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, Dec 27, 2009
MONTHS AFTER PURCHASING THIS CAR THE REAR LIFT GATE PANEL CRACKED DUE POOR DESIGN. *TR
Structure, Dec 24, 2009
2004 FORD EXPLORER XLT V6 REAR PANEL UNDER WINDOW ON TAILGATE CRACKING AND FALLING OFF ALSO TRANSMISSION FAILURE AT 60,000 MILES WAS OUTRAGED BY FORD WHEN THEY STATED THAT AFTER THE CAR LEAVES THE FACTORY ITS NOT THEIR PROBLEM. *TR
Power train, Structure, Dec 18, 2009
THE BACK HATCH HAS A CRACK UNDERNEATH THE WINDOW IN THE MIDDLE AROUND THE FORD EMBLEM. JUST APPEARED....AS I'VE NOTICED SEVERAL FORD 2004 EXPLORERS IN THIS AREA HAVE THE EXACT SAME DEFECT. RECALL IS VERY MUCH NECESSARY. AS WELL AS THE CAR JOLTING INTO DRIVE AND REVERSE....I STILL OWE SEVERAL THOUSAND DOLLARS ON THIS LOAN AND REFUSE TO PAY FOR ANY REPAIRS....FORD SHOULD DO A RECALL ON BOTH...THEY NEED TO HIRE SOME JAPANESE WORKERS SINCE THEIR CARS SEEM NOT TO HAVE THESE TYPES OF ISSUES.....I BOUGHT THIS CAR IN FEB OF 2008 AND HAD THE TRANSMISSION PROBLEMS RIGHT AFTER THAT.....CAR ONLY HAD 48K MILES ON IT. *TR
Visibility, Dec 16, 2009
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE REAR WINDOW PANEL HAD DEVELOPED CRACKS. THE VEHICLE HAS NOT BEEN DIAGNOSED BY THE DEALERSHIP . THE CURRENT AND FAILURE MILEAGES WERE 53000.
Power train, Dec 16, 2009
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE DRIVING THE TRANSMISSION WILL SLIP FROM SECOND TO THIRD GEAR. THE VEHICLE SHIFTS VERY ROUGHLY INTO THE REVERSE GEAR. ALSO THE GLASS FROM THE REAR WINDOW HAS LOOSENED FROM THE FRAME DUE TO THE CLIPS. THE MANUFACTURER WAS NOTIFIED, BUT NO ASSISTANCE WAS PROVIDED. THE FAILURE MILEAGE WAS 99,240.
Structure, Dec 15, 2009
A CRACK FORMED BELOW THE REAR GLASS PANEL ON OUR 2004 FORD EXPLORER. THE CRACK FORMED DUE TO A FLAW IN THE REAR DOOR PANEL. I HAVE NOTICED THE SAME CRACK ON THE SAME SPOT ON EITHER SIDE OF THE FORD EMBLEM ON NEARLY 80% OF THE FORD EXPLORER'S WE SEE ON THE HIGHWAY 'S IN THE ATLANTA AREA. *TR
Structure, Dec 15, 2009
2004 EXPLORER/EDDIE BAUER - THE PLASTIC TRIM BELOW THE REAR WIDOW CRACKED. AS STATED IN MANY OF THE OTHER COMPLAINTS, THE FORD DEALER SAYS THERE IS NOTHING THEY CAN DO, IT'S A FORD PROBLEM. CURRENT MILEAGE IS 76,000. *TR
Visibility, Structure, Dec 10, 2009
CRACKS APPEARED BELOW THE REAR WINDOW OF MY FORD EXPLORER. THERE WAS NO ACCIDENT. *TR
Suspension, Dec 10, 2009
VEHICLE HAS BOTH REAR COIL SPRINGS BROKE ON BOTH SIDES, EVIDENTLY IS SAME SPOT OF THE COIL. FORD REFUSES TO CONSIDER THIS PROBLEMATIC OR AN ISSUE TO THEIR CONCERN. UNFORTUNATELY, IT IS A SAFETY HAZARD. *TR
Wheels, Traction control system, Dec 8, 2009
FIRST THE ABS LIGHT CAME ON. THEN A LOUD NOISE CAME FROM THE FRONT. AFTER THE AUTO SHOP CALLED AND INFORMED ME THAT IT WAS ALL WHEEL BEARING AND BACKING PLATES WENT BAD AND$1500.00 DOLLARS LATER I LOOKED INTO PROBLEMS ON LINE WITH FORD EXPLORERS I SEEN OVER 42 COMPLAINTS WITH THE SAME THING. THAT IS A LOT OF MONEY SEEING AS HOW IM STILL PAYING OF THE LOAN! *TR
Structure, Dec 7, 2009
2005 FORD EXPLORER HAS A CRACK IN THE REAR HATCH. OUR FRIENDS HAD THE SAME ISSUE AND THE REAR WINDOW EVENTUALLY SHATTERED WHILE THEY WERE DRIVING. THIS SEEMS TO BE DANGEROUS BUT FORD HAS NOT ISSUED A RECALL. *TR
Suspension, Dec 4, 2009
MY 2004 FORD EXPLORER WAS MAKING A HORRIBLE RUBBING/GRINDING SOUND COMING FROM THE REAR OF THE VEHICLE. WHEN I TOOK MY FOOT OFF THE GAS PEDAL, THE NOISE WAS MORE PRONOUNCED. I TOOK THE VEHICLE TO MY MECHANIC THINKING IT WAS THE BRAKES AND HE INFORMED ME THAT THE ENTIRE REAR OF THE VEHICLE WAS "LOOSE" AND I SHOULD HAVE A DIAGNOSTIC TEST DONE BY A FORD DEALER. I TOOK IT TO MY LOCAL DEALER WHERE I PURCHASED THE VEHICLE. THE TECHNICIAN INFORMED ME THAT HE WOULD HAVE TO REMOVE THE ENTIRE REAR DIFFERENTIAL TO OPEN IT TO FIND THE PROBLEM. AFTER THAT BEING DONE, I WAS TOLD THAT HE FOUND "FAULTY" RING AND PINION AND CARRIER BEARINGS THAT NEEDED TO BE REPLACED SO AN ENTIRE NEW KIT HAD TO BE INSTALLED AND REFILLED WITH FLUIDS WHICH INTERN ENDED UP COSTING $1,400. I COULD NOT GET A SATISFACTORILY EXPLANATION AS TO WHY THIS WOULD HAVE HAPPENED TO MY VEHICLE WHICH ONLY HAS 46,000 MILES ON IT, NEVER BEEN IN AN ACCIDENT NOR HAS IT EVER TOWED ANYTHING. I TOLD MY MECHANIC THIS AND HE SAID THAT THIS SHOULD NOT HAVE HAPPENED WITH SUCH LOW MILEAGE. I AM VERY UPSET THAT THE CERTIFIED FORD DEALER ADMITS ON PAPER THAT MY VEHICLE HAD "FAULTY" PARTS YET I AM THE ONE WHO HAD TO PAY THE PRICE! *TR
Structure, Dec 2, 2009
CRACKED TAILGATE PANEL WHERE "FORD" EMBLEM IS. CRACKED WHILE VEHICLE WAS SITTING IN DRIVEWAY. HAVE NOTICED A LOT OF OTHER EXPLORERS WITH SAME CRACKS. I BELIEVE IT'S DEFECTIVE MATERIALS BEING USED AND FORD SHOULD TAKE CARE OF THE PROBLEM. *TR
Steering, Dec 1, 2009
IN THE DAYS PRIOR TO THE FAILURE, WHEN I TURNED THE WHEEL FAR RIGHT OR LEFT FOR EXTREME TURNS, THERE WOULD BE A SLIGHT THUMP TO THE EXTENT I THOUGHT SOMETHING LET LOOSE. I HAD THE CAR IN FOR A REGULAR OIL CHANGE ETC(SCHEDULED MAINT) AND TOLD THE SHOP ABOUT THIS EVENT BUT THEY SAID THEY CHECKED IT AND COULD FIND NOTHING WRONG. I WAS TURNING INTO A HEAD IN PARKING SPOT AND NOTICED WHEN I TURNED THE WHEEL TO THE LEFT, I FELT THAT I HAD LOST CONTROL OF THE STEERING. WHEN I PUT THE CAR IN PARK, THE GEAR SHIFT LEVER FELL APART IN MY HANDS. IT HAD DETACHED FROM THE STEERING COLUMN AND I COULD NOT REMOVE THE KEY. *TR
Structure, Nov 30, 2009
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE MANUALLY OPENING THE REAR LIFT-GATE, IT SPONTANEOUSLY CLOSED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR INSPECTION, AND THE LIFT-GATE HINGE KIT WAS ORDERED FOR THE REPAIR, BECAUSE THE LIFT-GATE HINGE HAD FRACTURED. THE FAILURE MILEAGE WAS 69,400. THE CURRENT MILEAGE WAS 69,450.
Structure, Nov 30, 2009
PAINT ON THE ROOF OF MY VEHICLE HAS PEELED OFF ONLY TO REVEAL RUST. OF COURSE, THE WARRANTY STATES THAT IF THERE IS NO PERFORATION THEN NOT THEIR FAULT IF MORE THAN 60 MONTHS HAVE PASSED. *TR
Power train, Nov 29, 2009
WHEN SHIFTING INTO REVERSE, THE CAR JERKS (SHIFTS HARD) BACKWARDS EVERY TIME. EVENTUALLY, TRANSMISSION HAD TO BE REBUILT. THE PROBLEM NO LONGER EXISTS. *TR
Steering, Power train, Nov 27, 2009
WHEN SHIFTING INTO REVERSE THERE IS A HARD SHIFT ALSO HARD SHIFTS UP AND DOWN WHILE GOING FORWARD. *TR
Steering, Nov 24, 2009
I OWN A 2004 FORD EXPLORER 4WD, XLT 6 CY ENGINE. I WAS DRIVING IT LAST WEEK AND THE FRONT END FELT LOOSE. I PULLED INTO A PARKING SPOT AND WHEN I TRIED TO PUT IT IN PARK THE SHIFT LEVER FELL APART IN MY HAND AND THE STEERING COLUMN FELL APART. I WAS ONLY GOING 5 MPH AT THE TIME BUT I WONDER WHAT WOULD HAPPEN IF I WAS GOING 40 OR SO., I HAD LOST CONTROL AS I PARKED!! THE FORD MECHANIC SAID HE HAD NEVER SEEN THIS BEFORE. *TR
Vehicle speed control, Nov 19, 2009
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT SINCE THE VEHICLE WAS PURCHASED IT HESITATES DURING ACCELERATION. THE DEALER CONFIRMED THAT THE VEHICLE WAS OPERATING NORMALLY AND MAY APPEAR ABNORMAL SINCE IT HAS A V8 ENGINE. THE CONTACT STATED THAT THE VEHICLE CURRENTLY IS NOT ACCELERATING AT ALL. A LOCAL MECHANIC STATED THE VEHICLE IS A SAFETY HAZARD DUE TO THE LACK OF ACCELERATION. THE CONTACT IS CONCERNED OF THE POSSIBILITY OF A CRASH OCCURRING. THE CURRENT MILEAGE WAS 100,000 AND THE FAILURE MILEAGE WAS 25,000.
Structure, Nov 18, 2009
MY 2004 FORD EXPLORER XLT HAS A CRACK IN THE TAILGATE/BACK HATCH. IT STARTS UNDER THE WINDOW SEAL AND CONTINUES DOWN TO THE HATCH LEVER. I'M AFRAID THE GLASS WILL BECOME COMPROMISED DUE TO THE DEFECT IN CRAFTMANSHIP. I WAS ON ANOTHER FORUM WHERE 387 COMPLAINTS FOR THE SAME ISSUE. HTTP://WWW.CARCOMPLAINTS.COM/FORD/EXPLORER/2002/BODY_PAINT/CRACKED_PANEL_BELOW_THE_REAR_WINDOW.SHTML I DON'T HAVE THE MONEY TO PAY FOR POOR CRAFTMANSHIP ISSUES. I FEEL AS IF FORD SHOULD RECTIFY THE SITUATION IMMEDIATELY AT NO COST TO IT'S CUSTOMERS. *TR
Power train, Nov 17, 2009
EXPLORER JERKING AND BUCKING WHEN PUT INTO REVERSE. PROBLEM EVENTUALLY WORSENED WITH BUCKING ONCE PUT INTO DRIVE. BOUGHT USED AT 31,000 MILES. SYMPTOM EVIDENCED AT JUST OVER 33,000 MILES. TRANSMISSION REPLACED AT COST OF NEARLY $4,000. ADDRESSED THIS ISSUE WITH FORD . RESPONSE- SYMPATHETIC BUT NOTHING THEY CAN DO? OR IS THERE? DESIGN OR MANUFACTURER ERROR. EITHER WAY ACCOUNTABILITY SHOULD NOT BE AN ISSUE. LAST FORD I WILL OWN. *TR
Power train, Nov 13, 2009
2004 FORD EXPLORER-SERIOUS TRANSMISSION ISSUES WITH GEARS SLIPPING/FAILING. HUGE DELAY IN REVERSE THEN A LARGE JOLT BACK IS VERY DANGEROUS. *TR
Power train, Nov 11, 2009, crash
HAVE A 2004 FORD EXPLORER WITH BAD TRANSMISSION. DELAY IN SHIFTING IN REVERSE AND A JOLT INTO GEAR CAUSED BE TO SLAM INTO ITEMS IN MY GARAGE. ALTHOUGH NO ONE WAS HURT, IT CAN HAPPEN. FORD HAS KNOW OF THIS ISSUE AS WELL AS 2-3 GEARS SLIPPING WHICH CAN CAUSE A SLOWING OF THE VEHICLE IN TRAFFIC. *TR
Power train, Nov 11, 2009, fire
2004/FORD EXPLORER FIRE WHILE PARKED IN PARKING DECK,THERE WAS NO PREVIOUS WARNINGS ,OF ANY KIND. TRUCK WAS RUNNING WELL ,NO SERVICE LIGHTS EVER CAME ON. TRUCK ONLY HAS 40,000 MILES ON IT. NEVER HAD ANY SINGS OR SYMPTOMS,THAT ANYTHING WAS GOING TO HAPPEN. I HAVE A POLICE REPORT. FIRE DEPT. REPORT. ALSO VALET PARKING MANAGERS REPORT FROM 11/6/09.NOW TRUCK IS AT TOMS FORD ,HAZLET NJ. WE NEED TO KNOW WHAT WENT WRONG , THERE WAS NO PRIOR WARNING TO THIS EVENT. THANK GOD I WASN'T ON THE HWY WHEN THIS OCCURRED WITH MY GRANDDAUGHTER 27 MTHS . PLEASE HELP! *TR