH THIS SOME PROBLEM AND HASN'T MADE IT RIGHT BY IT'S OWNERS. *TR
Structure, Dec 3, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT NOTICED TWO CRACKS BELOW THE REAR WINDOW ON THE TAILGATE. THE CONTACT CALLED THE MANUFACTURER WHO OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 98,000.
Service brakes, Hydraulic, Engine and engine cooling, Other or unspecified, Dec 1, 2010, crash
I BACKED SUV OUT OF GARAGE AND PUT IN PARK, GOT OUT OF VEHICLE WHILE STILL RUNNING (TO CLOSE GARAGE DOOR), CLOSED THE SUV DOOR, TURNED AROUND AND SAW THAT SUV WAS MOVING FORWARD INTO MY GARAGE. I OPENED THE SUV DOOR WHILE IT WAS MOVING AND JUMPED IN THE DRIVERS SEAT, PUSHED ON THE BRAKE AND SUV DID NOT STOP, I WAS LOOKING DOWN AT THE FLOOR TO SEE WHY SUV DID NOT STOP, PULLED UP MY FOOT AND PLACED IT BACK DOWN ON THE BRAKE. SUV STILL DID NOT STOP. IT THEN MADE A LOUD NOISE LIKE THE ENGINE WAS REEVING UP AND THEN THE SUV TOOK OFF FORWARD, RAN THROUGH THE BACK OF MY GARAGE, RAN THROUGH MY BACK YARD, RAN OVER A TREE IN THE YARD, RAN THROUGH MY BACK YARD FENCE AND MY NEIGHBOR'S FENCE AND CRASHED INTO THE BACK SIDE OF NEIGHBOR'S HOUSE. ALL WHILE THIS WAS OCCURRING, I WAS INSIDE OF THE VEHICLE WITH MY LEFT LEG STICKING OUT OF THE CAR (SINCE I JUMPED IN THE SUV IN A HURRY, I DIDN'T REALIZE THAT MY LEG WAS STILL OUT OF THE SUV), I CONTINUALLY ATTEMPTED TO STEP ON THE BRAKES (EACH TIME LIFTING MY FOOT UP SO THAT I COULD PLACE IT DIRECTLY ON THE BRAKE), THE ENGINE REEVED UP AGAIN WHILE GOING THROUGH THE YARD. THE ONLY THING THAT STOPPED THE SUV WAS THE TALL CONCRETE FOUNDATION OF MY NEIGHBOR'S HOUSE THAT IT RAN INTO. I JUMPED OUT OF THE SUV, FELL TO THE GROUND AND LAID THERE FOR A FEW SECONDS BEFORE I REALIZED THAT MY SUV WAS STILL RUNNING, THEN I JUMPED BACK INTO THE SUV AND TURNED THE IGNITION OFF.
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
Structure, Latches/locks/linkages, Nov 28, 2010
TAILGATE WINDOW HINGES FAILED ON 2004 FORD EXPLORER. THE WINDOW FELL OUT AND DAMAGED THE LIFT STRUTS. I WAS NOT INJURED. *TR
Power train, Other or unspecified, Nov 22, 2010
AS EVERYONE ELSE, I AM HAVE A LOT OF PROBLEMS WITH MY TRANSMISSION. IT SHIFTS VERY HARD AND JERKS WHEN PUT INTO REVERSE. ALSO HAVING ISSUES SHIFTING FROM 1ST TO 2ND AND 2ND TO 3RD. PROBLEM IS STEADILY GETTING WORSE. THIS MORNING THE O/D OFF LIGHT STARTED BLINKING. I KILLED THE CAR AND RESTARTED IT AND IT STOPPED. I DONT UNDERSTAND WHY THERE HAS NOT BEEN A RECALL ON THIS. FORD OBVIOUSLY KNOWS THAT THERE IS A PROBLEM. HOW COULD THEY NOT? I HAVE FOUND TONS OF MESSAGE BOARDS ON THE INTERNET WITH EVERYONE ELSE HAVING THE SAME PROBLEM.
Wheels, Nov 19, 2010
WHILE DRIVING, I TOOK A LEFT TURN AND FELT A BUMPING IN MY RIGHT REAR TIRE. I PULLED OVER THINKING IT WAS A FLAT TIRE. IN FACT, THE WHEEL BOLTS HAD BEEN SHEARED OFF COMPLETELY. WHEN I HAD THE CAR TOWED TO A REPAIR SHOP, THEY DISCOVERED THAT A TOTAL OF 10 BOLTS/NUTS NEEDED TO BE REPLACED AND 8 OUT OF THE OTHER 10 BOLTS WERE LOOSE OR WORN. I ALSO NEEDED TO GET A NEW WHEEL. THIS MORNING WHILE DRIVING TO WORK, I TOOK A LEFT TURN AND THE EXACT SAME THING HAPPENED, AGAIN WITH THE RIGHT REAR TIRE. THE BOLTS WERE SHEARED OFF. I HAVE NOT YET BROUGHT THE VEHICLE IN FOR REPAIRS FOR THE LATEST INCIDENT BUT I HAVE NO DOUBT THERE WILL BE ADDITIONAL BOLT DAMAGE ON AT LEAST SOME OF THE OTHER TIRES. *TR
Structure, Nov 17, 2010
2004 FORD EXPLORER HAS A CRACKED REAR PANEL SPLITTING THE ENTIRE BACK PANEL. I CONTACTED FORD AND THEY WILL NOT DO ANYTHING ABOUT IT. I THINK IT COULD BE A SAFETY CONCERN AS THE WHOLE PANEL COULD BREAK OFF BY THE REAR WINDOW. I'VE RESEARCHED THIS ON LINE AND THIS APPEARS TO BE A COMMON ISSUE WITH MY YEAR EXPLORER. FORD SHOULD TAKE RESPONSIBILITY FOR THEIR FAULTY PRODUCT.
Power train, Nov 16, 2010
WHILE DRIVING DOWN A 4-LANE HIGHWAY, TRANSMISSION FAILED. NO WARNING, JUST THUMP AND DONE. MY RESEARCH REVEALS THAT DEALERSHIP ARE REPORTING THAT 1 IN 10 2004 EXPLORERS HAVE TRANSMISSION FAILURE. ALSO, HEATER BLOWER MOTOR WENT OUT OVER 1 YEAR AGO, LEAVING NO DEFAULT HEAT FOR DEFROSTING THE WINDSHIELD.
Structure, Nov 15, 2010
CRACK SUDDENLY APPEARED IN THE REAR PANEL BELOW THE WINDOW. FROM THE GLASS TO THE BOTTOM OF THE HATCH. HAD WINDOW TIGHTENED. *TR
Suspension, Service brakes, Hydraulic, Fuel system, Gasoline, Structure, Nov 11, 2010
WERE A FAMILY A FORD EXPLORER MY FAMILY HAS 4 OF THEM RANGING FROM THE YEARS 1996,99,2002,2004 AND EVERYONE OF THESE VEHICLES HAVE SERIOUS ISSUES. RANGING FROM ROTTING SUSPENSION PARTS,TO WHEEL BEARING ISSUES ON NEWER MODELS,ROTTING FUEL AND BRAKE LINES,THIS IS SUPPOSED TO BE AN AMERICAN MADE COMPANY THAT IS JEOPARDIZING THE LIVES OF AMERICAN AND CHILDREN WITH TOTAL DISREGARD OF HUMAN LIFE,BUT I BET YOU THE OWNERS OF FORD DON'T HAVE THESE ISSUES THEY PROBABLY DRIVES FOREIGN HAHA BUT SERIOUSLY SOMEONE WILL GET HURT BY THIS AND IT COSTING THOUSANDS OF DOLLARS OUT OF POCKET TO FIX AN ONGOING PROBLEM WITH THESE TRUCKS PLEASE DO A RECALL ITS SO UNFAIR AT THIS POINT. *TR
Structure, Nov 10, 2010
CRACK SUDDENLY APPEARED IN THE REAR PANEL BELOW THE WINDOW, FROM THE GLASS TO THE BOTTOM OF THE HATCH.
Structure, Nov 10, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR HINGE ON THE TAILGATE WAS BROKEN WHERE THE GLASS WAS HANGING. THE DEALER WAS INFORMED ABOUT THE FAILURE AND STATED THAT THERE WERE NO RELATED RECALLS. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND THE CURRENT MILEAGE WAS 131,000.
Structure, Nov 8, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR LIFT GATE PANEL WAS FRACTURED BELOW THE GLASS. THE VEHICLE WAS NEVER INVOLVED IN A CRASH. THE VEHICLE WAS NOT TAKEN TO A DEALER FOR REPAIRS NOR WAS THE MANUFACTURER NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 47,000.
Power train, Nov 5, 2010
2004 FORD EXPLORER XLS WITH V6, BOUGHT NEW. INCORRECT TRANSMISSION FLUID PUT IN ALL 2004 EXPLORERS AT FACTORY. RECALLED AND PUT IN ADDITIVE AROUND 40,000 MILES. TRANSMISSION PROBLEMS STARTED ONE YEAR AGO, AROUND 50,000 MILES. TAKES SEVERAL SECONDS TO ENGAGE AND THEN SHIFTS HARD (CLUNKS) INTO REVERSE. HAPPENS 75% OF THE TIME. HAVE BEEN TOLD WE NEED A NEW (OR REBUILT) TRANSMISSION. *TR
Air bags, Nov 4, 2010, crash
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE DRIVING 45 MPH SHE HIT A DEER. THE AIR BAG ONLY OPENED IN THE COLUMN OF THE STEERING WHEEL. POWDER RESIDUE CAME OUT OF THE AIR BAG BUT THE AIR BAG DID NOT COME OUT AT ALL. NO ONE WAS INJURED; YET, THERE WAS DAMAGE TO THE FRONT END OF THE VEHICLE. THE VEHICLE WAS DRIVABLE TO HER RESIDENCE. THE DEALER WAS CONTACTED AND INFORMED HER TO BRING THE VEHICLE IN FOR INSPECTION. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILEAGE WAS 109,000.
Power train, Nov 3, 2010
2004 FORD EXPLORER, PURCHASED NEW. EVERY SINCE I HAVE OWNED THE CAR IT HAS HAD A TRANSMISSION PROBLEM AND WILL NOT GEAR DOWN WHEN TURNING OR SLOWING DOWN FROM A NORMAL RATE OF SPEED. THEN TAKES APX 20-25 SECONDS TO CATCH BACK UP WHEN ACCELERATOR PRESSED..HAS CAUSED ME TO ALMOST BE HIT SEVERAL TIMES.. BECAUSE IT WON'T GO WHEN IT DOES CATCH UP THERE IS A HARD BUMP IN THE CAR AND LOUD SOUND..VERY AGGRAVATING AND SCARY. HAS BEEN BACK TO THE DEALERSHIP AND TOLD ITS A (SP) SOLENOID PROBLEM AND HAD BEEN FIXED, BUT IT HASN'T HAVE BEEN DISGUSTED AND BEEN DRIVING IT THIS WAY BECAUSE I DON'T HAVE $2000 FOR REPAIRS. *TR
Visibility, Structure, Nov 3, 2010
BACK GLASS HATCH FELL OFF IN MY HANDS COULD HAVE REALLY HURT SOMEONE. *TR