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.
Structure, Feb 14, 2010
WENT TO LOAD SOMETHING IN THE BACK OF MY EXPLORER AND NOTICED A BLACK LINE RUNNING DOWN BETWEEN THE WINDOW AND TAILGATE AND COULD NOT BELIEVE IT WAS CRACKED,,DID NOTHING TO CAUSE IT TO CRACK. I GOT ONLINE AND FOUND THAT MANY OTHER OWNERS HAVE HAD THE EXACT SAME THING TO HAPPEN. I SUPPOSE IT WILL BE TREATED LIKE THE TRANSMISSION ISSUES THAT I AND MANY MANY OTHER OWNERS HAVE HAD ALSO, JUST IGNORED BUT NEVER RECALLED ALTHOUGH CASE AFTER CASE AFTER CASE HAVE BEEN REPORTED. *TR
Power train, Feb 13, 2010
I BOUGHT MY 2004 FORD EXPLORER LIMITED FEB 2008. THE ONLY WORK DONE WAS OIL CHANGES, TIRE ROTATIONS ETC....AROUND 50,000 MILES SUDDENLY 1) THE CRUISE CONTROL STOPPED FUNCTIONING PROPERLY. WHEN USED IT CAUSES THE VEHICLE TO STALL..... 2) A CRACK APPEARED IN THE HATCH FOR NO APPARENT REASON. NO ACCIDENTS, NO WEATHER ISSUES.... 3) THE O/D LIGHT COMES ON AND THE TRANSMISSION SYMBOL LIGHTS UP. HESITATES WENT PUT IN REVERSE THEN JERKS INTO MOVEMENT. REPAIR SHOP SAYS THE TRANSMISSION NEEDS REPAIRS COSTING 2000+. *TR
Structure, Feb 11, 2010
2004 FORD EXPLORER RIGHT REAR LIFTGATE HINGE PIN HAS CORROSION CAUSING THE HINGE TO BREAK LOOSE FROM THE GLASS. WHEN OPENING THE WINDOW IT BROKE AND FELL ON MY HUSBAND WHILE LOADING CARGO. THE RIGHT SIDE SHOCK (STRUT) HAS SEEMED TO GET STUCK AT TIMES MAKING IT HARD TO CLOSE THE HATCH. *TR
Vehicle speed control, Feb 11, 2010
I HAVE A 2004 FORD EXPLORER (V8 EDDIE BAUER) I RECENTLY RAN INTO A STRANGE SITUATION. I SET THE CRUISE CONTROL AT 35 MPH AND AS I WAS GOING DOWN A SMALL HILL, THE CAR STALLED. I PUT IT INTO NEUTRAL AND IT STARTED WITH NO PROBLEM AT ALL. IT IS VERY DANGEROUS WHEN THE 2004 EXPLORER STALLS WHENEVER THE CRUISE CONTROL IS SET AND IT IS GOING AT A SLOW SPEED. *TR
Structure, Feb 8, 2010
CRACK IN REAR PANEL ON LIFT GATE BELOW WINDOW AT THE FORD EMBLEM. *CN
Other or unspecified, Feb 7, 2010
I WAS LEAVING MY FRIEND'S HOUSE TO DRIVE APPROXIMATELY 2 MILES AND WHEN I WENT TO PARK MY TRUCK WHICH IS A 2004 FORD EXPLORER SPORT TRAC XLT, THE GEAR SHIFTER WAS VERY LOOSE GOING INTO PARK, BUT DID NOT ENGAGE BECAUSE I WAS STILL ROLLING BACK, I THEN PROCEEDED TO PUT ON THE EMERGENCY BRAKE. I TURNED OFF MY TRUCK AND THEN STARTED IT AGAIN AND THIS TIME MY TRUCK WILL NOT TURN OVER AND THE SHIFTER IS STILL EXTREMELY LOOSE. I LOOKED ON SEVERAL FORUMS AND THEY ALL SAY THAT I MIGHT HAVE TO REPLACE MY STEERING COLUMN, AND AS FAR AS MY TRUCK NOT STARTING, I DON'T KNOW. *TW
Structure, Feb 6, 2010
ON DECEMBER 15, I WENT SHOPPING AND WHEN I WENT TO PLACE ITEMS IN THE BACK OF MY VEHICLE, I NOTICED A CRACK ALL THE WAY FROM THE BACK WINDOW TO THE BOTTOM OF THE PANEL. I TAKE VERY GOOD CARE OF MY VEHICLE. THERE WAS NO INDICATION THAT THE VEHICLE HAD BEEN HIT AS THERE WERE NO DAMAGES. *CN
Wheels, Feb 4, 2010
TL*THE DRIVER OWNS A 2004 FORD EXPLORER. THE DRIVER STATED THAT FOUR OF THE STUDS ON THE RIGHT REAR ROTOR BROKE OFF AND THAT THE WHEEL ALMOST FELL OFF. HE HEARD A LOUD NOISE WHILE DRIVING APPROXIMATELY 25 MPH. THE VEHICLE WAS TOWED TO A REPAIR SHOP. A LOCAL MECHANIC INFORMED HIM THAT THE STUDS BROKE AND REPLACED ALL FIVE STUDS. THE CONTACT NEITHER TOOK THE VEHICLE TO THE DEALERSHIP NOR SPOKE WITH THE MANUFACTURER TO-DATE. THE CURRENT MILEAGE WAS APPROXIMATELY 80,000. THE FAILURE MILEAGE WAS APPROXIMATELY 79,950.
Structure, Jan 30, 2010
PLASTIC UNDER BACK GLASS AROUND FORD LOGO CRACKED AFTER A COOL MORNING. (MAYBE 35 DEGREES) NOW THE CRACK STRETCHES OPEN AND CLOSED VARIOUS AMOUNTS EACH DAY. *TR
Structure, Jan 24, 2010
I OWN A 2004 FORD EXPLORER THAT HAS JUST EXPERIENCED A RANDOM CRACK IN THE BODY IN THE HATCHBACK. THE CRACK APPEARS IMMEDIATELY BELOW THE REAR WINDOW, ABOVE AND BELOW THE FORD EMBLEM. THERE WAS NO PRECIPITANT TO THE EVENT AND THERE IS NO OBVIOUS TRAUMA TO THE VEHICLE. I HAVE HAD NO REPAIRS OR PROBLEMS WITH THIS AREA PREVIOUSLY. THE FORD DEALERSHIP I DO BUSINESS WITH SAID THEY HAVE SEEN SEVERAL VEHICLES WITH THE SAME ISSUE AND COULD FIX IT FOR BETWEEN $600 & $700. I SPOKE TO FORD MOTOR CO. WHO SAID THIS IS NOT UNDER MY WARRANTY BECAUSE IT IS NOT A RECALL. I DO NOT UNDERSTAND HOW A STRUCTURAL DEFECT ON MY VEHICLE, NOT CAUSED BY MYSELF OR A 3RD PARTY, CAN NOT CONSTITUTE A RECALL. HOW CAN FORD SAY THIS ISN'T DANGEROUS? IF A PIECE OF THE BODY WERE TO FLY INTO ANOTHER VEHICLE WHILE I AM DRIVING OR THE GLASS CRACKS AND SHATTERS, THERE COULD BE SERIOUS DAMAGE TO SOMEONE ELSE. WHY WOULD A "RECALL" ONLY BE INSTATED IF SOMEONE WERE TO BE HURT? WHY WAIT? I THINK FORD SHOULD FIX THIS ISSUE AT NO CHARGE TO ME, THE OWNER. *TR
Structure, Jan 23, 2010
CRACKED TAILGATE FRAME UNDER THE WINDOW, FROM TOP TO BOTTOM. *TR
Engine and engine cooling, Jan 23, 2010
HARMONIC BALANCER WENT BAD MAY 2009, JUST UNDER 19,000 MILES ON MY 2004 ST! LEFT MY FAMILY AND I STRANDED ON I-95 IN PHILADELPHIA. FORD HAS SOLD A LOT OF REPLACEMENTS BUT WON'T ISSUE RECALL OR TSB. THE SERPENTINE JUMPED OFF THE BALANCER PULLEY AND LANDED ON THE RUBBER MOUNT OF THE BALANCER THEN ATE THROUGH THE SENSOR. JAN 21, 2010: STARTED UP THE ST, NO PROBLEM. DROVE ONE BLOCK, STOPPED AT STOP SIGN. MADE RIGHT TURN AND ACCELERATED, THEN THE ST DIED; 22,000 MILES. JUST BEFORE IT LOST ALL POWER IN THE ENGINE, I HEARD WHAT SOUNDED LIKE A TURBINE QUICKLY DECELERATING. NOW I TURN THE KEY, HEAR THE STARTER CLICKING, AND NOTHING HAPPENS WITH THE ENGINE. TOWED TO FORD DEALERSHIP. THERE WAS A RATTLE JUST BEFORE THIS HAPPENED. FORD SERVICE DEPT. REP CALLED ME LATE YESTERDAY AND SAID IT MAY BE ATTRIBUTED TO POOR INSTALLATION OF HARMONIC BALANCER, POSSIBLY NOT TORQUED CORRECTLY; SOUNDED LIKE PASSING THE BUCK. HE NEEDED PERMISSION TO PULL THE FRONT OF THE ENGINE APART TO LOOK INSIDE, I GAVE HIM A GREEN LIGHT TO DO SO. HE JUST CALLED TODAY AND SAID THE "KEY WAY AND SPROCKET" ARE BAD. HE SAID THEY COME IN A KIT WITH A NEW TIMING CHAIN; PARTS AND LABOR AFTER A FRIENDLY DISCOUNT: $925. THE TRUCK IS ALREADY THERE AND APART, SO I GAVE THEM THE GO AHEAD TO FIX IT. NORMAL PRICE WOULD HAVE BEEN ABOUT $1100. STRANGE, THEY HAVE A "REPAIR KIT" TO FIX THIS PARTICULAR ISSUE, BUT FORD SAYS THERE IS NO PROBLEM WITH THE ENGINE! HARMONIC BALANCER GOES BAD, FIX IT WITH NEW AND IMPROVED ONE. THEN THIS HAPPENS, FIX IT WITH NEW AND IMPROVED PARTS FROM A "REPAIR KIT"! FORD SAYS THERE ARE NO KNOWN PROBLEMS WITH THIS ENGINE! *TR
Power train, Jan 22, 2010
I LEFT MY VEHICLE RUNNING IN PARK TO DROP OFF A GIFT TO A FRIEND. I ENDED UP STAYING LONGER THAN INTENDED, AND WAS TAKEN OUTSIDE BY A LOUD NOISE. AFTER IDLING IN PARKED FOR 20-30 MINUTES, MY EXPLORER HAD SMASHED INTO MY FRIENDS GARAGE DOOR CAUSING NEARLY $500 IN DAMAGES TO THE DOOR AND SCRATCHES TO THE VEHICLE. NOTHING HAS BEEN DONE ABOUT THE PROBLEM, EXCEPT WE WILL NOT LET THE EXPLORER IDLE IN PARK. *TR
Structure, Jan 21, 2010
MY 2004 FORD EXPLORER BACK HATCH HAS A BIG CRACK ON THE LEFT SIDE OF THE FORD EMBLEM. THIS HAPPENED OVERNIGHT WITH THE WEATHER CHANGE. I HAVE RESEARCHED THE INTERNET TO SEE THOUSANDS OD SIMILAR STORIES WITH THE SAME ISSUE. *TR
Structure, Jan 21, 2010
I HAVE A 2004 FORD EXPLORER XLT AND I WAS CLOSING THE REAR HATCH WHEN THE HINGE PINS SNAPPED AND LUCKILY I WAS HOLDING IT WHEN IT BROKE. IF THERE WAS A PROBLEM WITH OTHER VEHICLES THEN I THINK THERE SHOULD BE A RECALL ON ALL 2004S. *TR
Structure, Jan 21, 2010
THE REAR PANEL UNDER THE BACK WINDOW OF MY 2004 FORD EXPLORER IS CRACK, THERE WERE NO EVENTS LEADING TO THIS FAILURE, LIKE SO MANY OTHERS IT JUST CRACKED. *TR
Wheels, Jan 19, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER WHICH WAS PURCHASED IN SEPTEMBER 2007. WHILE DRIVING 25 MPH AND MAKING A RIGHT TURN, THE REAR DRIVER'S SIDE WHEEL CAME OFF OF THE VEHICLE. THE VEHICLE HIT THE GROUND AND WOULD NOT MOVE ANY FURTHER. THE LUG NUTS AND BOLTS SHEARED OFF OF THE WHEEL ASSEMBLY. THE VEHICLE WAS TOWED TO A LOCAL SERVICE CENTER WHERE THEY REPLACED THE LUG NUTS AND BOLTS. ON A SEPARATE OCCASION, WHILE DRIVING AT SPEEDS OF LESS THAN 30 MPH GOING THROUGH AN INTERSECTION, SHE HEARD A LOUD NOISE. SHE THEN MANEUVERED THE VEHICLE TO THE SIDE OF THE ROAD WHERE SHE FOUND THE BOLTS HAD SHEARED OFF INTO THE WHEEL COVER AND CAUSED THE LUG NUTS TO COME OFF OF THE PASSENGER'S SIDE REAR TIRE. THERE WERE NO RECALLS FOR THE FAILURE. THE CONTACT WAS AWAITING REPAIRS A SECOND TIME. THE FAILURE MILEAGE WAS 39,000 AND THE CURRENT WAS 56,000. THE VIN WAS NOT AVAILABLE.
Power train, Jan 19, 2010
THE TRANSMISSION WAS SLIPPING AND FINALLY ONE DAY I PUT THE CAR IN REVERSE AND THE CAR DID NOT EVEN MOVE. I HAD TO GET MY TRANSMISSION REBUILT AT 60,000 MILES. I ALSO AM HAVING A BIG PROBLEM WITH THE PAINT PEELING OFF THE ROOF OF THE CAR NEAR WHICH WAS NOT COVERED UNDER ANY WARRANTY WHICH IS CRAZY ESPECIALLY WHEN THE SERVICE DEPT AT MY LOCAL FORD DEALERSHIP SAYS THAT MY YEAR AND MAKE HAS PAINT PROBLEMS AND THEY HAVE SEEN IT HAPPEN MANY TIMES BUT NO RECALL WAS EVER ISSUED. *TR
Structure, Jan 15, 2010
A CRACK ON MY 2004 EXPLORER UNDER THE BACK WINDOW. THERE ARE 1000'S OF OTHERS ON THE ROAD ALSO HAVE SEE ALL THE COMPLAINTS ON THE INTERNET. THIS HAS TO BE RECALLED BEFORE THE BACK WINDOW FALLS OUT. *TR
Structure, Jan 15, 2010
MY BACK GATE TO MY 2004 FORD EXPLORER HAS CRACKED AND I HAVE READ WHERE THIS IS A SEVERE PROBLEM AS MY WINDOW COULD FALL OUT. THIS IS A VERY SERIOUS PROBLEM AND BY READING ONLINE THERE ARE HUNDREDS OF THOUSANDS OF THESE THAT HAVE DONE THIS. WHICH MEANS THERE NEEDS TO BE A RECALL. *TR
Structure, Jan 13, 2010
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. SHE STATED THAT WHEN CLOSING THE LIFT GATE THE HITCH SNAPPED AND THE GLASS ALMOST FELL OUT AS A CONSEQUENCE. THE DEALER WAS CONTACTED AND THEY STATED THAT THERE WERE RECALLS FOR THE SAME PROBLEM FOR THE 2002 AND 2003 VEHICLES. NHTSA ACTION NUMBER, RQ08003, STRUCTURE BODY, HATCHBACK/LIFTGATE, SUPPORT DEVICE VISIBILITY GLASS, SIDE /REAR STRUCTURE BODY, HATCHBACK/LIFTGATE, HINGE AND ATTACHMENTS WERE RELATED TO THE FAILURE AND WAS CLOSED ON OCTOBER 24, 2008. THE CONTACT TEMPORARILY REPAIRED THE VEHICLE. THE CONTACT IS AFRAID TO DRIVE THE VEHICLE SINCE THE HINGE COULD SNAP AND POTENTIALLY CAUSE SERIOUS INJURIES AND/OR A CRASH. THE FAILURE AND CURRENT MILEAGES WERE 79000.
Structure, Jan 12, 2010
WENT TO OPEN REAR DOOR AND NOTICED A CRACK RUNNING DOWN THE BACK PANEL BELOW THE REAR WINDOW. MY FORD EXPLORER IS A 2004 WITH LESS THAN 60,000 MILES THIS SHOULD NOT OF HAPPENED THIS IS A DEFECT THAT FORD SHOULD TAKE CARE OF. INSTEAD I WAS TOLD TO CALL MY INSURANCE COMPANY ARE YOU KIDDING THIS IS FORDS PROBLEM NOT MINE. IT COULD FALL OFF WHILE I'M DRIVING AND HURT SOMEONE WHAT IS GOING ON IN AMERICA. *TR
Visibility, Jan 1, 2010
PLASTIC PIN SECURING BLEND DOOR ACTUATOR BREAKS, FREEZING BLEND DOOR IN POSITION.(COOL) UNABLE TO GET HEAT FROM VEHICLE HVAC SYSTEM. CAN NOT DEFROST/DEFOG WINDOWS IN COLD/WET WEATHER. VISIBILITY IS LIMITED DURING COLD/WET WEATHER. THE REDUCED VISIBILITY CAUSED ME TO VEER OFF OF PAVEMENT IN A RURAL AREA NEAR MY HOME BECAUSE I COULD NOT SEE THE LANE MARKERS. RESEARCH ON THE INTERNET SHOWS THIS IS A RECURRING, COMMON PROBLEM. FORD MOTOR CO. IS AWARE OF THE ISSUE BUT HAS NOT TAKEN STEPS TO RESOLVE THIS DANGEROUS SITUATION. *TR
Parking brake, Dec 29, 2009
PARKING LEVER DOES NOT PROPERLY LINE UP. HOPE THAT THIS DOES NOT LEAD TO THE "ROLL AWAY" ISSUES. *TR
Structure, Dec 29, 2009
NO ACCIDENT INVOLVED, WALKED OUT OF MY HOUSE INTO THE DRIVEWAY AND NOTICED "THE EXPLORER CRACK" ON THE LEFT SIDE OF THE FORD EMBLEM. TEMP WAS 26 DEGREES THAT NIGHT. *TR