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, Nov 10, 2009
1. THE EVENTS LEADING TO THE FAILURE WERE NORMAL USE OF THE VEHICLE. 2. REAR LIFT-GATE HINGES ON 2004 FORD EXPLORER XLT BEGAN FAILING WITH A LOUD BANG FROM THE REAR OF THE VEHICLE. THE REAR WINDOW BEGAN TO SAG AND OVER THE COURSE OF SEVERAL MONTHS CRACKS APPEARED IN THE HINGE STRUCTURE. I HAVE PURCHASED NEW HINGES, BUT AT THIS TIME I STILL NEED TO INSTALL THEM. *TR
Structure, Nov 5, 2009
CRACKED REAR PANEL BELOW WINDOW, THIS CRACK ONE DAY, NO APPARENT REASON. *TR
Suspension, Power train, Electrical system, Structure, Vehicle speed control, Nov 5, 2009
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. WHEN HE ACTIVATED THE CRUISE CONTROL WHILE DRIVING, IT DEACTIVATED ITSELF WITHOUT WARNING. HE HAD TO RESTART THE VEHICLE TO RE-SET THE ERROR CODE. THE FAILURE OCCURRED INTERMITTENTLY, AND MOSTLY ON THE INTERSTATE. ALSO WHEN HE WOULD TURN ON THE TURN SIGNALS, THE AUTOMATIC WARNING SYSTEM WOULD MAKE AN ALARM NOISE AND BLINK UNTIL THE TURN SIGNAL WOULD CUT OFF. THE AUTOMATIC TRANSMISSION APPEARED TO LOSE FLUID, WHEN HE SHIFTED INTO REVERSE. HE HEARD A ROARING NOISE NEAR THE TIRE AREA. HE WAS TOLD BY THE DEALER THAT THE HUBS NEEDED TO BE REPLACED. LASTLY, THE AESTHETIC PIECE ON THE LOWER HALF OF THE HATCH-BACK HAD CRACKED AND SEPARATED FROM THE VEHICLE. HE TOOK THE VEHICLE BACK TO THE DEALERSHIP AND WAS ADVISED THAT THERE WAS AN ELECTRICAL FAILURE. NO REPAIRS WERE MADE. THE MANUFACTURER REFERRED HIM TO NHTSA. THE CURRENT MILEAGE WAS APPROXIMATELY 68,000. THE FAILURE MILEAGE WAS APPROXIMATELY 52,000.
Vehicle speed control, Nov 3, 2009
TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. WHILE PARKED IN THE DRIVE-WAY, SHE TURNED ON THE IGNITION, AND THEN SHIFTED THE VEHICLE INTO DRIVE. THE VEHICLE ACCELERATED OUT OF THE DRIVE-WAY FOR 50 FEET, WITHOUT INTENTION. THE VEHICLE RAN OVER A LARGE ROADWAY CURB, AND CAME TO A COMPLETE STOP AT THE NEIGHBOR'S PROPERTY. A POLICE REPORT WAS FILED. THE DRIVER SUSTAINED NO PERSONAL INJURY. THE INSURANCE COMPANY WAS NOTIFIED OF THE MALFUNCTION. THE FAILURE AND CURRENT MILEAGES WERE 90,000.
Engine and engine cooling, Nov 2, 2009, fire
2004 FORD EXPLORER XLT FIRE. *TR
Visibility, Oct 23, 2009
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE GLASS FOR THE REAR LIFT GATE HAS DEVELOPED CRACKS IN IT. THE REAR DEFROSTER WAS ALSO INOPERATIVE. HE NOTIFIED THE DEALER, AND A TECHNICIAN STATED THAT IT WOULD COST $500.00 TO REPLACE THE COMPONENT. THE TECHNICIAN ALSO ADDED THAT THEY WERE AWARE OF THE FAILURE. NO REPAIRS WERE MADE. THE MANUFACTURER WAS NOTIFIED, BUT NO ASSISTANCE WAS PROVIDED. HE HAS PICTURES OF MULTIPLE VEHICLES WITH THE SAME MODEL TYPE, INCLUDING HIS VEHICLE, WITH IDENTICAL FAILURES. THE FAILURE MILEAGE WAS 55,000. THE CURRENT MILEAGE WAS 65,000.
Wheels, Oct 18, 2009
I HAVE A 2004 FORD EXPLORER. I HAVE HAD TO REPLACE BOTH FRONT BEARINGS AND NOW THE REAR BEARINGS ARE BAD AND I WAS TOLD THAT THEY NEED TO BE REPLACED. APPARENTLY IT IS A SAFETY ISSUE AND FORD IS DOING NOTHING ABOUT THIS. DO YOU HAVE ANY SUGGESTIONS AS TO WHAT CAN BE DONE BEFORE AN ACCIDENT OCCURS WITH MY VEHICLE. I CANNOT AFFORD THE REPAIR. WHAT STEPS CAN BE TAKEN TO HAVE FORD RECALL THE EXPLORERS WITH THIS PROBLEM. IT SEEMS THAT THERE ARE MANY OUT THERE WITH THE SAME ISSUE. *TR
Wheels, Oct 18, 2009
I TOOK MY CAR FOR A NEW SET OF TIRES AT AMERICA'S TIRE (DISCOUNT TIRE). AFTER CHANGING THE TIRE, ONE THE TECHNICAL NOTICED I HAVE A "LOOSE HUB ASSEMBLY" ON MY LEFT REAR WHEEL AND HE SUGGESTED THAT I SHOULD GET THAT FIXED IMMEDIATELY BECAUSE IT'S A SAFETY ISSUE. THERE IS A POSSIBILITY THE WHEEL MAY COME OFF AT FREEWAY SPEED. I TOOK MY CARS IN TO MY MECHANIC THE NEXT DAY, AND HE JACKED UP MY CAR. THE MECHANIC PUT ONE OF HIS HAND AT 12 AND THE OTHER AT 6 O'CLOCK ON THE TIRE, AND ROCKS IT. THE TIRE WAS WOBBLING BACK AND FORTH WHEN HE DID THAT, WHICH SUGGESTED A BAD WHEEL BEARING, OR POSSIBLE BAD HUB ASSEMBLY. AT THE END, IT WAS DETERMINED THAT I HAD A BAD WHEEL BEARING, WHICH WAS REPLACED FOR $400. USUALLY A HUB ASSEMBLY/WHEEL BEARING SHOULD STILL BE IN GOOD CONDITION AT 52,000 MILES. I GUESS BECAUSE IT'S A FORD. I HAVE MANY PROBLEM WITH THIS VEHICLE, THE REAR RIGHT WINDOW SOMETIMES DOESN'T WORK, THE FUEL TANK SYSTEM MALFUNCTION (CHANGED IT UNDER WARRANTY), THE "SERVICE ENGINE SOON" LIGHT COMES ON EVERY 5,000 MILES. I'M NOT BUYING ANOTHER FORD. I THOUGHT AMERICAN CARS' QUALITY IS NOW COMPARABLE TO THE JAPANESE, UNFORTUNATELY THEY'RE STILL LAGGING. *TR
Service brakes, Hydraulic, Oct 16, 2009
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE ABS WARNING LIGHT WAS ILLUMINATED ON THE INSTRUMENT CONTROL PANEL. THE REAR BRAKES ALSO FAILED DURING BRAKE APPLICATION ON GRAVEL ROADS. THE VEHICLE WAS TAKEN TO THE DEALER AT LEAST FIVE TIMES, AND WAS REPAIRED ACCORDING TO THE EXTENDED WARRANTY. THE FAILURE MILEAGE WAS 5,000. THE CURRENT MILEAGE WAS 62,000.
Power train, Oct 13, 2009
MY 2004 FORD EXPLORER AWD HAS A TRANSMISSION ISSUE. WHEN THE TRANSMISSION IS PLACED IN REVERSE OR INTO DRIVE, THE TRANSMISSION WILL OFTEN SHIFT INTO GEAR VERY HARD AND CAUSE THE CAR TO SUDDENLY MOVE BACKWARDS OR FORWARDS IN A VIOLENT MANNER. THE CAR WILL MOVE WHILE THE BRAKE IS APPLIED AND I FEAR THIS TRANSMISSION ISSUE WILL CAUSE SOME TYPE OF FAILURE IN THE FUTURE CAUSING THE CAR TO GO FORWARD OR BACKWARD WITH NO CONTROL. IT SHIFTS SO HARD FROM PARK INTO GEAR IT FEELS AS IF ANOTHER CAR HAS RAN INTO THE BACK OF MY CAR. I HAVE READ IDENTICAL REPORTS ONLINE FROM NUMEROUS OTHER PEOPLE INVOLVING FORD EXPLORERS AROUND THIS MODEL YEAR TIMEFRAME. *TR
Engine and engine cooling, Oct 13, 2009
DRIVING MY 2004 FORD EXPLORER WITH THE 4.6L ENGINE ON THE HIGHWAY AT 60 MPH THE VEHICLE BLOW IT REAR DRIVERS SIDE SPARK PLUG. THE ENGINE STARTED SHAKING VIOLENTLY AND THERE WAS A STRONG SMELL OF FUEL IN THE PASSENGER COMPARTMENT. THE ORIGINAL FACTORY INSTALLED PLUGS WERE STILL INSTALLED. THE THREADS IN THE CYLINDER HEADS WERE STRIPED. THE REPAIR WAS THE INSTALLATION OF A HELI-COIL IN TO THE CYLINDER HEAD AT A COST OF $600. *TR
Visibility, Oct 10, 2009
BLEND DOOR ACTUATOR PIN IS DEFECTIVE. I HAVE RESEARCHED THIS PROBLEM ONLINE AND IT IS A WIDESPREAD ISSUE. HEAT / DEFROST WILL NOT WORK. IN THE WINTERTIME THIS MAKES DRIVING EXTREMELY HAZARDOUS. *TR
Tires, Oct 10, 2009
TIRE SIDEWALL CRACKING ON ALL 4 TIRES OF THE SAME TYPE, MFG., AND LOCATIONS. TREADWEAR 520, TRACTION A, TEMP B. NEXEN ROADIAN HT P235/70R16 104S M+S DOT 8EWL 2007 TIRES SPLITTING ON ALL 4 TIRES ON OUTSIDE ONLY. VISUALS OF WHITE UNDERLYING WHERE POOR VULCANIZATION AND SPLITS ARE OCCURRING. *TR
Power train, Oct 8, 2009
ABOUT 75,000 MILES ON VEHICLE, PURCHASED NEW, REGULARLY SERVICED. ACCELERATING, THE O/D LIGHT CAME ON AND THE TRANSMISSION WENT "THUNK" AS IT TRIED TO SHIFT FROM 2ND TO 3RD. RESTARTING THE CAR THE O/D LIGHT WENT OFF AND THE CAR SHIFTED NORMALLY EXCEPT OCCASIONALLY THE CAR SHIFTS ROUGH. THE FORD DEALER WANTS $1800 TO $4200 TO REPAIR. *TR
Visibility, Structure, Oct 8, 2009
FORD DESIGNED A PLASTIC PIECE OF MOLDING THAT IS GLUED TO THE BACK GLASS OF EVERY EXPLORER. THIS HAS CRACKED ON EVERY EXPLORER I HAVE SEEN. IT HAS BEEN FIXED ONCE BY FORD, BUT IT HAS BROKE AGAIN. I ASSUME THAT IF IT HAS BROKE EVERY TWO YEARS SO FAR, IT WILL CONTINUE TO BREAK. FORD HAS REFUSED TO FIX THIS DEFECT. *TR
Visibility, Oct 4, 2009
WHEN OPENING THE REAR HATCH OF MY 2004 EXPLORER THE HINGES FAILED. THE GLASS DOOR FELL AWAY FROM THE HINGES AND WAS BEING HELD ONLY BY THE HYDRAULIC ARMS. WHEN I TRIED TO MOVE THE GLASS WHICH I WAS HOLDING IN MY HANDS IT SHATTERED. I WAS TOLD THERE WAS A RECALL ON THE 2002 AND 2003 MODELS BUT NOT ON THE 2004S. OBVIOUSLY THE PROBLEM HAS NOT BEEN CORRECTED. *TR
Structure, Oct 2, 2009
REAR PANEL OF THE 2004 FORD EXPLORER IS CRACKED, WE ARE AFRAID TO OPEN AND CLOSE WITH THE POSSIBILITY THAT THE WINDOW WILL FALL OUT AND POSSIBLE HURT SOME ONE. *TR
Power train, Oct 2, 2009
MY 2004 FORD EXPLORER HAS A BAD TRANSMISSION PROBLEM !!! JERKS VERY HARD IN REVERSE , SLIPS BETWEEN 2ND & 3RD GEARS, SOMETIMES SLIPS WHILE IN TRAFFIC !! I FEEL THIS IS VERY DANGEROUS !! *TR
Power train, Oct 2, 2009
2004 FORD EXPLORER (SOLENOID PACK) REPAIR 2ND TIME. *TR
Structure, Sep 28, 2009
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. HE STATED THAT HIS VEHICLE DEVELOPED A VERTICAL CRACK IN THE PLASTIC TAILGATE WHICH IS ATTACHED TO THE REAR GLASS. THE CRACK APPEARED TO THE LEFT OF THE FORD EMBLEM. THE VEHICLE WAS TAKEN TO THE DEALER AND THEY STATED THAT THEY WOULD REPAIR IT AT THE OWNERS EXPENSE WITH A DISCOUNT. THE DEALER ALSO STATED THAT THE WARRANTY DOES NOT APPLY. THE UPPER PART OF THE GLASS IS MADE OF FIBER GLASS AND THE BOTTOM IS MADE OF METAL. THE CONTACT STATED THE MATERIAL IS DEFECTIVE AND THAT HE WAS NOT AWARE THAT FIBER GLASS WAS INCLUDED. THE COLD WEATHER COULD CAUSE THE CRACK IN THE WINDOW TO EXPAND. THE FAILURE AND CURRENT MILEAGES WERE 76356. UPDATED 10/20/09 *CN THE CONSUMER STATED THE CRACK IS AT THE CENTER OF THE EMBLEM AS WELL AS IN THE FIBER GLASS PART, NOT THE GLASS. UPDATED 10/22/09.*JB
Power train, Sep 23, 2009
2004 FORD EXPLORER NBX. OWNER PUT CAR IN PARK AND GEAR SHIFT LEVER CAME OFF IN HAND. CAR TRANSMISSION STUCK BETWEEN PARK AND REVERSE. HAD TO GET CAR TOWED TO DEALERSHIP. DEALER STATES THEY HAVE FIXED NUMEROUS EXPLORERS WITH SAME ISSUE IN THE RECENT PAST. IN MY OPINION, THIS IS A DESIGN FLAW WITH THE MATERIAL USED (APPEARS TO BE ALUMINUM) FOR THE "DONUT" SHAPED RING THAT CONNECTS THE GEAR SHIFT TO THE STEERING COLUMN. CONTACTED FORD AND THEY WERE UNWILLING HELP WITH EXPENSE ($1,500) OF FIXING THIS MANUFACTURER DEFECT. *TR
Structure, Sep 23, 2009
WHILE OPERATING 2004 FORD EXPLORER, STOPPED AT STOP SIGN AND THE REAR HATCH GLASS LITERALLY EXPLODED. UPON LOOKING, IT WAS REALIZED THE HATCH ARMS/ SPRINGS LET GO, BENDING THE HATCH CAUSING THE GLASS TO COMPLETELY SHATTER. *TR
Structure, Sep 21, 2009
LIFTGATE GLASS APPLIQUE CRACKED. *TR
Structure, Sep 15, 2009
THE REAR LIFTGATE GLASS HATCH ON MY MODEL YEAR 2004 FORD EXPLORER BROKE OFF AND LEFT THE GLASS HATCH HANGING ON ONE HINGE ALMOST FALLING OFF, WHILE I WAS OPENING THE GLASS HATCH FROM THE REAR OF MY VEHICLE. I IMMEDIATELY CALLED THE DEALER TO REPORT THE PROBLEM. I BROUGHT THE CAR TO THE DEALER AND WAS CHARGED $415.01. NOT INCLUDING RENTAL CAR COST,TO REPAIR MY CAR. I LITERALLY OPEN THE HATCH DOOR AND IT FELL OFF. NO ONE SHOULD OPEN A CAR DOOR AND IT FALLS OFF. THIS COULD HAVE BEEN ONE OF MY CHILDREN OPENING THE DOOR AND THEY COULD HAVE BEEN INJURED BADLY BY THIS DEFECT IN THE CAR. *TR
Power train, Sep 14, 2009
2004 FORD EXPLORER WITH, LESS THAN 75,000 MILES. NEEDS TO HAVE THE TRANSMISSION REPAIRED OR REPLACED. MY WIFE AND TWO CHILDREN WERE OUT DRIVING IN TRAFFIC WHEN FAILURE BEGAN TO OCCUR. UNABLE TO ACCELERATE PAST 30-35MPH. THIS IS ALL AFTER THE DEALERSHIP REPEATEDLY TOLD US NO PROBLEMS, OVERFILLED TRANS FLUID, AND ADDED THE RECALL ADDITIVE FROM FORD. MY WIFE REPORTED. WE INFORMED FORD MULTIPLE TIMES ABOUT HARD SHIFTING OR SLIPPING FEELING WHEN ACCELERATING, AND VERY HARD AND LOUD ENGAGEMENTS INTO REVERSE. THERE IS AN OBVIOUS PROBLEM, I GUESS IT WILL JUST TAKE A TRAGIC EVENT TO ADMIT THE PROBLEM. *TR