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, Structure, Nov 2, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT OBSERVED A LONG HAIR LINE FRACTURE ALONG THE PANEL BELOW THE REAR WINDSHIELD. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THEY INFORMED THE CONTACT THAT THE REAR WINDSHIELD PANEL WOULD NEED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 44,000. THE CONSUMER ALSO STATED HE HAD DIFFICULTY SHIFTING THE GEAR INTO REVERSE. UPDATED 01/06/11 UPDATED 01/24/11 *BF UPDATED 02/03/11
Structure, Oct 30, 2010
FORD 2004 EXPLORER PAINT BUBBLING AT FRONT OF ALUMINUM HOOD. CLEARLY A DEFECT. TOOK TO DEALER WHERE THE BODY SHOP MANAGER SAID HE REPAINTED 70 SO FAR THIS YEAR BUT FORD WILL NOT TAKE CARE OF IT. ASKED TO MEET WITH THE DISTRICT SUPERVISOR. SET UP A MEETING WHEN HE WOULD BE IN TOWN. HE WOULD NOT EVEN COME OUT TO TALK TO ME AND SENT SOMEONE ELSE OUT TO TELL ME FORD WILL NOT FIX IT BECAUSE IN MY WARRANTY IT READS, "RUST MUST PERMANENT FROM THE INSIDE OUT". I ARGUED THAT IT IS AN ALUMINUM HOOD AND WILL NEVER RUST! I THEN WROTE FORD MOTOR COMPANY AND HAVE NEVER HEARD BACK FROM THEM. I KEEP CHECKING FOR RECALLS AND HAVE SEEN NOTHING TO DATE. MY WIFE AND I SEE MANY OF THE SAME VEHICLES WITH THIS SAME PROBLEM ALL THE TIME. SHAME ON FORD!! I WOULD LIKE TO SEE SOMETHING TAKEN CARE OF WITH THIS. THIS IS CLEARLY A DEFECT AND NOT SOMETHING ANY OF US CONSUMERS EVER DID TO MAKE THIS HAPPEN. *TR
Engine and engine cooling, Oct 29, 2010
TL*THE CONTACT OWNS A FORD 2004 FORD EXPLORER. WHILE THE CONTACT WAS DRIVING APPROXIMATELY BETWEEN 55-60 MPH, THE ENGINE COMPLETELY STALLED AND THE INSTRUMENT PANEL WARNING INDICATORS ILLUMINATED. THE VEHICLE RESTARTED AND RESUMED WITHOUT THE ILLUMINATION OF THE WARNING INDICATORS. THE FAILURE OCCURRED ON NUMEROUS OCCASIONS AND BECAME PROGRESSIVELY WORSE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE MILEAGE WAS 68,000. UPDATED 01/13/11*LJ THE CONSUMER STATED THE ENGINE STALLS AT ANY SPEED. UPDATED 03/23/11
Structure, Oct 21, 2010
10/20/2010 - SPOKANE, WASHINGTON - REAR PANEL UNDER BACK GLASS AROUND FORD LOGO CRACKED AFTER A COOL MORNING 32-35 DEGREES. THE CRACK EXTENDS FROM THE WINDOW ALL THE WAY TO THE BOTTOM OF THE PANEL. *TR
Structure, Oct 21, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR LIFTGATE GLASS HINGE WAS FRACTURING FROM THE VEHICLE. THE DEALER INFORMED THE CONTACT THAT THE HINGE WOULD NEED REPLACING AND THERE WERE NO RECALLS FOR THE VEHICLE. ANY REPAIR TO THE VEHICLE WOULD BE AT THE CONTACTS EXPENSE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 115,000 AND THE CURRENT MILEAGE WAS 150,100.
Structure, Oct 20, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. ON OCTOBER 7, 2010, THE CONTACT NOTICED THAT THE REAR LIFTGATE GLASS HAD A CRACK IN THE PANEL. THE DEALER STATED THAT THERE WERE NO RELATED RECALLS. THE CONTACT CALLED THE MANUFACTURER WHO STATED SHE MIGHT BE ELIGIBLE FOR REIMBURSEMENT, IF THERE FAILURE BECAME A RECALL. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 57,000.
Structure, Oct 19, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE PLASTIC PANEL ON THE REAR HATCH WAS CRACKED AND COULD POTENTIALLY FALL OFF. THE CONTACT CALLED THE DEALER REGARDING THE CRACKED PANEL AND THE DEALER INFORMED HER THAT THERE WAS NO RECALL REGARDING THE PLASTIC PANEL AND STATED THAT THE PART WAS AVAILABLE FOR PURCHASE. THE CONTACT HAD NOT REPLACED THE PLASTIC PANEL. THE FAILURE MILEAGE WAS 74,000.
Structure, Oct 18, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR PANEL WAS CRACKED BY THE EMBLEM IN THE REAR LIFTGATE. THE VEHICLE HAD NOT BEEN INSPECTED OR REPAIRED AT THE TIME OF THE COMPLAINT. THE CONTACT CALLED THE MANUFACTURER WHO STATED THAT THERE WAS NO RECALL RELATED TO THE FAILURE. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 55,000.
Structure, Oct 17, 2010
2004 FORD EXPLORER CRACKED PANEL BELOW THE REAR WINDOW. *TR
Service brakes, Hydraulic, Vehicle speed control, Oct 15, 2010, fire
MY 2004 FORD EXPLORER CAUGHT ON FIRE TODAY. THE FIRE BEGAN UNDER THE HOOD. PER THE FIRE DEPARTMENT, THE FIRE STARTED AROUND THE CRUISE CONTROL AND BRAKE MASTER CYLINDER AREA. FORD DOES NOT HAVE A RECALL OUT FOR THIS YEAR MODEL, UNLIKE THE 2003 AND OLDER MODELS, BUT THIS IS DEFINITELY A MANUFACTURER PROBLEM. THE CAR WAS DRIVEN TO SEVERAL POINTS, DROP THE KIDS OF AT SCHOOL, ONE AT DAYCARE, AND A STOP FOR BREAKFAST. NOTHING WAS WRONG WITH OUR CAR. AFTER ARRIVING TO WORK, MY WIFE GOT A CALL THAT HER CAR WAS ON FIRE. THERE WERE NO SIGNS, MALFUNCTIONS THAT SOMETHING WAS WRONG WITH THE VEHICLE. REGULARLY SCHEDULED MAINTENANCE WERE ALWAYS PERFORMED. *TR
Vehicle speed control, Oct 14, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. WHEN THE CONTACT DEPRESSED THE ACCELERATOR PEDAL, THE VEHICLE WOULD NOT MOVE. WHEN SHE DEPRESSED THE PEDAL AGAIN, THE VEHICLE WOULD SUDDENLY TAKE OFF AT A HIGH RATE OF SPEED. THE CONTACT CALLED THE DEALER WHO STATED THAT THE PROBLEM WAS COMMON BUT THERE WAS NO REMEDY. THE MANUFACTURER HAD NOT BEEN NOTIFIED. THE FAILURE MILEAGE WAS APPROXIMATELY 58,000. UPDATED 12/30/10 *BF UPDATED -1/10/11
Seat belts, Structure, Oct 12, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER SPORT. WHILE THE VEHICLE WAS PARKED, THE CONTACT NOTICED A CRACK NEAR THE EMBLEM IN THE CENTER OF REAR LIFTGATE. THE VEHICLE WAS TAKEN TO A BODY SHOP AND REPAIRED. THE CONTACT ALSO STATED THAT THE DRIVER AND FRONT PASSENGER SEAT BELTS DID NOT RETRACT AT TIMES. SHE HAD TO REPEATEDLY PULL THE SEAT BELTS SO THAT THEY WOULD RETRACT. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 50,000 AND THE CURRENT MILEAGE WAS APPROXIMATELY 70,000.
Structure, Oct 7, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE PANEL IN THE REAR LIFTGATE WAS SPLIT. THE CONTACT CALLED THE DEALER WHO STATED THAT THE FAILURE WAS COMMON. THE CONTACT CALLED THE MANUFACTURER WHO STATED THAT THERE WERE NO RECALLS AND REPAIRS WOULD BE AT HIS EXPENSE. THE FAILURE MILEAGE WAS APPROXIMATELY 62,000.
Structure, Oct 6, 2010
A CRACK HAS FORMED IN THE REAR LIFT GATE PANEL. IT OCCURRED OVERNIGHT WHILE NOT IN USE ABOUT 2 WEEKS AGO. I DIDN'T THINK MUCH OF IT UNTIL I BEGAN NOTICING MANY OTHER EXPLORERS AND MERCURY MOUNTAINEERS OF ABOUT THE SAME YEAR (2002-2004) WITH THE SAME DEFECT. I DECIDED TO SEE IF THERE WAS A RECALL, BUT ALL I COULD FIND WAS A LOT OF PEOPLE COMPLAINING AND NO ACTION FROM FORD. I DON'T KNOW HOW MANY OTHERS HAVE FILED A COMPLAINT WITH YOU, BUT AT ONE WEBSITE THERE ARE AT LEAST 290 OTHER OWNERS WHO HAVE POSTED A COMPLAINT. IF YOUR INTERESTED, HERE IS THE LINK: HTTP://WWW.CARCOMPLAINTS.COM/FORD/EXPLORER/2004/BODY_PAINT/CRACKED_PANEL_BELOW_THE_REAR_WINDOW.SHTML. *TR
Power train, Oct 5, 2010
I HAVE 2004 AWD LIMITED EDITION FORD EXPLORER WITH 69,000 MILES. I AM NOW FACED WITH REPLACING THE TRANSMISSION AT A COST OF $5,000. THIS CAR IS FAR TOO NEW, WITH FAR TOO FEW MILES TO BE IN NEED OF A NEW TRANSMISSION. *TR
Engine and engine cooling, Power train, Oct 4, 2010
THERE ARE NUMEROUS COMPLAINTS ON THE INTERNET REGARDING THE 2004 FORD EXPLORER. THE CAR JERKS VIOLENTLY WHEN GOING INTO FIRST, SECOND AND REVERSE GEARS. THE FIRST REPAIR WAS ON 10/07 AT 15,690 MILES. THE DEALERSHIP REPLACED THE SOLENOID AND ASSURED THE PROBLEM WAS RESOLVED. AT 24,190 MILES THE SAME PROBLEM RECURRED AND THE DEALERSHIP RECALIBRATED AND CHARGED $118. NOW AT 26,900 MILES THE PROBLEM HAS RECURRED AND AGAIN THEY ARE GOING TO REPLACE THE SOLENOID. OF COURSE AT MY EXPENSE. THERE IS OBVIOUSLY SOMETHING WRONG AND FORD IS REFUSING TO ADDRESS THE PROBLEM. THEY SHOULD AT LEAST GUARANTEE THE WORK THAT WAS DONE UNDER WARRANTY. *TR
Structure, Latches/locks/linkages, Oct 1, 2010
2004 EXPLORER WITH 110K MILES - DEVELOPED CRACK IN LIFTGATE PANEL APP DEC 2008. FORD COVERED 80% OF REPAIR COST OF $750 SINCE VEHICLE WAS UNDER 75K MILES, EVEN THOUGH AN OBVIOUS DESIGN FLAW. SEPT 29, 2010 REAR HATCH WINDOW HINGE BREAKS CAUSING DOOR TO FALL ONTO MY HANDS AND LEGS...SORE BUT NOT PERMANENT. TWO CO-WORKERS HAD TO HELP ME RAISE IT UP ENOUGH TO LOCK IT IN PLACE. DEALER REPAIRED FOR $65 PARTS IN $170 LABOR. DANGEROUS AND UNSAFE. *TR
Wheels, Oct 1, 2010
RIGHT REAR TIRE KEEPS COMING OFF. THE LUG NUTS KEEP BREAKING OFF, THIS IS THE THIRD TIME IT HAPPENS. THE RIM WAS REPLACED, BUT STILL ARE BREAKING OFF. *TR
Steering, Sep 30, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE THE VEHICLE WAS PARKED, HE ATTEMPTED TO SHIFT AND THE SHIFTER LEVEL BROKE. THE CONTACT TURNED THE VEHICLE OFF AND VEHICLE WAS TOWED TO AN AUTHORIZED DEALER WHERE THE CONTACT WAS INFORMED THAT THE STEERING COLUMN NEEDED TO BE REPLACED. THE VEHICLE WAS BEING REPAIRED AT THE TIME OF THE COMPLAINT. THE CURRENT AND FAILURE MILEAGES WERE 27,650.
Vehicle speed control, Sep 28, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT WHILE DRIVING 70 MPH, THE CHECK ENGINE LIGHT FLASHED ON THE INSTRUMENT PANEL AND THE VEHICLE SUDDENLY SHUT OFF. THE CONTACT DISCONNECTED THE BATTERY TO RESET THE COMPUTER SO THE VEHICLE WOULD START. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE CONTACT WAS INFORMED THAT THE TRANSMISSION NEEDED TO BE REPLACED. THE VEHICLE WAS THEN TAKEN TO A LOCAL REPAIR SHOP WHERE THE CONTACT WAS TOLD THAT THE TRANSMISSION DID NOT NEED TO BE REPLACED BUT THE THROTTLE BODY DID. THE VEHICLE WAS REPAIRED AT THAT TIME; THE CONTACT HAD NOT EXPERIENCED ANY FURTHER PROBLEMS SINCE THE REPAIR. THE FAILURE MILEAGE WAS APPROXIMATELY 56,000.
Vehicle speed control, Sep 24, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT WAS DRIVING APPROXIMATELY 55-60 MPH WHEN THE ELECTRONIC THROTTLE WARNING LIGHT ILLUMINATED. THE VEHICLE INDEPENDENTLY BEGAN TO DECELERATE AND BEFORE STALLING. THE CONTACT SHIFTED INTO NEUTRAL AND COASTED TO THE SIDE OF THE ROAD. SHE WAS ABLE TO RESTART THE VEHICLE AFTER TEN MINUTES. THE FAILURE OCCURRED TWICE. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THEY WERE UNABLE TO DUPLICATE THE FAILURE. THE DEALER SUGGESTED THAT THE THROTTLE BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 93,830 AND THE CURRENT MILEAGE WAS 93,839.
Power train, Sep 23, 2010
FORD EXPLORER 2004 - TRANSMISSION FAILURE - PREMATURE TRANSMISSION FAILURE WITH ONLY 56,497 MILES ON VEHICLE. DRIVEN NORMALLY WITH NO OFF ROAD DRIVING. NO RECALLS OR CLASS ACTIONS AT THIS TIME ACCORDING TO FORD. NUMEROUS COMPLAINTS OF THIS PROBLEM POSTED ON LEGITIMATE INTERNET SITES. COST OF REPAIR $2800.00. *TR
Engine and engine cooling, Sep 21, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE CHECK ENGINE LIGHTS CONTINUED TO ILLUMINATE EVERY TWO MONTHS AFTER THE VEHICLE WAS REPAIRED. EACH TIME THE VEHICLE WAS TAKEN TO THE DEALER, SHE WAS CHARGED A DIAGNOSTIC FEE TO PERFORM THE TEST AND REPAIR A DIFFERENT PROBLEM. THE CONTACT DID NOT KNOW WHAT REPAIRS WERE PERFORMED ON THE VEHICLE. THE MANUFACTURER WAS CALLED WHO STATED THAT THEY WOULD SEND HER INFORMATION ON HOW TO TRADE THE VEHICLE IN FOR ANOTHER VEHICLE, WHICH INCLUDED ADDITIONAL DISCOUNTS; HOWEVER, SHE HAD NOT HEARD FROM THEM. THE FAILURE MILEAGE WAS 59,078.
Visibility, Sep 17, 2010
DEFROSTER HEAT CONTROL FAILED, COULDN'T SEE THROUGH WINDSHIELD. *TR
Visibility, Structure, Sep 16, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE EXAMINING THE VEHICLE THE CONTACT NOTICED A CRACK ON THE PANEL BELOW THE REAR WINDOW. THE VEHICLE HAS NOT BEEN DIAGNOSED AND THERE WERE NO PRIOR WARNINGS. THE CURRENT AND FAILURE MILEAGES WERE 89000. UPDATED 01/03/11