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.
Air bags, Sep 14, 2010, crash
TL* THE CONTACT OWNS A 2004 FORD EXPLORER SPORT TRAC. THE CONTACT WAS DRIVING 30 MPH WHEN A VEHICLE UNEXPECTANTLY PULLED IN FRONT OF HIM. THE CONTACT CRASHED INTO THE RIGHT PASSENGER SIDE OF THE OTHER VEHICLE AND THE AIR BAGS DID NOT DEPLOY. THE CONTACT SUSTAINED INJURIES TO THE LEFT SHOULDER AND WAS TRANSPORTED TO THE HOSPITAL VIA AMBULANCE. THE VEHICLE WAS TOWED BY THE CONTACTS INSURANCE COMPANY WHO DEEMED THE VEHICLE AS DESTROYED. A POLICE REPORT WAS AVAILABLE. THE MANUFACTURER WAS NOT CONTACTED. THE FAILURE MILEAGE WAS 87,000. UPDATED 01/31/11 *BF UPDATED 04/21/11
Structure, Sep 14, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE LIFTGATE WAS FRACTURED DOWN THE CENTER. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE CONTACT WAS INFORMED THAT HE WOULD BE RESPONSIBLE FOR REPLACING THE ENTIRE LIFTGATE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 45,000 AND THE CURRENT MILEAGE WAS APPROXIMATELY 48,000. UPDATED 12/21/10*BF THE CONSUMER STATED NO REPAIRS WERE MADE. HE BELIEVED THE INTEGRITY OF THE REAR WINDOW LIFTGATE HAS BEEN COMPROMISED. UPDATED 12/29/10
Structure, Sep 13, 2010
THERE IS A CRACK IN THE REAR PANEL UNDER THE WINDSHIELD OF MY 2004 FORD EXPLORER XLT. ASIDE FROM BEING UNSIGHTLY, I'M AFRAID THAT THIS CRACK WILL WEAKEN THE PANEL WHICH IS INTEGRAL TO KEEPING THE REAR WINDSHIELD SEATED PROPERLY. *TR
Structure, Latches/locks/linkages, Sep 13, 2010
IN JULY 2010, I NOTICED A CRACK IN THE PANEL PORTION OF THE BACK WINDOW HATCH OF MY 2004 FORD EXPLORER. I REPORTED THIS TO MY DEALER, WHO MORE OR LESS SAID WELCOME TO THE CLUB, AND TOLD ME TO CONTACT THE BODY SHOP. THE COST OF $500-600 WOULD HAVE TO BE PAID BY ME AND THERE IS NO REASON TO THINK THAT IT WON'T HAPPEN AGAIN. I AM SO DISAPPOINTED IN FORD MOTOR CO., I THOUGHT I COULD EXPECT MORE FROM A LOCAL MANUFACTURER. IT SEEMS TO ME THAT THIS IS SOMETHING THAT SHOULD HAVE BEEN DISCOVERED IN PRODUCT TESTS AND/OR TRIALS. WHY DIDN'T FORD KNOW THAT THE MATERIAL THEY USED WAS NOT CAPABLE OF STANDING UP TO THE USE IN THE AREA THEY PLACED IT? *TR
Engine and engine cooling, Sep 10, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE DRIVING 65 MPH THE VEHICLE STALLED WITHOUT WARNING. THE CONTACT WAS ABLE TO DRIVE ONTO THE EMERGENCY LANE. THE VEHICLE WAS TOWED TO THE DEALER, DIAGNOSED AND STATED THAT THE FAILURE WAS CAUSED BY THE ENGINES TIMING CHAIN. THE VEHICLE WILL BE REPAIRED. THE MANUFACTURER TOOK REPORT 1644590504, BUT DIDN'T OFFER TO ASSIST WITH THE REPAIRS, BECAUSE THE MOTOR WASN'T COVERED BY WARRANTY. THE CURRENT AND FAILURE MILEAGES WERE 70,000.
Structure, Sep 9, 2010
PANEL BENEATH REAR GLASS CRACKS ON FORD EXPLORERS. SEVERAL REPORTS OF SAME OCCURRENCE ON INTERNET AND 3 (INCLUDING MYSELF) WHERE I WORK. ALMOST ALL SAME DESCRIPTION, "PANEL BREAKS NEAR FORD EMBLEM". *TR
Suspension, Sep 8, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE DRIVING APPROXIMATELY 40 MPH HE HEARD A LOUD LOW PITCH GRINDING NOISE COMING UNDERNEATH THE REAR WHEELS. A PASSENGER IN THE VEHICLE STATED THAT SHE COULD FEEL VIBRATIONS UNDERNEATH THE SEATS. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND WAS IN THE PROCESS OF HAVING THE FAILURE DIAGNOSED. THE FAILURE MILEAGE WAS 79,500 AND THE CURRENT MILEAGE WAS 79,664.
Structure, Sep 6, 2010
CRACKED REAR PANEL IN TAILGATE BELOW WINDOW. *TR
Visibility, Structure, Sep 4, 2010
1. PANEL BELOW REAR WINDOW CRACKED NOV 2009; CRACK IS LOCATED TO THE LEFT OF FORD EMBLEM AND IS THE LENGTH OF THE PANEL. FORD REFUSED TO REPAIR FREE OF CHARGE; WE DID NOT REPAIR IT. 2. THIS MORNING TAILGATE GLASS BLEW OUT WHILE CAR WAS PARKED IN OUR GARAGE AND THANKFULLY NO ONE WAS NEAR IT WHEN IT HAPPENED AS GLASS FLEW EVERYWHERE. CAR HAD NOT BEEN DRIVEN FOR OVER 24 HRS. *TR
Trailer hitches, Sep 1, 2010, crash
2004 FORD EXPLORER, WAS EASTBOUND WHEN THE TONGUE OF THE TRAILER HE WAS PULLING BROKE OFF DUE TO RUST. THE TRAILER TRAVELED ACROSS ALL THREE LANES STRIKING THE CENTER WALL AND OVERTURNING. *BF (OHIO TRAFFIC CRASH REPORT #10-0447-90)*JB UPDATED 09/13/10*BF
Engine and engine cooling, Aug 31, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER . WHILE DRIVING 55 MPH, THE VEHICLE STALLED AND THE CONTACT HAD TO GET THE BATTERY JUMPED IN ORDER TO DRIVE TO HER RESIDENCE. THE ALTERNATOR FAILED AND WAS REPLACED; HOWEVER, AFTER THE ALTERNATOR WAS REPLACED THE CONTACT WAS UNABLE TO MOVE THE VEHICLE EVEN WHEN THE ACCELERATOR PEDAL WAS ENGAGED. THERE WAS A WRENCH SYMBOL THAT ILLUMINATED ON THE INSTRUMENT PANEL WHERE THE DEALER STATED THAT THE COMPUTER SHIFTED INTO LIMP MODE. THERE HAVE BEEN NO ADDITIONAL REPAIRS TO THE VEHICLE. THE FAILURE AND CURRENT MILEAGES WERE 120,000.
Visibility, Aug 31, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR WINDOW PANEL WAS FRACTURED. THE VEHICLE WAS TAKEN TO THREE REPAIR FACILITIES WHERE THE CONTACT WAS ADVISED THAT THE REAR WINDOW PANEL WOULD NEED REPLACING. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 28,000 AND THE CURRENT MILEAGE WAS 28,990. UPDATED 12/01/10. *LJ UPDATED 12/07/10
Structure, Aug 30, 2010
CRACKED REAR PANEL ON 2004 FORD EXPLORER. DROVE IT THROUGH A CAR WASH AND IT SHATTERED. IT CAN FLY OFF AND HIT SOMEONE. *TR
Power train, Aug 29, 2010
VEHICLES EXHIBIT AN AXLE WHINE OR HUM DURING ACCELERATION, DECELERATION AND/OR CRUISE. *TR
Power train, Aug 29, 2010
THIS IS IN REGARDS TO TRANSMISSION PROBLEMS WITH FORD EXPLORERS ESPECIALLY FROM THE YEAR 2000 TO 2005. THERE HAVE BEEN FEW THOUSAND COMPLAINTS THAT I HAVE SEEN ON THE INTERNET AND HEARD AND ALSO EXPERIENCE MYSELF ABOUT THE TRANSMISSION AN THESE VEHICLES AND ITS RIDICULOUS. THE TRANSMISSION BANGS INTO GEARS LIKE SOMETHING IS FALLING UNDERNEATH BOGS DOWN WHEN CHANGING GEARS. HESITATES WHEN CHANGING GEARS AND JUST PLAIN TRANSMISSION FAILURE IN WHICH ITS HAPPENING BEFORE THE VEHICLE EVEN GETS TO 60K. I KNOW HUNDREDS OF PEOPLE THAT HAVE HAD THEIR TRANSMISSION REPLACED AT LEAST TWICE BEFORE 100K SO CONSUMERS PLEASE MAKE NOTE OF THESE TRANSMISSION PROBLEMS ON HERE BECAUSE THIS IS A REAL SAFETY PROBLEM FOR YOU AND YOUR CHILDREN. THANKS *TR
Wheels, Aug 27, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT WAS DRIVING LESS THAN 10 MPH AND APPROACHING AN INTERSECTION TO ATTEMPT A LEFT TURN. SUDDENLY, THE FRONT END OF THE VEHICLE COLLAPSED AND THE FRONT PASSENGER WHEEL FRACTURED FROM THE VEHICLE. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER YET THE TECHNICIAN WAS UNABLE TO LOCATE THE PROBLEM. THE MANUFACTURER REFERRED THE CONTACT TO AN INDEPENDENT MECHANIC FOR FURTHER INVESTIGATION. THE VEHICLE WAS REPAIRED FOR THE FRONT END DAMAGES AND THE TECHNICIAN WAS UNABLE TO PROVIDE AN EXPLANATION TO THE CAUSE OF THE FAILURE. THROUGH RESEARCH, THE CONTACT DISCOVERED THE FAILURE WAS A COMMON OCCURRENCE WITH THIS MODEL, AS A RESULT OF DEFECTIVE WHEEL LUG BOLTS. THE VEHICLE WAS TAKEN BACK TO THE DEALER AND THE LUG BOLTS WERE REPLACED ON THE FOUR WHEELS. THE FAILURE MILEAGE WAS APPROXIMATELY 77,000.
Engine and engine cooling, Aug 23, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE DRIVING 25 MPH, THE VEHICLE BEGAN MAKING AN ABNORMAL SQUEALING NOISE FROM THE FRONT END. THE VEHICLE WAS THEN TAKEN TO AN INDEPENDENT MECHANIC WHERE THE CONTACT WAS ADVISED THAT THE HARMONIC BALANCER FAILED AND CAUSED THE AIR CONDITIONING LINE TO FAIL. HE ALSO STATED THAT THE SERPENTINE BELT WOULD NEED REPLACING. THE MECHANIC REPAIRED ALL COMPONENTS AT THE CONTACT'S EXPENSE. NEITHER THE DEALER NOR THE 'MANUFACTURER WAS CONTACTED TO REPORT THE FAILURE. THE FAILURE MILEAGE WAS 78,350 AND THE CURRENT MILEAGE WAS 78,470.
Visibility, Aug 22, 2010
SUN VISOR ANCHOR BASED OF 2004 FORD EXPLORER CRACKED AND FELL OUT, CAUSING PLASTIC PIECES TO FALL ON FACE, AND MAKING VISOR FALL IN FRONT OF LINE OF SIGHT WHILE DRIVING ON HIGHWAY . USING SUN VISOR IS NOW NOT POSSIBLE. *TR
Power train, Aug 22, 2010
AT 25526 MILES TOOK VEHICLE TO DEALER FOR DELAY IN SHIFTING. DEALER FLUSHED WITH BG CONDITIONER. AT 26073 MILES RETURNED TO DEALER FOR CLUNKING ON SHIFTING, DEALER REMOVED PAN FOUND DEBRIS, OVERHAULED VALVE BODY AND REPLACED SOLENOID PACK. CONTINUED TO HAVE ISSUES BUT DEALER WAS UNABLE TO REPLICATE. TRANSMISSION FAILURE AT 63323 MILES ON 04 FORD EXPLORER, TOTAL REPLACEMENT OF TRANSMISSION FOR THE COST OF $3527.60 OUT OF OUR POCKET, NO WARRANTIES HONORED. *TR
Visibility, Latches/locks/linkages, Aug 22, 2010
DEFECTIVE REAR WINDOW HINGES ON MY 2004 FORD EXPLORER. I RARELY USE THE WINDOW HATCH AND TODAY I AM SORRY I DID. WHILE OPENING THE REAR WINDOW IT FELL ON TO MY HEAD. THE BRACKETS ON THE WINDOW BROKE. I AM WAITING FOR MY MECH. TO HELP ME REMOVE THE WINDOW SO I CAN BRING IT INTO TO GET REPAIRED. I OWN A 2002 FORD EXPLORER AND IT HAD A RECALL FOR THE SAME THING. SO WHY NOT THE 2004, IT IS THE SAME HINGE. *TR
Power train, Aug 20, 2010
2004 FORD EXPLORER. CONSUMER STATES TRANSMISSION PROBLEM *TGW THE CONSUMER STATED THE TRANSMISSION WOULD SLIP OUT OF GEAR AND THEN THERE WAS A HARSH BANG WHEN IT WAS PUT INTO REVERSE. THE CONSUMER BEGAN TO EXPERIENCE PROBLEMS NOT LONG AFTER THE VEHICLE WAS PURCHASED. HE TOOK THE VEHICLE TO THE DEALER AND UPON INSPECTION IT WAS DISCOVERED THE FACTORY PUT IN THE WRONG FLUID. HOWEVER, TWO YEARS LATER THE PROBLEM RESURFACED. THE CONSUMER WENT BACK TO THE DEALER AND THEY REPLACED THE TRANSMISSION FLUID. THE PROBLEM WENT AWAY FOR A WEEKS, BUT SOON RETURNED. *JB
Structure, Aug 19, 2010
I DISCOVERED A CRACK IN THE PLASTIC PANEL BELOW THE REAR WINDOW OF MY 2004 FORD EXPLORER LAST NIGHT WHILE UNLOADING GROCERIES. THERE HAD BEEN NO IMPACT TO THIS AREA OF THE VEHICLE SO I HAD NO IDEA WHERE IT CAME FROM. I CHECKED WITH A LOCAL BODY SHOP AND THE ESTIMATOR TOLD ME THIS IS A VERY COMMON ISSUE WITH FORD EXPLORERS AND MERCURY MOUNTAINEERS. IT WAS APPARENTLY A MANUFACTURING DEFECT AND THAT I SHOULD CHECK WITH FORD. I STOPPED BY THE LOCAL FORD DEALERSHIP BUT THE SERVICE MANAGER WAS OUT TO LUNCH. THE SALESMAN I TALKED TO SAID HE SAW THE PROBLEM A NUMBER OF TIME WHEN HE WORKED AT THE LINCOLN MERCURY DEALER. WAITING FOR THE SERVICE MANAGER TO CALL ME. *TR
Structure, Aug 19, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT ATTEMPTED TO CLOSE THE REAR LIFT GATE WINDOW AND THE HINGES FRACTURED CAUSING THE GLASS TO FALL AND SHATTER OVER HER HEAD. SHE SUFFERED MINOR INJURIES AS A RESULT. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE SHE WAS AWAITING A DIAGNOSIS OF THE FAILURE AND REPAIRS. THE FAILURE AND CURRENT MILEAGE WAS 80,000.
Structure, Aug 17, 2010
TAILGATE/DOOR WITH GLASS CRACKED AND BROKE. FIBERGLASS WAS MADE FAR TOO WEAK AND CRACKED. THIS IS A COMMON PROBLEM WITH THIS VEHICLE. *TR
Power train, Aug 17, 2010
BOTH REAR WHEEL BEARINGS WERE WORN AND NOISY AT LESS THAN 74,000 MILES. THESE BEARINGS SHOULD HAVE LASTED MUCH LONGER. $800.00 TO REPAIR/REPLACE. *TR