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, Dec 15, 2008
I PURCHASED A 2004 EXPLORER LIMITED WITH 18,000 MILES. AT 28,000 MILES THE DEALERSHIP REPLACED A SOLENOID IN THE TRANSMISSION PER FORD TO ELIMINATE A LARGE "THUD" WHEN THE VEHICLE WAS SHIFTED INTO REVERSE. THE PROBLEM WENT AWAY FOR AWHILE BUT RETURNED. TODAY AT 78,000 THE VEHICLES TRANSMISSION HAS FAILED AND THE DEALERSHIP STATES IT NEEDS REPLACEMENT. EXTENDED WARRANTY PROVIDER REFUSES TO COVER THE WORK. I HAVE READ THAT FORD INSTALLED THE WRONG TRANSMISSION FLUID AT THE FACTORY AS WELL. BOTTOM LINE IS THE FORD TRANSMISSION IS DEFECTIVE AND EVERYONE KNOWS IT. HOW ABOUT A LITTLE JUSTICE HERE FOR THE CONSUMER? *TR
Structure, Dec 15, 2008
PLASTIC BODY PART JUST UNDER REAR LIFT GATE HAS CRACKED IN THE MIDDLE. LOCAL FORD DEALER SAID THEY WERE AWARE OF A PROBLEM, BUT FORD HAS DECLINED ACTION. THIS VEHICLE HAD APPROX. 30,000 MILES WHEN NOTICED. FORD SHOULD HAVE TO FIX IT. *TR
Structure, Dec 12, 2008
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE CLEANING THE REAR WINDOW OF THE VEHICLE, THE CONTACT NOTICED A CRACK BETWEEN THE WINDOW AND THE HANDLE. THE VEHICLE WAS DRIVEN TO THE DEALER AND THEY REFERRED HIM TO A LOCAL BODY SHOP. AFTER ARRIVING AT THE BODY SHOP, THE MECHANIC STATED THAT THERE WERE SEVERAL FORD EXPLORERS WITH THIS DEFECT. THE MANUFACTURER STATED THAT THEY WERE NOT LIABLE FOR THE REPAIRS. THE CURRENT MILEAGE WAS 14,136 AND FAILURE MILEAGE WAS 13,636.
Structure, Dec 12, 2008
1. WASHED MY 2004 FORD EXPLORER AND THE PAINT BEGAN PEELING OFF THE FRONT OF THE ROOF. 2. THE PROBLEM JUST STARTED AND NOW THERE IS A 1.5 FOOT CIRCLE ON THE FRONT ROOF WHERE THE PAINT HAS PEELED. 3. THE ROOF IS GOING TO BE REPAINTED. *TR
Structure, Dec 9, 2008
HAVE 2004 EDDIE BAUER EXPLORER WITH CRACK IN THE REAR GATE. NEEDS TO BE RECALLED. I WAS ONLINE AND FOUDN AT LEAST 200 PEOPLE WITH THE SAME CRACK. FORD WILL NOT REPLACE. *TR
Structure, Dec 9, 2008
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE GLASS ON THE HINGE OF THE REAR WINDSHIELD WOULD GLIDE UP AND DOWN, AS IF IT WERE NOT SECURED OR MOLDED PROPERLY. THE MANUFACTURER STATED THAT THE ENTIRE HATCH NEEDED TO BE REPLACED IN ORDER TO CORRECT THE FAILURE AT AN ESTIMATED COST OF $1,200. THE FAILURE AND CURRENT MILEAGES WERE LESS THAN 40,000. UPDATED 12/30/08 *CN UPDATED 12/30/08. *JB
Structure, Dec 9, 2008
THE PLASTIC BELOW THE GLASS ON MY REAR HATCH- 04 FORD EXPLORER. I HAVE GONE THROUGH TWO DEALERS AND FORD.COM. I HAVE SPOKEN WITH OVER 10 PEOPLE AND THIS INCLUDES SERVICE MANAGERS. I HAVE ONLY 49,000 MILES ON MY VEHICLE AND EVERY DAY I DRIVE AROUND AND I SEE THIS PROBLEM. THEY SAY IT IS NOT A SAFETY DEFECT, BUT WHAT HAPPENS WHEN A 2" BY 3' PIECE FLIES OFF AND A OLD LADY SWERVES INTO A SEMI. NOW LOOK WHAT IT WILL COST . IF THIS WAS AN ISOLATED CASE I WOULD HAVE NO PROBLEM. IF NOTHING IS DONE IN THE NEXT WEEK, I AM CURRENTLY IN THE PROCESS OF PHOTOGRAPHING EVERYONE THAT I SEE. THEN I AM GOING TO TROUBLE SHOOTER TV. AND I WANT PEOPLE TO SEE WHY YOU SHOULD NEVER BUY A FORD. THERE IS NO WONDER THEY NEED A BAIL OUT. IF I CHOOSE TO RUN MY BUSINESS TO THE GROUND, I DON'T GET GOVERNMENT ASSISTANCE. FORD MOTOR COMPANY WHAT A JOKE. PLEASE NEVER BUY ONE. WHEN A COMPANY MAKES A MISTAKE ADMIT IT AND PEOPLE WILL RESPECT YOU. LOOK AT WHAT A $200 PIECE OF PLASTIC CAN COST YOU. JUST GOOGLE THE PROBLEM AND YOU CAN SEE IT IS NOT ISOLATED. *TR
Visibility, Dec 7, 2008
THE BLEND DOOR BEHIND THE GLOVE COMPARTMENT WON'T CLOSE. THIS PREVENTS PROPER DEFROSTING, HEATING AND COOLING REGARDLESS OF THE WEATHER. IN THE WINTER FREEZING AIR BLOWS THROUGH, CHILLING ALL PASSENGERS. IN THE SUMMER, ALL THE HEAT FROM THE ROADS COMES THROUGH. OUR FORD DEALER SAYS THEY CAN FIX IT FOR OVER $1000!! THERE ARE TOO MANY OF THESE DEFECTS ON THE ROAD AND FORD KNEW OF THE DEFECT AT LEAST 2 YEARS BEFORE MY SUV WAS EVEN MADE. *TR
Vehicle speed control, Dec 4, 2008
DETAILS: ON GOING PROBLEM WITH THROTTLE CONTROL, WHEN YOU ARE STOPPED OR JUST STARTING OUT AND GIVE GAS IT DOSE NOT START TO GO SO YOU GIVE IT A LITTLE BIT MORE GAS AND THEN IT WILL JUMP FORWARD OR BACKWARD( IF YOU ARE BACKING UP) TO APPOINT THAT IT WILL SOME TIMES SQUEAL THE TIRES. THE TRANSMISSION ALSO WOULD SHIFT SO HARD IT FEELS LIKE YOU ARE HIT FROM BEHIND. IN FOR REPAIR AT SELLERS SEXTON FORD, ST ROBERT MO. *TR
Latches/locks/linkages, Dec 3, 2008
HINGE OH REAR LIFT-GATE FRACTURED CAUSING LIFT GATE TO SAG DOWN AND BREAK HYDRAULIC LIFT ON THAT SIDE. *TR
Structure, Dec 1, 2008
TL*THE CONTACT OWNS A 2004 FORD EXPLORER SPORT. SHE STATED THAT THE TAILGATE ABOVE THE GLASS CRACKED. THE MANUFACTURER CONFIRMED THAT THERE WAS NO RECALL FOR HER VIN. THE VEHICLE WILL NOT BE REPAIRED SINCE THE CONTACT DOESN'T HAVE A WARRANTY. THE FAILURE AND CURRENT MILEAGE WAS 35,133.
Visibility, Structure, Dec 1, 2008
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT NOTICED THAT THE FRAME SUPPORTING THE SIDE/REAR GLASS WAS FRACTURED. THE DEALER STATED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER 07E104000 (VISIBILITY:GLASS, SIDE/REAR); THEREFORE, THE CONTACT WOULD BE RESPONSIBLE FOR THE REPAIR COSTS. THE VEHICLE HAS NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 66,783.
Structure, Nov 28, 2008
LONG CRACK UNDER REAR WINDOW OF TAILGATE,BESIDE FORD EMBLEM, APPEARED OVERNIGHT,NO ACCIDENTS, 39,00 MILES, OTHERWISE EXCELLENT CONDITION. *TR
Structure, Nov 26, 2008
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE ATTEMPTING TO SHUT THE REAR GLASS ON THE LIFTGATE, THE HINGES FAILED AND PREVENTED THE GLASS FROM CLOSING. THE HINGES WERE BENT BACK INTO PLACE IN ORDER FOR THE LIFTGATE GLASS TO CLOSE, BUT CURRENTLY IT CANNOT BE USED AT ALL. THE VEHICLE HAS NOT BEEN TAKEN TO THE DEALER FOR REPAIR. THE CONTACT IS IN THE PROCESS OF NOTIFYING THE MANUFACTURER. THE FAILURE MILEAGE WAS 90,000 AND CURRENT MILEAGE WAS 91,000.
Structure, Nov 25, 2008
PLASTIC APPLIQUE ON LIFTGATE CRACKED WHILE VEHICLE WAS PARKED AND LIFTGATE WAS NOT BEING USED. THIS IS THE SECOND TIME THIS HAS HAPPENED SINCE WE PURCHASED THE VEHICLE FIVE YEARS AGO. THE CRACK CONTINUED TO SPREAD UNTIL NOW THE PIECE IS IN TWO SEPARATE PIECES. THE PIECES ARE LOOSE AND COULD POSSIBLY COME OFF WHILE DRIVING WHICH COULD BE A DANGEROUS SITUATION. FORD REFUSES TO FIX THIS EVEN THOUGH IT IS CLEARLY A DESIGN FLAW IN ALL 2002-2005 EXPLORERS. WE HAVE SEEN MANY EXPLORERS ON THE ROAD AND ON USED CAR LOTS WITH THIS SAME DEFECT. *TR
Power train, Nov 7, 2008
A COUPLE OF MONTHS AGO I NOTICES THAT MY EXPLORER MADE A WEIRD HUMMING SOUND WHEN I REMOVE MY FOOT OFF THE GAS GOING DOWNHILL AT HIGHWAY SPEEDS. I ALSO GET THE HARD/CLUNK SHIFT SOUND WHEN GOING FROM PARK TO REVERSE WITH A COUPLE SECOND DELAY. IT TAKES LONGER THEN NORMAL FOR VEHICLE TO ACCELERATE AS IF THE TRUCK IS HAVING DIFFICULTY SHIFTING ITSELF. WHALING CITY FORD IN NEW LONDON CT SAID PROBLEM WAS THAT WE HAVE TWO TIRES THAT ARE A BIT SMALLER THEN THE REST AND PROCEEDED TO TRY TO SELL US FOUR NEW TIRES. I TOOK IT FOR A SECOND OPINION AND THE AUTO SHOP ACTUALLY SPENT TIME ON MY VEHICLE AND SAID THAT OUR TIRES ARE FINE, IT IS THE TRANNY. HOW CAN FORD GET AWAY WITH THIS AND WHAT IS MY RECOURSE SINCE SO MANY OTHERS ARE HAVING THIS ISSUE? *TR
Engine and engine cooling, Electrical system, Nov 6, 2008
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. IN 2007, THE CONTACT STATED THAT THE INSTRUMENTAL PANEL LIGHTS CONSTANTLY FLASHED AND LOST POWER. THE DEALER REPLACED A HOSE, WHICH CORRECTED THE FAILURE FOR APPROXIMATELY TEN MONTHS. ON NOVEMBER 2, 2008, THE VEHICLE LOST POWER AND SHUT OFF. THE CONTACT HAD TO WAIT SEVERAL MINUTES TO RESTART THE VEHICLE. THE DEALER WAS UNABLE TO DIAGNOSE THE FAILURE. THE VEHICLE HAS NOT BEEN REPAIRED. THE FAILURE MILEAGE WAS 45,000 AND CURRENT MILEAGE WAS 55,000.
Electrical system, Nov 5, 2008
APPROXIMATELY IN SEPTEMBER 2007, MY LIGHTER WENT OUT AND I TOOK IT TO THE DEALER, CARL GREGORY ON BOX ROAD IN COLUMBUS, GA. THEY CHARGED ME $35.00 FOR A FUSE AND NOW IT WON'T WORK AGAIN THIS YEAR. THE FUSES ARE FINE BUT THE LIGHTER JUST ISN'T WORKING. I NEED THE LIGHTER TO CHARGE MY PHONE. IS THIS STILL COVERED UNDER WARRANTY. MY VEHICLE IS A 2004 FORD EXPLORER WITH ONLY 73600 MILES. *TR
Wheels, Nov 3, 2008
I WAS DRIVING TO WORK WHEN MY 2004 FORD EXPLORER LOST THE REAR PASSENGER RIM AND TIRE. THE CAR RATTLED AND THEN THERE WAS A LOUD THUD AND SPARKS COMING FROM THAT AREA. THIS HAS ONLY OCCURRED ONCE BUT IT STRIPPED AND BROKE SOME OF THE STUDS WERE THE WHEEL ATTACHES. I HAD THE CAR TOWED WHERE I HAD THE TIRES REPLACED, BRAKES CHECKED AND FIXED, ALIGNMENT, AND BROKEN STUDS FIXED AND REPLACED. *TR
Power train, Oct 27, 2008
BLINKING O/D LIGHT, SERVICE ENGINE LIGHT, PARK TO REVERSE GEAR SLIPPAGE, FIRST TO SECOND GEAR SLIPPAGE. *TR
Power train, Structure, Oct 21, 2008
I BOUGHT IT BRAND NEW IN 2004 AND HAVE TAKEN VERY GOOD CARE OF THIS VEHICLE, BUT IT HASN'T RETURNED THE FAVOR. I HAVE HAD MULTIPLE TRANSMISSION PROBLEMS THAT FORD SAYS THAT THEY ALL DO IT AND WON'T FIX IT. MY TAILGATE CRACKED NEXT TO THE FORD SYMBOL, ONCE AGAIN WON'T FIX IT. MY PAINT ON MY HOOD IS PEELING OFF. I ONLY HAVE 50,000 EASY MILES ON IT BUT LOOKING AT IT AND DRIVING IT YOU WOULD THINK THAT IT HAD 150,000 ON IT. I WILL NEVER BUY FORD AGAIN! *TR
Suspension, Oct 20, 2008
TWO OUT OF FOUR WHEEL BEARINGS ARE HOWLING ON THIS VEHICLE. *TR
Structure, Latches/locks/linkages, Oct 20, 2008
2004 FORD EXPLORER RIGHT REAR LIFTGATE GLASS HATCH HINGE HAS FAILED. GLASS HATCH DID NOT FALL BUT IS HANGING BY REMAINING HINGE AND IS UNSTABLE OR UNSAFE. ISSUE SAME AS NHTSA ACTION NUMBER: RQ08003. *TR
Engine and engine cooling, Oct 16, 2008
ON MY WAY TO THE AIRPORT FOR A BUSINESS TRIP, I WAS DRIVING THE VEHICLE ON THE INTERSTATE WHEN ALL OF A SUDDEN AND WITHOUT ANY WARNING, THE ENGINE STOPPED. I HAD TO MANEUVER ONTO TRAFFIC AND STOP TO TRY TO START THE ENGINE WITHOUT SUCCESS. I CALLED AAA AND THEY HAD THE VEHICLE TOWED TO MY HOME. WHEN I CAME BACK I SENT IT TO THE SHOP AND THE MECHANIC ADVISED ME THAT THE TIMING CHAIN SPROCKET RETAINER PIN BROKE, AND BECAUSE OF THAT ALL VALVES BENT, SO I HAVE TO REPLACE THE ENGINE. FOR 72900 MILES AND KEEPING ALL MAINTENANCE IN ORDER I CONSIDER THIS A SAFETY ISSUE AND UNACCEPTABLE IN TERMS OF QUALITY. I HAVE SPOKEN TO THE MANUFACTURER AND THEY REFUSE TO TAKE ACTION BECAUSE THE VEHICLE IS OUT OF WARRANTY. *TR
Vehicle speed control, Service brakes, Electric, Oct 16, 2008
I HAVE A 2004 EXPLORER LIMITED AND JUST TURNED 14,000 MILES AND MY ABS LIGHT COMES ON EVERY TIME I START THE CAR AND ACCELERATE. ALSO THE CRUISE STOPPED WORKING. FROM WHAT I HAVE READ IT SOUNDS LIKE THE ABS MODULE WHICH FORD HAS APPARENTLY BEEN AWARE OFF. NOT HAPPY!! I WOULD NOT EXPECT THIS SORT OF PROBLEM WITH ONLY 14,000 MILES. *TR