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, Electrical system, Jun 11, 2010
2004 FORD EXPLORER ANOTHER BAD TRANSMISSION ! 3000.00 REBUILD OVER DRIVE LIGHT FLASHING , INTERIOR LIGHTS STAY ON , WINDOWS DON'T GO DOWN, DOOR OPEN LIGHTS ON DASH ARE ON .. SEEMS TO BE ALOT OF THESE COMPLAINTS I BEEN READING ON THE INTERNET ! FORD HAD TO HAVE SOME FAULT IN ALL THESE COMPLAINTS ???? *TR
Structure, Jun 9, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR LIFT GATE PANEL WAS CRACKED BELOW THE GLASS AND THE VEHICLE HAD NEVER BEEN INVOLVED IN ANY ACCIDENTS. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALERSHIP WHERE THE CONTACT WAS INFORMED THAT THE FAILURE WAS KNOWN BUT SHE WOULD BE RESPONSIBLE FOR REPAIR COSTS. THE VEHICLE HAD NOT BEEN REPAIRED AT THE TIME OF THE COMPLAINT. THE FAILURE MILEAGE WAS APPROXIMATELY 34,000. THE CURRENT MILEAGE WAS 35,373.
Power train, Jun 8, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE DRIVING AT SPEEDS OF 50 MPH, THE TRANSMISSION WARNING LIGHT ILLUMINATED AND THERE WAS AN UNUSUAL NOISE COMING FROM THE WHEEL BEARINGS. THE VEHICLE WAS TAKEN TO A LOCAL REPAIR FACILITY WHERE THE CONTACT WAS ADVISED THAT THE TORQUE WAS DEFECTIVE AND CAUSED THE TRANSMISSION TO MALFUNCTION. THE DEALER WAS CONTACTED AND ALSO ADVISED HAVING THE TRANSMISSION REPLACED. THE FAILURE AND CURRENT MILEAGES WERE 84,000. UPDATED 08/27/10. *LJ
Visibility, Jun 6, 2010
WHILE ATTEMPTING TO CLOSE THE WINDOW ON HATCHBACK, THE WINDOW HINGES BROKE. *TR
Structure, Jun 4, 2010
LETTER TO THE DEPUTY ADMINISTRATOR FROM SENATOR BURR ON BEHALF OF CONSTITUENT CONCERNING A CRACK IN THE PLASTIC SURROUNDING THE REAR WINDOW OF HER 2004 FORD EXPLORER *TGW
Wheels, Jun 2, 2010, crash
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE DECELERATING AT APPROXIMATELY 5 MPH, THE FRONT PASSENGER SIDE TIRE BROKE OFF OF THE VEHICLE RESULTING IN A CRASH. A POLICE REPORT WAS FILED. NO INJURIES WERE REPORTED. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC FOR INSPECTION. THE CURRENT AND FAILURE MILEAGES WERE UNKNOWN. THE VIN WAS NOT AVAILABLE.
Structure, Jun 2, 2010
ON FRIDAY, MAY 28, 2010 MY HUSBAND ATTEMPTED TO OPEN THE LIFTGATE ON OUR 2004 FORD EXPLORER WHEN THE GLASS SEPARATED FROM THE VEHICLE AND LANDED IN HIS HANDS. IT DID NOT SHATTER BECAUSE HE WAS HOLDING ONTO IT. UPON INSPECTION, WE DISCOVERED THAT THE LEFT HINGE THAT CONNECTS THE LIFTGATE TO THE VEHICLE HAD SNAPPED. THE LIFTGATE IS CURRENTLY HANGING ON THE RIGHT HINGE AS WE DO NOT HAVE THE RESOURCES AT THIS TIME TO HAVE IT REPAIRED. I HAVE SINCE LEARNED THAT INVESTIGATION OF THE SAME PART WAS OPENED IN JUNE 23, 2004 AND CLOSED ON OCTOBER 24, 2008. ALTHOUGH ON PAGE 12 OF THE RESPONSE TO NHTSA FORD MOTOR COMPANY ADMITS THAT THIS FAILURE IS CAUSED BY "THE USE OF NON-OPTIMAL COATING ON THE STEEL PIN THAT JOINS THE TWO ZINC DIE-CAST SECTIONS OF THE HINGE", THE COMPANY ASSUMES NO FINANCIAL RESPONSIBILITY IN COVERING THE REPAIRS BECAUSE NO RECALL HAS BEEN ISSUED. I URGE YOU TO TAKE A PROACTIVE APPROACH TO THIS ISSUE AS IT COULD CAUSE SERIOUS INJURY AND THERE ARE NUMEROUS COMPLAINTS FROM CONSUMERS WHO ARE NOT AWARE THAT THEY CAN REPORT THEM TO THIS AGENCY. *TR
Electrical system, May 27, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT WHILE THE VEHICLE WAS BEING SERVICED FOR ROUTINE MAINTENANCE AT AN AUTHORIZED DEALER, HE WAS INFORMED THAT THE BLEND DOOR MOTOR HAD FAILED. THE BLEND DOOR MOTOR WAS REPLACED AT THE OWNERS EXPENSE. THE FAILURE AND CURRENT MILEAGES WERE 88,820.
Structure, May 25, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THE PLASTIC LINING UNDER THE TAILGATE WINDOW WAS CRACKED. THE MANUFACTURER WAS CONTACTED SEVERAL TIMES BUT WOULD NOT PROVIDE ANY ASSISTANCE. THE DEALER ADVISED THEY WERE AWARE OF THE FAILURE HOWEVER THEY WERE NOT LIABLE FOR THE FAILURE WITHOUT A RECALL. THE CONTACT STATED THAT EVERY YEAR AND MODEL OF HIS VEHICLE THAT HE HAS OBSERVED EXHIBITS THE SAME FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE APPROXIMATELY 52,000. UPDATED 07/23/10*JB
Service brakes, Hydraulic, May 20, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE BRAKING FROM SPEEDS OF 25 MPH, THE ABS WARNING LIGHT ILLUMINATED ON THE DASHBOARD. THE VEHICLE WAS TAKEN TO A LOCAL MECHANIC WHERE THE CONTACT WAS INFORMED THAT THE BRAKE SENSOR WOULD NEED TO BE REPLACED. THERE WERE NO PRIOR WARNINGS. THE CURRENT AND FAILURE MILEAGES WERE 92,505.
Visibility, May 19, 2010
REAR WINDOW HINGES ON 2004 FORD EXPLORER BROKE. *TR
Structure, May 17, 2010
THE REAR HATCH PANEL ON MY FORD 2004 EXPLORER CRACKED FOR NO APPARENT REASON. WHEN I WENT TO THE LOCAL DEALER HE SAID IT IS A COMMON DEFECT. WHEN I ASKED HOW MUCH IT WOULD COST TO REPAIR HE QUOTED ME $650.00 I HAVE SEEN DOZENS OF THIS MODEL IN MY DAILY DRIVING EXPERIENCE IN AZ. WHY HASN'T FORD MADE A REPLACEMENT FOR ALL OF US WHO HAVE THIS PROBLEM. IT IRRITATES ME THAT THEY SAY QUALITY IS NUMBER ONE BUT WON'T OWN UP TO A DEFECT THAT IS REPLETE IN EMAILS ON LINE? *TR
Power train, May 16, 2010
I HAVE A BAD TRANSMISSION. I SHIFTS TERRIBLY INTO THE UPPER GEARS AND WHEN IT SHIFTS INTO REVERSE, IT OFTEN HESITATES AND THEN WHEN IT DOES SHIFT, IT SOUNDS LIFE THE TRANSMISSION IS ABOUT TO FALL OUT. IT SHIFTS INTO REVERSE WITH A LOUD CLANK AND BIG JOLT. THIS HAS BEEN HAPPENING SINCE DAY ONE, 2004, AND IT WAS TAKEN BACK TO THE DEALER, WHO SAID IT WAS AN ELECTRONIC PROBLEM, BUT THEY DIDN'T FIX THE PROBLEM. *TR
Air bags, May 13, 2010, crash
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT WHILE THE VEHICLE WAS PARKED, ANOTHER VEHICLE HIT THE REAR. THE CRASH CAUSED THE AIR BAG LIGHT TO FLASH ON THE INSTRUMENT PANEL. THE CONTACT DROVE THE VEHICLE TO AN AUTHORIZED DEALERSHIP TO HAVE THE AIR BAG LIGHT INSPECTED. THE DEALER INFORMED THE CONTACT THAT THE AIR BAG SENSOR NEEDED TO BE REPLACED. UPON STARTING THE VEHICLE, THE ENGINE MALFUNCTIONED AND THE VEHICLE BECAME COMPLETELY INOPERABLE. THE FAILURE MILEAGE WAS APPROXIMATELY 105,000. UPDATED 11/03/10. *LJ
Structure, May 10, 2010
REAR HATCH CRACKED ON MY 2004 FORD EXPLORER. *TR
Power train, May 10, 2010
WHILE DRIVING NORMALLY, 'O/D OFF' LIGHT ON DASHBOARD COMES ON. UNABLE TO ACCELERATE AND/OR VEHICLE SHUTS OFF; THE REMEDY: HAVING TRANSMISSION REBUILT OR REPAIRED. THIS HAS OCCURRED THREE TIMES IN 3 YEARS. SAW ON A 6PAGE FORUM OF OTHER FORD OWNERS HAVING THE SAME PROBLEM. REPAIRING A TRANSMISSION IS COSTLY AND ITS NOT ONE REPAIR IT'S MULTIPLE OVER THE LIFE OF OWNING THE VEHICLE. *TR
Steering, May 10, 2010
GEAR SHIFTER FELL INTO MY HAND WHILE TRYING TO PUT MY 2004 FORD EDDIE BAUER EXPLORER FROM PARK INTO REVERSE. THE VEHICLE IS PARKED BUT NOT IN PARK. IT IS ONLY BEING HELD STILL BY PARKING BRAKE AS IT IS STUCK IN BETWEEN PARK AND REVERSE. THE KEY CAN NOT BE REMOVED BECAUSE THE CAR IS NOT IN PARK. THERE WERE ZERO EVENTS LEADING UP TO THIS FAILURE. FORTUNATELY, I WAS PARKED IN MY DRIVE WAY BUT I CAN ONLY IMAGINE THE CONSEQUENCES HAD I BEEN PARKED ON A HILL OR HAD THE SHIFTER BROKE WHILE IN GEAR WHERE IT WOULD HAVE REMAINED. I HAVE NOT REPAIRED THE PROBLEM AS OF YET IT JUST HAPPENED TODAY, BUT AFTER DOING RESEARCH IT APPEARS AS IF ENTIRE STEERING COLUMN NEEDS TO BE REPLACED AND I AM TO SPEND ANY WHERE FROM $1000 TO $2000 TO REPLACE A DEFECTIVE PART WITH A BRAND NEW DEFECTIVE PART TO HAVE IT HAPPEN AGAIN AT ANY TIME. I WAS ABLE TO LOCATE OVER 100 COMPLAINTS ON THE EXACT SAME ISSUE DATING BACK TO 2/2007. I AM CURIOUS AS TO WHY THERE HAS BEEN NO RECALL FOR THIS SITUATION. *TR
Visibility, May 3, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE FIBER GLASS FITTING UNDER THE WINDOW NEXT TO THE TAILGATE BEGAN CRACKING AND WAS BECOMING PROGRESSIVELY WORSE. THE OWNER HAD NOT CONTACTED THE DEALER. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 57,000.
Structure, Apr 30, 2010
NOTICED THE LIFT GATE HINGE OF OUR 2004 FORD EXPLORER IS CRACKED. WE'VE NOW REMOVED THE GLASS FROM THE LIFT GATE AND ARE TRYING TO FIND PARTS FOR IT. THIS IS A POTENTIAL DANGER, NOT KNOWING WHEN THE GLASS CAN CRACK/SHATTER. THIS IS OBVIOUSLY A DEFECT IN THE MANUFACTURING OF THE PART. *TR
Power train, Apr 21, 2010
I HAVE BEEN DRIVING A 2004 FORD EXPLORER SINCE DECEMBER 2004 WHEN MY DAUGHTER LEFT IT FOR ME WHEN SHE MOVED. IT HAD APPROXIMATELY 11,000 MILES. SHE HAD NOTICED A HARD SHIFT, ESPECIALLY WHEN GOING INTO REVERSE AND A ROUGH IDLE AND VIBRATION, BUT HAD NOT HAD A CHANCE TO HAVE IT LOOKED AT. EXCEPT FOR WHEN I HAVE BEEN OUT OF TOWN, I HAVE SERVICED THAT CAR AT A FORD DEALERSHIP RELIGIOUSLY. I COMPLAINED ABOUT THESE PROBLEMS BUT NOTHING WAS EVER FOUND. I WAS NOT EVEN TOLD ABOUT SOME OF THE THINGS I HAVE READ ABOUT ON YOUR WEBSITE WHICH SEEM TO INDICATE THAT FORD WAS AWARE OF THE PROBLEMS AND CAUSES. FINALLY, AT JUST UNDER 36,000 MILES, THE TRANSMISSION FAILED AND HAD TO BE REPLACED. NOW, 47,000 MILES LATER, THIS NEW TRANSMISSION IS LEAKING AND THEY HAVE TO TAKE IT OUT TO SEE WHERE IT'S LEAKING FROM. I READ HERE ABOUT THAT PROBLEM, TOO. TO ME, IT IS CLEAR THAT FORD IS USING MICKEY MOUSE TRANSMISSIONS WHICH, OF COURSE, POSE A SAFETY HAZARD DEPENDING ON WHEN, WHERE, AND HOW THE FAILURE MANIFESTS ITSELF, AND IS ALSO AN AFFRONT TO THE CONSUMER WHO IS BEING DEFRAUDED BY BEING SOLD A FAR MORE INFERIOR VEHICLE THAN THE ONE FOR WHICH THEY BARGAINED. SO, HOW'S YOUR INVESTIGATION GOING? *TR
Suspension, Apr 21, 2010
REAR DIFFERENTIAL FAILURE-I THINK THIS SHOULD BE LOOKED INTO AS I HAVE SEARCHED THE INTERNET AND THERE ARE TOO MANY COMPLAINTS ABOUT THIS. MAYBE IT WAS NOT THE TIRES CAUSING ALL THE CRASHES BUT THE BAD REAR ENDS THAT FORD IS AWARE OF. REAR WHINING NOISE AND GRINDING FROM ALL SUV MODELS. *TR
Structure, Apr 16, 2010
THE BACK PANEL UNDER THE BACK WIDOW CRACKED AND FORD WAS CONTACTED TO SEE IF ANY RECALLS WERE IN PLACE FOR THAT PART. WE WERE TOLD THERE WAS NOT A RECALL FOR THAT ISSUE. MY HUSBAND WAS SLOWING DOWN TO TURN INTO A PARKING LOT AND WENT OVER A BUMP. BECAUSE THE GLASS RUNS UNDER THE PANEL, IT GOT STRESSED AND BUSTED. WE HAVE REPLACED THE PART WITH ANOTHER FORD BACK HATCH. *TR
Latches/locks/linkages, Apr 15, 2010
REAR RH HINGE FAILED ON 2004 FORD EXPLORER, WHEN WIFE WAS CLOSING GLASS HATCH, SHE WAS VERY LUCKY SHE DID NOT GET HURT, BECAUSE IT PUT TO MUCH STRAIN ON LH HINGE, DAMAGING IT ALMOST TO POINT OF FAILURE ALSO. *TR
Structure, Apr 14, 2010
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE SITTING IDLE, THE CONTACT PRESSED THE PASSENGER REAR WINDOW RELEASE BUTTON AND THE HINGE FRACTURED FROM THE VEHICLE. THE MANUFACTURER WOULD NOT PROVIDE ANY ASSISTANCE. THE VEHICLE HAD NOT YET BEEN REPAIRED. THE CURRENT AND FAILURE MILEAGES WERE 74,800. UPDATED 06/03/10*BF UPDATED 06/07/10.*JB
Power train, Apr 12, 2010, crash
WHEN I SHIFT FROM DRIVE OR NEUTRAL INTO REVERSE, THERE IS A LONG HESITATION BEFORE THE CAR THEN LEAPS BACKWARD HARD. DELAY THEN HARD REVERSE. WHEN I AM PARALLEL PARKING, I HAVE SOMETIMES HIT THE CAR BEHIND ME HARD BECAUSE OF THIS. THIS PROBLEM HAS BEEN EXTENTED SINCE I PURCHASED THE CAR NEW IN 2004. I HAVE BROUGHT THE CAR INTO THE DEALER AT LEAST TEN TIMES WHEN IT WAS NEW. THEY MADE MANY CHANGES, INCLUDING AN ENTIRELY NEW "BOX" OF A SORT I DON'T RECALL, ALL TO NO AVAIL, FINALLY TELLING ME THE PROBLEM WAS CAUSED BY INSTALLING THE WRONG TRANS FLUID AT MANUFACTURING. RECALL NECESSARY. *TR