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 16, 2008
MY WIFE AND I NOTICED A CRACK UNDER THE REAR WINDOW, (1/8 BY 6") TO THE LEFT OF THE FORD EMBLEM IN THE CENTER OF THE REAR HATCH.. THERE WAS NO IMPACT INVOLVED, IT JUST APPEARED OVERNIGHT. LATER THE REAR WINDOW WAS RAISED AND THE HINGE ON THE LEFT SIDE IS LOOSE, AND CANNOT BE TIGHTENED. NOW WE CAN'T CLOSE THE THE REAR WINDOW ALL THE WAY. WHEN IS SOMETHING GOING TO BE DONE ABOUT THIS ONGOING PROBLEM WITH THE 2004 EXPLORERS? FORD IS VERY AWARE OF THIS PROBLEM AND AND THEY COULD CARE LESS. I COULD HAVE TAKEN OUR EXPLORER TO A KIA DEALER INSTEAD OF A FORD DEALER AND RECEIVED THE SAME TYPE OF SERVICE..NO HELP AT ALL. IT SEEMS THAT FORD DOESN'T CARE ABOUT QUALITY ANYMORE AND ONLY ABOUT THE MIGHTY DOLLAR, NO MATTER HOW THEY GET IT! *TR
Structure, Feb 13, 2008
THE PAINT ON MY HOOD IS PEELING AWAY. I DID NOT NOTICE SOME PAINT "BUBBLING" ON THE HOOD OF MY 2004 FORD EXPLORER WHEN I BOUGHT IT BRAND NEW. AFTER WASHING IT I SAW THE PAINT WAS CLEARLY DEFECTED. IT DID NOT BOTHER ME AT FIRST, BUT NOW AFTER 3 YEARS AND 52,000 MILES THE PAINT IS CHIPPING AWAY WHERE IT WAS "BUBBLED". THE AREA IN QUESTION IS THE FRONT LEFT CORNER OF THE HOOD, IN TWO SMALL PLACES. WHEN I NOTICED IT WAS CHIPPING AWAY THERE WAS ALREADY 4" SQUARE INCHES OF SHEET METAL SHOWING. I TOOK IT TO THE DEALER WHERE I BOUGHT IT AND THEY SAID IT WAS A KNOWN ISSUE (FORD TSB 04-25-1) BUT THEY COULD NOT DO ANYTHING ABOUT IT SINCE MY TRUCK IS OUT OF THE WARRANTY PERIOD. THEY EXPLAINED THE ALUMINUM HOOD IS THE PROBLEM AND AN ENTIRE NEW HOOD WOULD COST $1300. THEY EXPLAINED THAT FORD KNOWS ABOUT THE PROBLEM BUT HAS DECIDED NOT TO ISSUE A RECALL. *TR
Service brakes, Hydraulic, Structure, Latches/locks/linkages, Equipment, Feb 13, 2008
WHILE GOING TO OPEN THE REAR HATCH OF MY 2004 FORD EXPLORER, I NOTICED A CRACK IN THE HATCH DOOR FROM JUST BELOW THE WINDOW DOWN TO THE NEXT PANEL. WHEN I OPENED THE WINDOW ON THE HATCH DOOR, I NOTICED THAT THE LEFT HINGE THAT HOLDS THE GLASS IS COMING LOOSE. I AM UNABLE TO UTILIZE THE REAR CARGO AREA OF MY VEHICLE NOW FOR FEAR THAT THE LEFT HINGE WILL BREAK OFF RESULTING IN THE ENTIRE DOOR COMING OFF THE VEHICLE AND FALLING OR DROPPING ONTO ME OR ONE OF MY CHILDREN, CAUSING SEVERE PERSONAL INJURIES. THE MILEAGE ON MY VEHICLE IS APPROXIMATELY 70,000 MILES. NOTHING HAS BEEN DONE YET TO CORRECT THIS FAILURE BECAUSE AFTER READING OTHER PEOPLE'S EXPERIENCE WITH HAVING FORD REFUSE TO ACKNOWLEDGE THE PROBLEM AND THE GOVERNMENT THUS FAR REFUSING TO ISSUE A RECALL, MY HANDS ARE TIED. I DO NOT WANT TO PAY FOR THE REPAIR MYSELF BECAUSE I HAVE ALREADY BEEN BURNED BY FORD ON OTHER ISSUES RELATING TO THIS VEHICLE, I.E., THE ABS MODULE AND THE AIR CONDITIONING SYSTEM. *TR
Latches/locks/linkages, Feb 12, 2008
REAR HATCHBACK WINDOW PANEL CRACKED DOWN THE CENTER. THE WINDOW SEEMED HARD TO CLOSE, DID NOT SEEM TO ALIGN WITH THE LATCH. *TR
Power train, Equipment, Feb 3, 2008
2004 FORD EXPLORER TRANSMISSION FAILURE, SHIFT SLIPPAGE, DELAYED ACCELERATION. *TR
Power train, Jan 29, 2008
I OWN A 2004 FORD EXPLORER AND IN 2006 I HAD TO HAVE THE SOLENOID SHIFTERS REPLACED IN MY VEHICLE. AFTER RESEARCHING THIS PROBLEM ON THE INTERNET I HAVE FOUND THAT THIS TRANSMISSION PROBLEM IS VERY COMMON WITH THE 2004 EXPLORER MODEL. MY VEHICLE IS NOW OUT OF WARRANTY AND THE SAME PROBLEM HAS OCCURRED AGAIN. MY HOPE IS THAT YOU WILL TAKE THIS COMPLAINT AND RESEARCH FOR YOURSELF THE MANY PEOPLE EXPERIENCING THE SAME PROBLEM AND PLACE A GOVERNMENT RECALL CORRECT THE MATTER ONCE AND FOR ALL. IT IS A DANGEROUS PROBLEM AND CAUSES THE TRANSMISSION TO HESITATE BETWEEN 3RD AND 4TH GEAR IN MY CASE. THIS COULD POTENTIALLY CAUSE SERIOUS ISSUES WHILE AT HIGH SPEEDS. PLEASE LOOK INTO THIS MATTER AND FEEL FREE TO CONTACT ME WITH ANY OTHER QUESTIONS. THANKS. *CN
Visibility, Jan 22, 2008
I WAS TOLD BY MY MECHANIC THAT THE HANDLE ON THE DOOR THAT ALLOWS THE DEFROST TO OPERATE WAS BROKE OFF. NOT SURE WHY THIS WOULD EVER OCCUR. I WAS TOLD IT WOULD COST CLOSE TO 1,000.00 TO FIX. IT IS NOW A SAFETY HAZARD WHEREAS WINDOW WILL NOT DEFROST IN BAD WEATHER. I WAS WONDERING IF THIS WAS A DEFECT, AND OTHERS HAD THIS PROBLEM? *TR
Visibility, Structure, Electrical system, Jan 17, 2008
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE VEHICLE WAS QUALITY CHECKED WITH A 115 POINT INSPECTION; HOWEVER, SHE WAS LATER NOTIFIED THAT THE VEHICLE WAS IN A MAJOR CRASH. THE DRIVER SIDE DOOR IS MISALIGNED. THE SUNROOF WAS REPLACED WITH TAPE. SHE DOESN'T KNOW IF THE VEHICLE IS EQUIPPED WITH AIR BAGS. THE WINDOWS HAVE CONDENSATION ON THE INSIDE OF THE VEHICLE. THE SPEEDOMETER DOES NOT REGISTER THE PROPER SPEED IN THE VEHICLE. THE APPROXIMATE SPEED CAN RANGE FROM 20 TO 50MPH. THE FUEL PUMP AND SENSORS WERE REPLACED. THE VEHICLE WAS PURCHASED MARCH 20, 2007. THE DEALER STATED THAT THE VEHICLE IS CURRENTLY OPERATING NORMALLY. THE DEALER HAS DIAGNOSED THE FAILURE ON SEVERAL OCCASIONS. THE FAILURE MILEAGE WAS 20,000 AND THE CURRENT MILEAGE WAS 23,000.
Power train, Jan 12, 2008
1 - TRANSMISSION SHIFTS HARD INTO REVERSE. STARTING HAPPENING AT APPROX. 11K MILES. TOOK TO DEALER TWICE UNDER WARRANTY TO HAVE REPAIRS MADE, BUT STILL SHIFTED HARD. ONE REPAIR AT 11K AND ONE REPAIR AT 34K. EACH TIME I WAS TOLD THAT THIS WAS 'NORMAL' BY DEALER (BERGSTROM FORD OF NEENAH). HOWEVER, AFTER REPEATED COMPLAINTS, DEALER (BERGSTROM FORD OF NEENAH) MADE REPAIRS THAT THEY BELIEVED WOULD HELP RESOLVE THE ISSUE. ISSUE NEVER WENT AWAY. 2 - COMPLETE TRANSMISSION FAILURE AT 67K. TRANSMISSION WOULD NOT SHIFT INTO REVERSE. COULD NO BACK OUT OF A PARKING STALL AT A RETAIL STORE. TOOK TO FORD DEALER (LES STUMPF FORD) AND GOT NO ASSISTANCE. VEHICLE IS OUT OF WARRANTY AND I HAD TO PAY FOR REPAIRS. ENTIRE TRANSMISSION NEEDED REPLACEMENT. NO ASSISTANCE FROM FORD TO MAKE REPAIRS. *TR
Air bags, Jan 9, 2008, crash
TL*THE CONTACT OWNS A 2004 FORD EXPLORER SPORT TRAC. WHILE DRIVING 10 MPH, ANOTHER VEHICLE RAN A RED LIGHT AND STRUCK THE DRIVER'S SIDE OF THE CONTACT'S VEHICLE. A POLICE REPORT WAS FILED. BOTH SIDES OF THE VEHICLE WERE DAMAGED AND THE CONTACT FEELS THAT IT MAY BE DESTROYED. THE AIR BAGS FAILED TO DEPLOY. THE CONTACT SUSTAINED A BRUISED CHEST AND STRUCK HER HEAD ON THE STEERING WHEEL. THE CURRENT AND FAILURE MILEAGES WERE 60,000. UPDATED 02-14-08 *BF
Vehicle speed control, Jan 8, 2008
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CRUISE CONTROL SWITCH WAS DISCONNECTED ON OCTOBER 16, 2007 UNDER RECALL NUMBER 05S28. THE DEALER STATED THAT THE PART MAY NOT BE AVAILABLE UNTIL MARCH OF 2008. THE CONTACT FELT THAT THIS WAS AN UNREASONABLE AMOUNT OF TIME FOR THE REPAIR. THERE HAD BEEN NO FAILURE TO DATE. THE CURRENT MILEAGE WAS 74,000.
Suspension, Jan 6, 2008
I PURCHASED MY 2004 EXPLORER AND AT ABOUT 36,000 MILES I HAD TO BRING THE VEHICLE IN TO HAVE THE WHEEL BEARINGS REPLACED. NOW AT 65,000 MILES ONCE AGAIN THE WHEEL BEARINGS ARE GOING BAD. I HAVE NEVER OWNED NOR HAVE I EVER HEARD OF A VEHICLE WHERE THE WHEEL BEARINGS ONLY LASTING ABOUT 30,000 TO 40,000 MILES. THE FIRST TIME THE DEALER REPLACED THE BEARINGS HOWEVER THIS TIME THE VEHICLE IS NOT UNDER WARRANTY. TO BUY A NEW VEHICLE AND HAVE TO REPLACE THE WHEEL BEARINGS EVERY 30,000 TO 40,000 MILES IS NOT ACCEPTABLE. *TR
Electrical system, Vehicle speed control, Jan 4, 2008
CRUISE CONTROL HAS FAILED AND NEEDED TO BE REPAIRED 3 TIMES IN THE PAST YEAR AND A HALF. THE DEALER TELLS ME THAT THE SWITCH IN THE STEERING WHEEL IS DEFECTIVE, BUT I DO NOT BELIEVE HIM. HOW CAN THE SAME SWITCH FAIL AND BE REPLACED 3 TIMES. IT IS SOMETHING DEEPER IN THE SYSTEM, HOWEVER CHANGING THE SWITCH OUT ALLEVIATES THE PROBLEM FOR A WHILE. NOW THAT THE TRUCK IS OUT OF WARRANTY, IT WILL BECOME A MAJOR HEADACHE. *CN
Structure, Dec 31, 2007
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE GLASS ON THE REAR HATCH DOOR HAS CRACKED AND THE CONTACT FEELS THAT IT MAY SHATTER AT ANY MOMENT WHILE DRIVING. THE DEALER STATED THAT IT IS NOT A DEFECT AND THE CONTACT WOULD HAVE TO PAY FOR THE REPAIR. THE VIN, ENGINE SIZE, AND NUMBER OF CYLINDERS WERE UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 49,000.
Structure, Dec 31, 2007
2004 FORD EXPLORER'S REAR HATCH/TAILGATE HINGES BROKE. *TR
Electrical system, Dec 28, 2007
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE DRIVING 40 MPH, ALL OF THE WARNING INDICATOR LIGHTS ILLUMINATED ON THE INSTRUMENT PANEL. THE SPEEDOMETER AND TACHOMETER MALFUNCTIONED AND THE HEADLIGHTS DIMMED. THE DEALER INSTALLED A WIRE HARNESS, CLUSTER, AND PCM; HOWEVER, THE FAILURE CONTINUED. THE VIN AND ENGINE SIZE WERE UNKNOWN. THE FAILURE MILEAGE WAS 35,000 AND CURRENT MILEAGE WAS 66,000.
Power train, Dec 24, 2007
TOOK CAR BACK TO THE DEALER I PURCHASED IT FROM, COMPLAINED OF A ROUGH SHIFT INTO REVERSE, TECHNICIAN SAID NORMAL WITH THIS TRANSMISSION, TOOK IT TO ANOTHER DEALER IN CITY WHERE I WORK THEY FOUND THE PROBLEM TO BE A SOLENOID IN THE TRANSMISSION AND IT WAS REPAIRED UNDER WARRANTY. 20000 MILES LATER AND 18 MONTHS LATER THE SAME PROBLEM DIAGNOSED, NOT IN WARRANTY ANY LONGER I CONTACTED FORD AND THEY GAVE ME A DECISION THAT THERE WAS NOTHING THEY COULD DO FOR ME. THIS SAME PROBLEM APPEARS AT LEASE 3 TIMES ON YOUR WEBSITE AS SERVICE BULLETINS. *TR
Structure, Dec 17, 2007
A LARGE CRACK HAS FORMED ON THE REAR LIFT GATE PANEL RIGHT NEXT TO THE FORD EMBLEM. THE CRACK RUNS VERTICALLY AND RUNS THE LENGTH OF THE PANEL WHICH IS SEVERAL INCHES. THIS CRACK IS NOT DUE TO ANY PHYSICAL DAMAGE AND APPEARS TO EXPAND/CONTRACT IN DIFFERENT OUTDOOR TEMPERATURES. THIS PANEL SUPPORTS THE GLASS IN THE REAR LIFT GATE. *TR
Power train, Dec 14, 2007
DRIVING VEHICLE, STOPPED, PUT VEHICLE IN PARK, GOT OUT OF VEHICLE BRIEFLY , GOT BACK IN VEHICLE, PULLED ON GEAR SHIFT LEAVER TO PUT IN DRIVE WOULD NOT GO IN DRIVE OR ANY OTHER GEAR, PRNDL LEAVER BROKE OFF, COULD NOT REMOVE KEY, COULD SHUT OFF THE MOTOR, HAD TO HAVE VEHICLE TOWED TO FORD DEALER FOR REPAIRS. TOTAL COST OF REPAIR $1,501.19. I DID NOT BY THIS VEHICLE FROM OURISMAN FORD. I BOUGHT IT FROM A PRIVATE OWNER. *TR
Structure, Dec 13, 2007
CRACKED PANEL BELOW THE REAR WINDOW. *TR
Electrical system, Dec 7, 2007
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE DRIVING APPROXIMATELY 45 MPH WITH THE CRUISE CONTROL ACTIVATED, THE VEHICLE'S SPEED DECREASED DRAMATICALLY. ALL OF THE WARNING LIGHTS ILLUMINATED ON THE INSTRUMENT PANEL AND THEN THE ENGINE STALLED. TWO MINUTES LATER, THE VEHICLE RESTARTED AUTOMATICALLY. THREE WEEKS LATER, THE FAILURE RECURRED. THE MANUFACTURER STATED THAT THE VEHICLE HAS NOT BEEN REPAIRED. CURRENT AND FAILURE MILEAGES WERE 54,325. UPDATED 03-05-08 *BF
Power train, Dec 6, 2007
IN ORDER TO MOVE THE SHIFT LEVER INTO THE PARK POSITION, IT IS NECESSARY TO PUSH THE LEVER UP, LET IT RETURN DOWN A SHORT BIT, AND THEN PUT IT INTO PARK. THE LEVER WANTS TO STOP HALF WAY. THIS IS A SAFETY HAZARD BECAUSE THE VEHICLE MAY RETURN TO REVERSE WITHOUT ACTUALLY BEING IN THE PARK POSITION. *TR
Structure, Dec 4, 2007
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT NOTICED A CRACK ON THE REAR HATCH OF THE LIFTGATE. THE DEALER INSPECTED THE VEHICLE AND STATED THAT THE FAILURE IS A COMMON OCCURRENCE. AS OF DECEMBER 4, 2007, THE DEALER HAD NOT REPAIRED THE VEHICLE. THE MANUFACTURER OFFERED RESTITUTION OF $150; HOWEVER, THE CONTACT DECLINED THE OFFER. THE FAILURE MILEAGE WAS 27,846 AND CURRENT MILEAGE WAS 27,946. UPDATED 01-11-08. *KB THE CONSUMER STATED THE COST OF REPAIRS SHOULD NOT BE PASSED ONTO THE CONSUMER. UPDATED 12/31/07 *TR
Structure, Dec 3, 2007
A CRACK HAS APPEARED IN THE PLASTIC PANEL BELOW THE WINDOW ON THE REAR LIFT GATE. IT EXTENDS FROM TOP TO BOTTOM JUST LEFT OF THROUGH FORD EMBLEM. IT HAS NOT BEEN HIT OR DAMAGED IN ANY WAY. IT SPLIT ON ITS OWN. *TR
Latches/locks/linkages, Nov 29, 2007
REAR HATCH WINDOW DROPPED OFF HINGES. *TR