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.
Suspension, Nov 29, 2007
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE ACCELERATING FROM A STOP OR ATTEMPTING TO MAKE A RIGHT OR LEFT TURN AT VARIOUS SPEEDS, THE VEHICLE VIBRATED AS IF SOMETHING WAS RUBBING IN THE REAR. THE VEHICLE HAS BEEN TAKEN TO THE DEALER TWICE REGARDING THIS FAILURE. THE DEALER IS CURRENTLY STATING THAT THE VEHICLE HAS REAR SUSPENSION FAILURE IN THE CLUTCH PACK. THE VEHICLE HAS A TSB 06-4-4 FOR THIS FAILURE. THE CURRENT MILEAGE WAS 79,900 AND FAILURE MILEAGE WAS 23.
Visibility, Nov 16, 2007
THE HEATERS BLENDING DOOR IS BROKEN SO THE AIR FLOW WILL NOT BE REDIRECTED. IT IS CURRENTLY IN THE DASHBOARD SETTING AND I AM UNABLE TO REDIRECT AIR FLOW TO THE DEFROSTER. THE DEALERSHIP WANTED $1500 TO REPLACE THE HEATER BECAUSE THE BROKEN PART IS MOLDED ONTO THE HEATING ELEMENT AND THEY NEED TO REMOVE THE ENTIRE DASHBOARD. I SEARCHED FOR SIMILAR COMPLAINTS, AND FORDS VEHICLES HAVE A LONG HISTORY OF BLENDING DOOR PROBLEMS. NOT BEING ABLE TO REDIRECT THE AIR FLOW IS EXTREMELY DANGEROUS, ESPECIALLY DURING THE WINTER MONTHS. *TR
Fuel system, Gasoline, Fuel system, Other, Power train, Electrical system, Vehicle speed control, Wheels, Seats, Nov 8, 2007
2004 FORD EXPLORER LIMITED-OWNED SUV FOR 38K BEEN IN SHOP REPEATEDLY-FROM MINOR TO MAJOR THINGS. SUV IS A $ 34,000 TURD. CURRENTLY NEEDING TO GO BACK TO SHOP FOR MULTIPLE REPAIRS. THE DAY OUR WARRANTY EXPIRES CAR IS GONE. *TR
Structure, Nov 7, 2007
I HAVE A CRACK ON THE REAR LIFT GATE OF MY 2004 FORD EXPLORER. IT RUNS VERTICALLY FROM UNDER THE WINDOW, AROUND THE LEFT SIDE OF EMBLEM, TO THE BOTTOM OF PANEL. I UNDERSTAND THAT THIS IS A COMMON DESIGN FLAW. I HAD THIS REPAIRED ONCE ALREADY IN SEPTEMBER 2006. THIS IS THE 2ND OCCURRENCE AND FORD IS NOT REPAIRING IT UNDER WARRANTY, BECAUSE MY 12 MONTH PERIOD ENDED 6 WEEKS AGO. I FEEL THIS NEEDS TO BE RECTIFIED, AS IT IS A 2ND OCCURRENCE AND OBVIOUSLY A MANUFACTURER FLAW. *TR
Structure, Oct 31, 2007
BUBBLING AND BLISTERING OF THE PAINT FROM THE HOOD OF 2004 FORD EXPLORER. *TR
Power train, Oct 31, 2007
REAR AXLE NOISE/WHINING. *TR
Structure, Oct 30, 2007
THE REAR WINDOW LIFTGATE HINGE ON MY 2004 FORD EXPLORER FRACTURED. THIS WAS OBVIOUSLY A DEFECTIVE HINGE IN THAT IT SHOULDN'T HAVE WORN OUT LIKE IT DID. I HAD TO BRING IT TO THE DEALER WHO REPLACED BOTH HINGES FOR APPROX $165. THEY TOLD ME THERE WAS A RECALL FOR THIS SAME PROBLEM FOR THE YEARS PRIOR TO MY MODEL YEAR. THEY ALSO SAID THAT THE HINGE WAS THE SAME TYPE THAT WAS FAILING IN THE PRIOR MODEL YEARS. I AM FILING THIS COMPLAINT IN ORDER TO HAVE ANY OF THIS TYPE OF HINGE THAT WAS USED TO BE INCLUDED IN THE RECALL. THE RECALL WAS # 04V442000. *TR
Structure, Oct 29, 2007
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE LIFT GATE FELL OFF THE HINGES WHEN IT WAS BEING CLOSED. THE CONTACT WAS FORCED TO DRIVE THE VEHICLE WITH THE LIFT GATE DISCONNECTED. A MECHANIC STATED THAT IT NEEDED TWO GLASS BRACKETS AND THE HINGES NEEDED TO BE REPLACED. THE REPAIR COST WOULD BE MORE THAN $600 AT THE OWNER'S EXPENSE. THERE WERE NO WARNING SIGNS THAT THE LIFT GATE WAS LOOSE. THE DEALER STATED THAT THERE WAS NO WARRANTY AVAILABLE. THE FUEL SYSTEM WAS UNKNOWN. THE FAILURE AND CURRENT MILEAGES WERE 45,000. UPDATED 11/14/07
Fuel system, Gasoline, Oct 24, 2007
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. AFTER FILLING THE VEHICLE WITH GAS AND DRIVING A FEW MILES, THE FUEL CAP PRESSURE LIGHT ILLUMINATES AND THE ENGINE SHUTS OFF. THE CONTACT HAS TO EXIT THE VEHICLE AND RETIGHTEN THE FILLER CAP, WHICH THEN ALLOWS THE ENGINE TO RESTART. THE FAILURE HAS OCCURRED TWICE WITHIN 3 OR 4 GAS TANK FILL-UPS AND USUALLY WHILE DRIVING 50 MPH. HE HAS NOT YET TAKEN THE VEHICLE TO THE DEALER. FAILURE MILEAGE WAS 29,000 AND CURRENT MILEAGE WAS 29,500. UPDATED 12/12/07 *BF
Power train, Oct 19, 2007
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE THE VEHICLE WAS PARKED AND THE ENGINE WAS RUNNING, THE VEHICLE ROLLED INTO THE CONTACT'S HOME. WHILE DRIVING TO THE DEALER AT 15 MPH, THE VEHICLE FAILED AND WOULD NOT MOVE. THE VEHICLE WAS PLACED IN EACH GEAR, BUT IT STILL WOULD NOT MOVE AND THE ENGINE REVVED. THE VEHICLE WAS TOWED TO THE DEALER. WHEN IT ARRIVED, THE VEHICLE WAS PLACED IN REVERSE AND DROVE BACKWARDS. WHEN THE GEAR WAS PLACED IN DRIVE, IT DROVE FORWARD. THE MECHANIC STATED THAT THE VEHICLE HAD A DEFECTIVE SHIFT INDICATOR AND IT WAS REPLACED. THE VEHICLE OPERATED NORMALLY WHEN IT WAS TEST DRIVEN. FOUR DAYS LATER, THE FAILURE RECURRED. THE TRANSMISSION IS MAKING NOISES WHEN DRIVING AT ANY SPEED, ESPECIALLY WHEN SHIFTING GEARS. THE VEHICLE IS CURRENTLY BACK AT THE DEALER. THE FAILURE AND CURRENT MILEAGES WERE 51,578. UPDATED 12-12-07. *KB
Structure, Oct 18, 2007
FOUND A CRACK IN THE LIFTGATE PANEL. NO IMPACT WAS SUFFERED TO THE PANEL. CRACK GOES FROM TOP TO BOTTOM RIGHT THOUGH THE FORD EMBLEM. *TR
Power train, Oct 17, 2007
ON MY EXPLORER IT HAS BEEN TO THE DEALER ON 5 OCCASIONS NOW FOR THE TRANSMISSION. DELAYED ENGAGEMENT WHEN GOING FROM REVERSE TO DRIVE, SOMETIMES FEELING AS IF SOMEONE HAS REAR ENDED ME. ON THE FIRST TRIP IN AN ADDITIVE WAS ADDED TO THE TRANSMISSION, SECOND TRIP THE TRANSMISSION SOLENOID PACK WAS REPLACED, THIRD TRIP THE TRANSMISSION SOLENOID PACK WAS REPLACED, FOURTH TRIP THE DEALER COULDN'T REPRODUCE THE PROBLEM AND THE FIFTH TRIP THE PROBLEM COULDN'T BE REPRODUCED. WAS TOLD BY THE DEALER SERVICE MANAGER THAT THIS IS WHAT THE TRANSMISSION IS SUPPOSED TO DO. 1 DAY AFTER GETTING MY EXPLORER BACK SAME ISSUE. I DON'T FEEL THAT THIS VEHICLE IS SAFE TO DRIVE. *JB
Visibility, Structure, Oct 17, 2007
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE USING THE REMOTE TO OPEN THE REAR WINDOW, THE GLASS HINGE FAILED AND CAUSED THE WINDOW TO FALL FROM THE WINDOW FRAME. THE CONTACT NOTIFIED THE DEALER AND MANUFACTURER AND THEY STATED THAT HIS VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER 01I010000 (VISIBILITY:GLASS, SIDE/REAR). THE WINDOW HAS YET TO BE REPAIRED. THE CURRENT AND FAILURE MILEAGES WERE 33,500 UPDATED 01/02/08. UPDATED 01/02/08.*LJ
Power train, Oct 17, 2007
OUR 2004 FORD EXPLORER HAS A SIGNIFICANTLY DELAYED RESPONSE WHEN SHIFTING INTO REVERSE. ONCE THE TRANSMISSION ENGAGES THERE IS A LOUD AND HARD "CLUNK". THIS HAPPENS EVERY TIME YOU PUT THE TRUCK IN REVERSE. *TR
Structure, Oct 14, 2007
2004 FORD EXPLORER EDDIE BAUER. PANEL UNDER TAILGATE CRACKED. CLEAR CRACK FROM TOP TO BOTTOM WHERE FORD EMBLEM IS, APPEARED OVERNIGHT. WAS NOT INVOLVED IN ANY ACCIDENT. 53,385 MILES *JB
Power train, Oct 4, 2007
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE DRIVING APPROXIMATELY 35MPH AND CHANGING GEARS, THE TRANSMISSION HESITATED. WHEN REVERSE IS ENGAGED, THERE WAS A DELAY, A HARD NOISE AND DIFFICULT TO SHIFT. THE DEALER HAS NOT DIAGNOSED THE FAILURE. THE CURRENT AND FAILURE MILEAGES WERE 36,000.
Steering, Oct 3, 2007
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE DRIVING 20 MPH, THE CONTACT HEARD A HUMMING NOISE. THE VEHICLE WAS TAKEN TO THE DEALER AND THEY STATED THAT THE BEARINGS WERE WORN IN THE RACK AND PINION AND NEEDED TO BE REPLACED. THE REPLACEMENT WOULD COST $400 BECAUSE NO RECALLS WERE AVAILABLE. THE POWERTRAIN WAS UNKNOWN. THE CURRENT MILEAGE WAS 54,000 AND FAILURE MILEAGE WAS 52,768.
Power train, Sep 25, 2007
FORD HAS AN OBVIOUS DESIGN FLAW IN THE TRANSMISSION FOR THE 2004 EXPLORER. SIMILAR TO THOUSANDS OF OTHERS,WHEN PUT INTO REVERSE THE VEHICLE HESITATES FOR 5 - 10 SECONDS AND THEN BANGS INTO GEAR WITH A SUDDEN POWER SURGE. WE'VE BARELY MANAGED TO AVOID HITTING THE HOUSE AND OTHER VEHICLES. A "REPAIR" JUST COST US ~$900. FORD CLAIMS NO KNOWLEDGE OF A PROBLEM. WHAT A JOKE! *JB
Engine and engine cooling, Power train, Structure, Vehicle speed control, Sep 25, 2007, fire
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE VEHICLE WOULD NOT START. SHE DEPRESSED THE ACCELERATOR PEDAL AND THE VEHICLE STARTED AND BEGAN TO VIBRATE. SHE THEN PLACED THE VEHICLE IN REVERSE AND HEARD A LOUD CLUNKING NOISE. SHE SMELLED A STRONG GAS ODOR INSIDE THE PASSENGER COMPARTMENT. THE CONTACT LOOKED IN HER REARVIEW MIRROR AND NOTICED A LARGE AMOUNT OF SMOKE COMING FROM THE EXHAUST SYSTEM. SHE PARKED THE VEHICLE AND HAD IT TOWED. SHE THEN NOTICED THAT ALL OF THE RADIATOR FLUID LEAKED OUT. THE MECHANIC STATED THAT THE VALVE FAILED AND DAMAGED THE ENTIRE ENGINE. THE MECHANIC ALSO STATED THAT THE ENGINE NEEDED TO BE REPLACED AND APPEARED TO BE A MANUFACTURER DEFECT. THE CURRENT AND FAILURE MILEAGES WERE 63,000. THE CONSUMER ALSO STATED HAD PROBLEMS PRIOR TO INCIDENT WITH SUN VISOR FALLING OFF, GEAR SHAFT WOULD NOT SHIFT INTO PARK, ENGINE SLUGGISH, AND WHILE USING CRUISE CONTROL VEHICLE WOULD JUST SHUT OFF. UPDATED 10/22/07 *TR
Visibility, Structure, Sep 16, 2007
CRACK IN PANEL BELOW REAR WINDOW NEXT TO FORD EMBLEM. BOTH REAR WINDOWS WILL NOT GO UP OR DOWN. *TR
Structure, Sep 16, 2007
2004 FORD EXPLORER 33,663. MILES PANEL UNDER WINDOW OF HATCHBACK HAS CRACKED DOWN THE MIDDLE. AFTER VIEWING THE SAME COMPLAINT FROM OWNERS OF THIS SAME VEHICLE, I DO NOT UNDERSTAND WHY THEIR HAS NOT BEEN A RECALL. *TR
Power train, Sep 14, 2007
2004 EXPLORER (AUTOMATIC) COLUMN GEAR SHIFT BROKE WHEN SHIFTED INTO REVERSE. PART WAS NOT SOLD SEPARATELY SO HAD TO PURCHASE ENTIRE STEERING COLUMN. ESTIMATE COST OF NEW PART WAS APPROXIMATELY $500. LUCKILY WAS ABLE TO LOCATE USED PART FOR HALF THE COST. REPLACED ONLY THE BROKEN PART WHICH HAS GEAR SHIFT LEVER ATTACHED. *JB
Structure, Sep 13, 2007
DEVELOPED CRACK IN BACK PANEL UNDER REAR WINDOW ON LIFTGATE. NOTHING TOUCHED IT. CAME OUT ONE MORNING AND FOUND IT THERE. FORD WILL NOT FIX IT WITHOUT ME PAYING $150. I'VE SEEN 200+ COMPLAINTS ON THE INTERNET WITH THE SAME PROBLEM. I BET OVER 50% OF THE EXPLORERS SOLD DO THIS. THIS IS NOT NORMAL.
Structure, Sep 11, 2007
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. AFTER DRIVING 55 MPH, THE CONTACT NOTICED PAINT CHIPPING ON THE HOOD OF THE VEHICLE. SHE TOOK THE VEHICLE TO THE DEALER AND THEY STATED THAT THE FAILURE WAS NOT COVERED BY THE WARRANTY AND ADVISED HER TO REPAIR IT HERSELF. SHE TOOK THE VEHICLE TO A MECHANIC AND HE STATED THAT THE FAILURE WAS A MANUFACTURER DEFECT AND SHE SHOULD NOT HAVE TO PAY FOR THE PAINT JOB. THE CURRENT AND FAILURE MILEAGES WERE 46,500.
Power train, Sep 10, 2007
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE VEHICLE WAS NOT REPAIRED AFTER IT HAD BEEN SERVICED FOR A RECALL ON THE TRANSMISSION. SHE PLACED THE VEHICLE IN REVERSE AND FIVE SECONDS LATER IT JERKED BACKWARDS. THE CONTACT EXPERIENCED THE SAME FAILURE NUMEROUS TIMES. THE VEHICLE WAS RETURNED TO THE DEALER FOR INSPECTION. THE CURRENT MILEAGE WAS 48,500 AND FAILURE MILEAGE WAS 15,000.