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.
Wheels, Service brakes, Engine, May 24, 2015
CAR STARTS BUT WILL GO FORWARD WHEN SHIFTED IN REVERSE. TURNED THE CAR OFF THEN BACK ON, BUT WHEN I WOULD PUT THE CAR BACK IN REVERSE OR DRIVE, IT STALLED OUT. HAD IT TOWED AND THEN IT WAS FINE AFTER THAT. NOW ITS ABOUT 6 MONTHS LATER, NOW MY ORANGE WRENCH LIGHT POPS UP AND CRUISE CONTROL SHUTS OFF AT 65MPH. THEN IT JERKS A COUPLE TIMES. HAVE HAD IT CHECKED AND CAME BACK WITH 14 CODES MAINLY FOR TRANSMISSION.
Other or unspecified, May 21, 2015
TRUCK SUDDENLY ACCELERATED WHEN I WAS IN TRAFFIC NOT MOVING.
Other or unspecified, May 19, 2015
OVERDRIVE LIGHT COMES ON AND THE CAR WILL NOT SHIFT GEARS.. CODED PRESSURE CONTROL SOLENOID. PUT ONE IN AND IT STILL HAS THE LIGHT BLINKING AND RUNS LIKE CRAP..
Steering, Electrical system, Engine, May 17, 2015
COMPLETE ENGINE FAILURE WHILE DRIVING. SERVICE ENGINE SOON LIGHT APPEARED 2 DAYS PREVIOUS BUT DID NOT YET MAKE IT TO THE MECHANIC. COMPUTER READING SUGGESTED A SENSOR PROBLEM. ENGINE SHUT DOWN, LOST POWER STEERING AND ALL SYSTEMS. ENGINE RESTARTED BUT NOW IDLES ROUGH.
Structure, May 6, 2015
CAR WAS PARKED. I OPENED REAR HATCH (JUST THE WINDOW PART) AND THE PASSENGER SIDE HINGE BROKE CAUSING HATCH TO FALL DOWN ON MY HEAD (QUITE PAINFUL!). ABOUT A YEAR AGO THIS SAME THING HAPPENED WITH THE DRIVERS SIDE HINGE (THOUGH I WAS ABLE TO CATCH IT BEFORE IT HIT MY HEAD). I HAD THAT SIDE REPAIRED, BUT NOW IT LOOKS CORRODED SO I WORRY IT WILL HAPPEN AGAIN. *TR
Power train, May 5, 2015
TRANSMISSION FAILURE, COMMON FOR FORD EXPLORER 2004. *TR
Exterior lighting, Structure, May 5, 2015
MY REAR HATCH IN THE BACK OF MY EXPLORER HAS A CRACK IN IT. WHICH I THINK HAS CAUSED THE BACK WINDOW TO SHIFT WHICH IN TURN HAS CAUSED MY DOOR AJAR LIGHT TO FLASH WHILE THE DOOR CHIMES GO OFF AND THE INTERIOR FLICKER WHILE YOU ARE DRIVING DOWN THE ROAD BUT THERE ARE NO DOORS OPEN . THE LIGHTS FLICKERING MAKE IT HARD TO DRIVE IN THE NIGHT. I THINK FORD SHOULD FIX THIS PROBLEM FOR EVERYONE. *TR
Engine, Apr 24, 2015
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE DRIVING AT APPROXIMATELY 55 MPH, THE SERVICE ENGINE SOON WARNING INDICATOR ILLUMINATED AND THE ENGINE STALLED. THE VEHICLE RESTARTED AND STARTED BLOWING FUEL FUMES INTO THE DRIVER'S CABIN. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE SPARK PLUG BLEW OUT OF THE CYLINDER AND NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED BUT THE FAILURE RECURRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 130,000. MA 08/06/15 UPDATED 10/11/2017*CN
Tires, Apr 20, 2015
TL* THE CONTACT OWNS A 2004 FORD EXPLORER EQUIPPED WITH CAPITOL PRECISION TRAC II TIRES, SIZE: 245/65R17. WHILE DRIVING APPROXIMATELY 55 MPH, THE CONTACT WAS ALERTED BY ANOTHER DRIVER THAT THERE WAS A BULGE IN THE REAR PASSENGER SIDE TIRE. THE CONTACT DISCOVERED THAT THE TIRE HAD A BULGE ON THE OUTSIDE WALL. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 14T013000 (TIRES). THE VIN WAS UNAVAILABLE. THE APPROXIMATE VEHICLE FAILURE MILEAGE WAS 147,000 AND APPROXIMATE TIRE FAILURE MILEAGE WAS 3,500. THE DOT NUMBER AND VIN WERE NOT AVAILABLE.
Structure, Apr 9, 2015
THERE IS A VERTICAL CRACK ON THE TOP REAR LIFT GATE 10" TO THE LEFT OF THE VEHICLE LOGO TOWARD THE REAR DOOR. IN COLD TEMPERATURES, THE CRACK IS BARELY VISIBLE YET IN WARMER TEMPERATURES, THE CRACK WOULD EXPAND. *TR
Structure, Mar 25, 2015
THE LIFTGATE GLASS HINGE ON MY 2004 FORD EXPLORER BROKE AS I WAS CLOSING THE REAR WINDOW GLASS. WITHOUT WARNING IT JUST CAME UNDONE WITH THE SCREW POPPING LOOSE. CHEAPLY MADE MATERIAL OF THE LIFTGATE GLASS HINGE WAS CLEARLY THE CAUSE, ALONG WITH A FAULTY DESIGN THAT ALLOWS THE BOLT TO STRIP OUT OF THE HINGE. *TR
Structure, Mar 22, 2015
CRACKED REAR HATCH. I HAD HEARD ABOUT THIS PROBLEM AND MY HATCH DIDN'T CRACK TILL AFTER THIS COLD WINTER. BUT, THIS IS THE FIRST WINTER THAT THIS EXPLORER HAS BEEN KEPT OUTSIDE, NOT GARAGED. MY GARAGED IS UNDER MY HOUSE AND INSULATED. IT NEVER GETS BELOW FREEZING IN THE GARAGE. I CALLED FORD AND ASKED THEM IF THEY CAN HELP FINANCIALLY WITH THE REPAIRS. THEY SAID NO. *TR
Power train, Engine, Mar 16, 2015
HAD MY USED 2004 FORD EXPLORER FOR A WEEK AND I NOTICED THE TRANSMISSION JERKING WHEN IT SHIFT INTO THE LAST GEAR. SOMETIMES WHEN I PUT IT IN REVERSE, I HAVE TO WAIT FOR A FULL MINUTE FOR IT TO FINALLY REVERSE. SOMETIMES IT JERKS HARD WHEN I PUT IT IN REVERSE OR DRIVE. I'M SURE THE DEALERSHIP KNEW ABOUT ALL THIS BUT NEVER REVEALED IT. OF COURSE WHEN YOU BUY AS IS, YOUR SCREWED. *TR
Structure, Mar 16, 2015
HAD MY USED 2004 FORD EXPLORER FOR ONE WEEK AND THE LIFTGATE LATCHES BOTH BROKE. IF IT HADN'T BEEN FOR THE SHOCKS THAT WERE ON THE LIFTGATE, THE WINDOW WOULD HAVE CRASHED TO THE GROUND AND SHATTERED IN A THOUSAND PIECES. FROM WHAT I'M TOLD, I'M GOING TO HAVE TO CONTACT THE DEALERSHIP AND PAY GOD KNOWS WHAT TO HAVE IT FIXED. CAN'T EVEN USE MY TRUNK NOW. THE DEALERSHIP IS A JOKE. *TR
Wheels, Mar 16, 2015
BOUGHT MY USED 2004 EXPLORER A WEEK PRIOR AND HAD TO HAVE THE BACK WHEEL BEARINGS REPLACED. USED DEALERSHIP TOLD ME THAT THEY WOULD HELP OUT AND NEVER FOLLOWED THRU. *TR
Power train, Mar 11, 2015
I WAS DRIVING INTERSTATE 64 GETTING OFF THE EXIST GOING AROUND THE RAMP AND A KNOCKING NOISE STARTED AS I ROUNDED THE CURB, THEN OIL PRESSURE DROPPED, MY POWER WAS GONE AND, I BARELY MADE IT OFF THE RAMP, BUT LUCKILY THE VEHICLE HAD ENOUGH SPEED TO COAST THE CURB TO GET TO A SAFE PLACE TO STOP. UPON HAVING IT CHECKED OUT BY A LOCAL MECHANIC HE SUGGESTED THAT THE ENGINE AND OIL PUMP NEEDED TO BE REPLACED? AS A SINGLE MOTHER I DON'T HAVE THE MONEY FOR THE REPAIRS, AND FROM OTHERS COMPLAINTS THAT I'VE SEEN IT MAKES ME WONDER IF ITS WORTH THE TROUBLE TO FIND ANOTHER ENGINE AND WILL IT HAPPEN AGAIN. I THOUGHT HAD FOUND A GOOD VEHICLE THAT ONLY LASTED A FEW MONTHS...FEELING IRRITATED...GET IT TOGETHER FORD BECAUSE THIS 2004 EXPLORER IS TROUBLE!! WAS THIS JUST A TEST DUMMY MODEL TO SEE WHAT PROBLEMS WOULD COME OF IT??? WE WANT AND NEED ANSWERS TO THESE PROBLEMS. WE'RE SPENDING SO MUCH HARD EARNED MONEY ON A VEHICLE THAT HAS MORE PROBLEMS THAT KEEPS HAPPENING OFTEN. *TR
Structure, Mar 2, 2015
REAR CRACKED PANEL ON 2002-2005 FORD EXPLORER -WHEN IT RAINS WATER FRY THE REAR TAILLIGHTS . *TR
Structure, Mar 1, 2015
LIFTGATE HAS A CRACK AND THE HINGE TO THE LIFTGATE BROKE DUE TO CRACK. IT IS HAZARDOUS TO DRIVE DUE TO POSSIBLE FALLING WHILE DRIVING OR PARKED. *TR
Power train, Engine, Fuel/propulsion system, Feb 25, 2015
I'VE HAVE MY VEHICLE FOR 10 YEARS. PAID THE DEALERSHIP $450 TO HAVE A WARRANTY FOR THE POWER TRAIN AND WHEN I WENT TO THE DEALERSHIP FOR THEM TO FIX IT THEY WOULDN'T. I FIND OUT THAT MY MAJOR ISSUES ARE THE MECHANICAL DIFFERENTIAL. STILL HAVING THE THIS ISSUE TO THIS DAY AND CAN NEVER HAVE MY TRANSMISSION CLEANED OR FLUSHED BECAUSE OF THAT. ALSO, MY FUEL SYSTEM GETS CLOGGED A LOT AND GAS MILEAGE IS HORRIBLE. ALSO, MY ANTIFREEZE LEAKS AFTER I PAID MONEY TO HAVE THE CRACKED SEAL FIXED. THIS IS JUST SCRATCHING THE SURFACE. I HAVE MANY THINGS WRONG WITH MY VEHICLE I FEEL SHOULD BE COVERED BY THE MANUFACTURER BUT I WOULD LIKE TO KNOW WHAT DEFECTS ARE OUT THERE FOR MY VEHICLE. *JS
Visibility, Feb 9, 2015
WHILE CLOSING THE REAR WINDOW GLASS HATCH THE DRIVER SIDE HINGE BROKE ALLOWING THE WINDOW TO FALL OUT ON THAT SIDE. THE REAR GLASS HATCH WINDOW IS HEAVY AND COULD HAVE EASILY BROKEN THE HINGE SIDE ALLOWING THE GLASS TO FALL OFF THE VEHICLE. A PREVIOUS FORD RECALL ON THE VERY SAME COMPONENT COVERED VEHICLES UP TO 2003. THE EXACT SAME PROBLEM IS OCCURRING TO THIS 2004 VEHICLE. CONTACTED FORD AND THEY ARE NOT WILLING TO HELP OWNERS OUT. HAD THE VEHICLE BEEN TRAVELING AT HIGHWAY SPEEDS AND THE HINGE LET GO, THERE WOULD BE A VERY HIGH PROBABILITY OF PROPERTY DAMAGE AND A VERY HIGH PROBABILITY OF PERSONAL INJURY TO OTHERS ON THE ROAD. *TR
Steering, Electrical system, Engine, Feb 5, 2015
DRIVING DOWN THE ROAD AT 10:52 PM AND WITH NO WARNING THE ENTIRE TRUCK SHUT DOWN/OFF. ALL LIGHTS INSIDE AND OUT SHUT OFF, ENGINE SHUT OFF, NO POWER TO THE ENTIRE VEHICLE. COASTED TO A STOP, PUT IT IN PARK AND TURNED THE KEY OFF AND THEN BACK ON - THE TRUCK STARTED RIGHT UP WITH OUT A PROBLEM. *TR
Electrical system, Jan 30, 2015
GOOD MORNING, MY CAR WAS PARKED IN THE DRIVEWAY, NOT RUNNING, 11:15PM, WHEN HORN STARTED TO CONTINUOUSLY AND WOULD NOT STOP. SMELT WIRES BURNING. I STARTED THE CAR AND WAS ATTEMPTING TO MOVE IT OUT OF MY NEIGHBORHOOD AND UPON DRIVING, I TAPPED THE HORN AND IT STOPPED. SMELL OF WIRES BURNING. IT HAPPENED AGAIN, YESTERDAY AM AND TODAY AM, ON THE WAY TO GO, AND I HIT THE HORN AND IT STOPPED. CAN THIS BE AIRBAG RELATED??? I AM SCARED TO DRIVE MY CAR, FEARING THE AIRBAG WILL OPEN OR A FIRE IS GOING TO START. *TR
Visibility, Jan 30, 2015
SUN VISORS HAVE BEEN REPLACED TWICE. HORIZONTAL PLASTIC PANEL WITH THE FORD LOGO HAS CRACKED AND BEEN REPLACED 3 TIMES. CURRENT ONE ON VEHICLE IS CRACKED. SENT AN E-MAIL TO FORD AND WAS TOLD BASICALLY "TOO BAD--OUT OF WARRANTY ". FORMOCO HAS KNOWN OF THIS PROBLEM ON BOTH THE FORD AND MERCURY BUT HAS DONE NOTHING TO FIX IT BECAUSE IT IS NOT A SAFETY ISSUE. AND OF COURSE THIS " DAMAGE " WILL LOWER THE VALUE OF MY VEHICLE WHEN I SELL/TRADE IT FOR SOMETHING OTHER THAN A FORD. *TR
Power train, Jan 27, 2015
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 25 MPH, THE TRANSMISSION SEIZED. THE CONTACT STATED THAT WHEN THE ACCELERATOR WAS DEPRESSED, THE VEHICLE HESITATED TO ACCELERATE. THE VEHICLE WAS TAKEN TO THE DEALER, WHERE IT WAS DIAGNOSED THAT THE GEARS FAILED TO SHIFT AND THE TRANSMISSION HAD TO BE REPLACED. THE VEHICLE WAS TAKEN TO THE DEALER. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 65,000.
Power train, Jan 25, 2015
REAR PANEL CRACKED IN THE SHED. I HAVE HAD TO REPLACE MY TRANSMISSION A YEAR AGO REPLACE FRONT HUBS SEVERAL TIMES. AND JUST LAST WEEK I HAD TO REPLACE THE BACK WHEEL BEARING AGAIN. I DON'T UNDERSTAND WHY FORD HAS NOT DONE A RECALL ON THESE THINGS.I SEE A LOT OF FORDS WITH THE SAME CRACK ON THE BACK HATCH.THIS IS JUST CRAZY. IF I NEW WE COULDN'T CHECK TRANSMISSION FLUID I WOULD HAVE NEVER GOT THIS TRUCK.I WILL NEVER BUY A FORD AGAIN. WE ALSO HAVE A 1994 DIESEL THAT WE HAD TO PUT A TRANSMISSION IN AT 80,000 MILES IT SITS IN THE SHED AND NOW MY HUSBAND DRIVES A CHEVY.OUR FORD DIESEL ONLY HAS 134,000 ON IT WHAT ASHAMED. IT WILL NOT EVEN CRANK WHEN ITS COLD. BAD WORK FORD!!!! *TR