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, Nov 18, 2004
WHEN GEARS ARE PUT IN REVERSE, THE TRANSMISSION HESITATES FOR 3-5 SECONDS THEN A LOUD CLUNK IS HEARD AND THE VEHICLES MOVES. JUST PURCHASESD THE EXPLORER FROM DEALER TODAY WITH 20,750 MILES ON IT AND NOTHING WAS DISCLOSED ABOUT THESE PROBLEMS. I'LL TAKE BACK TOMMORROW AND HOPE THEY WILL FIX THE PROBLEM. LEMON????*AK
Power train, Nov 12, 2004
MY TRANSMISSION STARTED SLIPPING GEARS. IT WOULD ALSO CLUNK AND HANG UP IN REVERSE. SOMETIMES WHEN ENGAGED IN DRIVE IT WOULD SURGE FORWARD. SEVERAL TIMES I HAVE BEEN VERY LUCKY AND KEPT MY FOOT ON THE BRAKE. IF NOT, I AM AFRAID TO THINK OF THE CONSEQUENCES. AFTER TAKING TO A CERTIFIED FORD DEALERSHIP, IT NO LONGER SLIPS IN GEAR, BUT IT STILL CLUNKS. NOW IT HESITATES WHEN CHANGING GEAR. THE DEALER SAYS THIS IS NORMAL. I HAVE TRIED 4 TIMES TO GET THEM TO FIX THIS BUT THEY KEEP SAYING ITS NORMAL. THIS IS NOT MY FIRST FORD EXPLORER 4X4 AND I HAVE NEVER EXPERIENCE ANY HESITATIONS WHEN THE GEARS CHANGE IN ANY VEHICLES I HAVE EVER DRIVEN OR OWNED. THIS WILL BE MY LAST FORD EVER! *JB
Power train, Nov 12, 2004
FOR THE PAST 8 MONTHS, WHEN I PUT SUV INTO REVERSE, THERE IS A LOUD BANG. SOMETIMES SUV STICKS IN "PARK", THEN SLAMS BACK. ALSO WHILE DRIVING SOMETIMES IT HESITATES AND FINALLY SHIFTS. UPON STOPPING, SUV ROLLS FORWARD OR BACKWARDS A GREAT DISTANCE UNTIL IT FINALLY LOCKS INTO "PARK." TOOK SUV TO SERVICE DEPT. @ DEALER AND WAS TOLD THEY DID NOT FIND ANYTHING WRONG. *JB
Power train, Nov 10, 2004
WHEN SHIFTING FROM DRIVE TO REVERSE, HESITATION UP 5 SECONDS THEN BANGS INTO REVERSE. DEALER SAID IT WAS NORMAL BECAUSE OF COMPUTER LAG. STILL DOING IT AND TAKING IT BACK TO DEALER AGAIN. THIS IS AN ON GOING PROBLEM.
Steering, Nov 9, 2004
I BROUGHT MY SUV DEC 2004. I HAD ONLY 40 MILES ON IT. I NOW HAVE A LITTLE OVER 7,000. ONE MONTH AFTER PURCHASING MY SUV IT WOULDN'T START UP. I TOOK IT IN TO BE SERVICED BUT THEY WERE UNABLE TO FIND ANYTHING. A MONTH LATER IT WOULD STALL WHILE DRIVING AND WHEN I SHIFT FROM DRIVE TO REVERSE THE WHOLE TRUCK JUMPS INTO REVERSE. IT ALSO HESITATE TO GO INTO REVERSE. I'VE BEEN HAVING THIS PROBLEM FOR THE PAST 8 MONTHS. I CONTINUE TO TAKE IT FORD TO GET SERVICE. FIRST THEY DIDN'T FIND ANYTHING WRONG NOW THYE'RE SAYING THAT IT'S A RECALL AND "FIXED" THE PROBLEM. BUT I CONTINUE TO HAVE THE PROBLEM.. I'M CURRENTLY IN THE PROCESS OF TRYIMG TO GET FORD TO GIVE ME A NEW TRUCK. BUT THEY ONLY TRYING TO OFFER 2,500 DOLLARS. I DON'T WANT THE MONEY I WANT A NEW TRUCK. I PAID FOR A NEW TRUCK NOT A TRUCK THAT WILL CONTIUE TO HAVE PROBLEMS. MY ABS LIGHT KEEPS COMING ON TOO. I'M GOING TO TAKE IT BACK TO FORD TO HAVE IT LOOKED AT AGAIN. IT'S SUCH A HASSEL TO KEEP TAKING MY TRUCK BACK FOR THE SAME PROBLEMS AND IT'S NOT BEING FIXED. I DON'T THINK THEY KNOW WHAT IS WRONG WITH MY TRUCK. I HAVE LEMON. *AK
Power train, Nov 6, 2004
VEHICLE HESITATES WHEN PUT INTO REVERSE, THEN SLAMS INTO REVERSE WITH A SUDDEN JERK. HAVE TO KEEP BRAKE TO THE FLOOR WAITING FOR IT TO ENGAGE TO KEEP THE VEHICLE FROM HURTING ANYONE. UPON WAITING FOR PART THAT IS ON BACK ORDER, THE VEHICLE NOW MISSES GEARS WHEN DRIVING DOWN THE ROAD AND SOMETIMES SLAMS INTO THE NEXT GEAR EVEN IF IT IS DOWN SHIFTING. PART WAS SUPPOSED TO BE HEAR LAST WEEK AND NOW THEY ARE TELLING US THAT IT MAY BE MIDDLE OF NEXT MONTH BEFORE IT GETS HERE! WE HAVE CHILDREN AND ARE VERY WORRIED ABOUT WHAT WILL HAPPEN IF THIS IS NOT FIXED VERY SOON! MECHANIC SAID THAT ALL 2004 EXPLORERS ARE HAVING THIS PROBLEM AT ABOUT 15,000 MILES WHICH IS WHEN THIS BEGAN IN OURS. VERY WORRIED!!!!! *JB
Engine and engine cooling, Structure, Nov 5, 2004
WHILE DRIVING SMOKE BEGAN COMING FROM THE ENGINE COMPARTMENT, THE ENGINE BOGGED DOWN AND THE ENGINE STALLED. *NM THE ENGINE RAN ROUGHLY AND SMOKE EMITTED FROM THE VEHICLE. SINCE THE REPAIR THE CONSUMER NOTICED A HISSING NOISE COMING FROM THE AIR CONDITIONER. AIR COMING THROUGH THE WINDSHIELD WAS THE REASON FOR THE NOISE COMING FROM THE AIR CONDITIONER. THE WINSHIELD WAS REMOVED AND RESEALED. *TC *JB
Service brakes, Hydraulic, Seat belts, Nov 5, 2004, crash
OCTOBER 28, 2004, MOTOR VEHICLE ACCIDENT, CHAIN REACTION 3 VEHICLE, I WAS AT FULL STOP WITH FOOT ON BRAKE. VEHICLE BEHIND ME STOPPED, NEXT VEHICLE DID NOT STOP, PUSHED VEHICLE BEHIND ME INTO AND UNDER THE DRIVER SIDE REAR OF MY VEHICLE. BUMPER DAMAGE, TRUCK BED TWISTED SEVERAL INCHES, ETC. MY SEAT BELT DID NOT HOLD/CATCH OR STOP MY FORWARD MOVEMENT. I WAS THROWN INTO THE STEERING WHEEL AND THEN SNAPPED BACK, INJURING MY HEAD, NECK, MID AND LOW BACK, I HAD NUMBNESS AND TINGLING BILATERAL LOWER EXTREMITIES, AND BILATERAL UPPER EXTREMITIES. I ALSO EXPERIENCED SEVERE MUSCLE SPASMS NECK AND MID BACK. I HIT THE STEERING WHEEL HARD. THE AIR BAG DID NOT ENGAGE. PASSENGER SEAT BELT ENGAGED AND PROTECTED MY PASSENGER. I WAS TAKEN TO AN EMERGENCY HOSPITAL, C-SPINE/BACKBOARD, NECK AND BACK SPASMS, LOTS OF PAIN, TINGLING BILATERAL ARMS AND LEGS, ETC. NOW UNABLE TO WORK, UNKNOWN TIME DUE TO NECK AND BACK INJURY. I AM AN ER NURSE. IF MY SEAT BELT HAD HELD ME, I WOULD PROBABLY BE AT WORK RIGHT NOW AND NOT WRITING THIS COMPLAINT. YOUR QUESTION OF NUMBER OF FAILURES: THE BELT CATCHES ABOUT 1 IN 30 OR MORE ATTEMPT TO GET IT TO HOLD/CATCH. I AM AWAITING A SCHEDULED MRI OF MY SPINE, AND WILL BE FOLLOWING UP WITH A NEUROLOGIST. THE SEAT BELT HAS NOT BEEN REPAIRED AT YET AND REMAINS FAULTY. *AK
Power train, Nov 4, 2004
THE VEHICLE CONTINUED TO GO INTO 4- WHEEL DRIVE ON ITS OWN. THE VEHICLE ACCELERATED, THEN STALLED. THE MECHANIC WAS UNABLE TO DUPLICATE THE PROBLEM. *JB THERE WERE SEVERAL TIMES WHEN THE VEHICLE WAS PLACED IN REVERSE OR FORWARD THE VEHICLE WOULD BUCK. *SC
Power train, Nov 3, 2004
1- IN REVERSE VEHICLE PAUSES- THEN PROCEEDS TO SURGE BACKWARD. TOOK TO DEALERSHIP- THEY FIXED IT- ADV BAD TRANSMISSION SENSOR. 2- VEHICLE WOULD GO FROM 65- TO - 40 AS IF I WAS HITTING THE BRAKE. TOOK TO DEALER - THEY ADVERTISING GENERAL CODE READ FINE FOR ABOUT 2 MONTHS. 3- NOW IT HAS ACTUALLY BEGAN TO DIE INSTEAD OF JUST STALLING AND HESITATING. NOW THEY ADVISE ITS THE THROTTLE SENSOR. IN ALL 3 CASES - THE LITTLE WRENCH COMES ON AND THE CHECK ENGINE LIGHT. THIS IS A 2004 BOUGHT BRAND NEW AND ONLY HAS 16,450 MILES ON IT....... WHAT WILL GO WRONG NEXT?? LAST DATE IS LISTED BELOW THE STALLING IS AN ON/OFF THING. *AK
Power train, Vehicle speed control, Nov 3, 2004
WHEN SHIFTING GEARS FROM DRIVE TO REVERSE A HEAVY KNOCKING NOISE IS PRODUCED. *AK THE GEAR SELECTOR WOULD HANG UP IN DRIVE AND THE SELECTOR DID NOT RETURN. THE VEHICLE WOULD ALSO UNEXPECTEDLY JUMP OUT OF DRIVE. THE SHIFT SOLENOID WAS REPLACED BUT THE PROBLEM REMAINED THE SAME. *SC
Power train, Nov 2, 2004
MY 2004 FORD EXPLORER XLT MAKES A CLUNKING NOISE AND HARSHLY SHIFTS WHEN GOING INTO REVERSE. SOMETIMES THERE IS A LAG OF UP TO 5 SECONDS BEFORE ENGAGING INTO REVERSE, WHICH MAY PUT ME IN DANGER WHEN TRYING TO TURN AROUND IN TRAFFIC. *AK
Engine and engine cooling, Oct 31, 2004
I BOUGHT A 2004 FORD EXPLORER XLT AT DARCARS TOYOTA IN SILVER SPRING MD. IT HAD ONLY 28,000 MILES. THE PLASTIC VALVE COVER WAS FOUND TO HAVE A CRACK WHERE ONE POURS THE OIL IN. THERE WAS AN OIL LEAK AROUND THIS AREA. APPLE FORD IN COLUMBIA, MD. SAID THIS WOULD NOT BE COVERED BY FORD WARRANTY. I THOUGHT FORD'S WARRANTY COVERS TO 3 YEARS OR 36,000 MILES. THIS VALVE COVER WAS OVER $400.00. WHY SHOULDN'T THIS BE COVERED. I SIGNED A PAPER THAT STATES THAT THE FORD WARRANTY SHOULD STILL BE IN EFFECT TO 36,000 MILES. I DON'T KNOW HOW OR WHEN THIS CRACK OCCURRED, BUT I HAVE ONLY HAD THE VEHICLE FOR 3 WEEKS. I THINK THIS SHOULD BE COVERED BY FORD WARRANTY. *JB
Power train, Oct 26, 2004
WHEN REVERSING, LOUD BANGING/CLUNKING NOISE IS HEARD FROM THE BACK. THE CAR JERKS BACK HARSHLY.*AK
Power train, Oct 21, 2004
WHEN PUTTING TRANSMISSION IN REVERSE IT HESITATES AND SLAMS IN TO GEAR. VERY LOUD HUMMING NOISE IN REAR WHEN IN ANY SPEED OF ACCELERATION. VEHICLE IS GOING TO DEALERSHIP TOMMOROW.
Visibility, Equipment, Oct 13, 2004
CAR WAS PARKED IN A DRIVEWAY WITH REAR WINDOW TOWARDS GARAGE DOOR. THE BACK WINDOW OF THE CAR ALONG WITH A PIECE OF THE ACTUAL DOOR EXPLODED OFF. THE PIECE OF THE DOOR FLEW UP INTO THE AIR AND CAME CRASHING BACK DOWN ONTO THE CAR. THEIR WAS GLASS EVERYWHERE. HAD ANYONE BEEN FACING THE CAR IT COULD HAVE CAUSED SOME SERIOUS BODILY INJURY. OR HAD THE CAR BEEN IN MOTION ANYONE INSIDE THE CAR COULD HAVE BEEN HURT OR ANYONE DRIVING BEHIND COULD HAVE BEEN HURT.*AK
Power train, Oct 8, 2004
WHEN SHIFTING TO REVERSE- STEP ON GAS - DOES NOT ENGAGE THEN SUDDENLY A CLUNK AND TAKES OFF VERY FAST IN REVERSE- WORRIED ABOUT HITTING SOMEONE- DEALER HAS REFLASHED & THEN REPLACED SOLENOID IN TRANSMISSION PROBLEM STILL EXISTS. *NM
Power train, Oct 6, 2004
VEHICLE WAS TAKEN TO DEALER FOR TRANSMISSION PROBLEM. CONSUMER WAS TOLD THAT WHEN PLACING VEHICLE IN REVERSE, IT JERKED, AND SOMETIMES IT RACED. CONSUMER WAS TOLD THAT PART OF THE TRANSMISSION NEEDED TO BE REPLACED. *AK
Power train, Sep 27, 2004, crash
TRANSMISSION GOT STUCK IN NEUTRAL WHEN COLUMN SHIFTER WAS PUT IN THE PARK POSITION. AS MY WIFE GOT OUT TO HELP HER SISTER WITH HER NEW BORN AND BAGGAGE THE EXPLORER STARTED ROLLING, MY NIECE (IN THE BACK SEAT) GOT SCARED AND JUMPED OUT OF THE VEHICLE AND GOT RAN OVER. THE VEHICLE HIT A POLE AND TRAPPED MY NIECE UNDER THE REAR TIRE. I HAVE SINCE TAKEN IT TO DEALERSHIP 3 TIMES SO FAR, AND IT IS STILL NOT FIXED. ACTUALLY SINCE I HAVE GOTTEN THE EXPLORER BACK IT HAS STARTED TO CLUNG REALLY HARD GOING INTO REVERSE, AND HAS GOT STUCK BETWEEN THIRD AND FOURTH GEAR. WHILE DRIVING, CAUSING THE RPMS TO SHOOT UP. I AM WAITING ON FORD TO FINALLY RESOLVE THIS ISSUE AS I HAVE BEEN GIVEN THE RUN AROUND AND AM GETTING VERY FRUSTRATED.*AK
Power train, Sep 21, 2004
PLACING THE VEHICLW IN REVERSE, VEHICLE HESITATES AND THEN ENGAGES WITH A "CLUNK"; SHIFTING INTO DRIVE THE SAME PHENOMENON OCCURS RANDEMLY. THE MAJOR CONCERN IS THAT THIS JUMPING INTO GEAR HAPPENS SPORADICALLY AS WELL !*AK
Power train, Sep 20, 2004
CONSUMER HAD PROBLEMS WITH THE AUTOMATIC TRANSMISSION. EACH TIME THE VEHICLE WAS BACKED UP, IT WOULD HESITATE WHEN PLACED IN DRIVE. THE VEHICLE ALSO LEAPED FORWARD WITH THE CONSUMERS FOOT ON THE BRAKE, IT WAS PLACED IN DRIVE AND THE VEHICLE DID NOT MOVE. *SC THE VEHICLE WAS A RENTAL. *JB
Power train, Sep 17, 2004
ENGAGING THE TRANSMISSION IN "REVERSE" IT HESITATES, SLIPS THEN SURGES. LOUD BANGING/CLUNKING NOISES HEARD, SOUNDS LIKE UNIVERSAL JOINT. DEALER STATES PARTS ON ORDER. APPARENTLY THIS IS A KNOWN DEFECT TO FORD, DEALER BLAMES IT ON A DEFECTIVE SERVO, SYNCHRO OR SOLINOID. AWAITING NATIONWIDE BACK ORDERED PARTS FROM THE SAME MANUFACTURE, WHAT MAKES ME THINK THAT THIS SAME PART WON'T AGAIN FAIL. WHAT IS FORD'S RESPONSIBILITY REGARDING WARRANTY EXTENSION FOR THE TRANSMISSION WHICH STILL IS ENCOUNTERING THE SAME PROBLEMS AS I AWAIT THE REPAIR PARTS? SOUNDS LIKE A SAFETY PROBLEM TO ME.*AK
Service brakes, Hydraulic, Sep 14, 2004
THE BRAKE LINE IS LEAKING FLUID. THIS WOULD CAUSE THE PEDAL TO GO TO THE FLOOR WHEN DEPRESSED AND EXTENDED STOPPING DISTANCE. THE DEALERSHIP WAS NOTIFIED, BUT DID NOT RESOLVE THE PROBLEM. PLEASE PROVIDE MORE INFORMATION.
Engine and engine cooling, Sep 13, 2004
WHILE DRIVING VEHICLE STALLED. CONSUMER PULLED OVER AND RESTARTED THE VEHICLE. DEALERSHIP WAS NOTIFIED, BUT DID NOT RESOLVE THE PROBLEM. *AK
Power train, Sep 10, 2004
GRINDING FEEL FROM THE REAR END RESULTED IN A REPLACED AND UPDATED COMPLETE REAR END FROM FORD. STILL HAVE VERY LOUD WHINING NOISE WHEN AUTOMATIC TRANSMISSION IS IN FIRST GEAR. DEALER SAYS THIS IS NORMAL AND I HAVE TO GET USE TO IT. ALSO HAVE NOTICABLE THUMPING FROM TRANSMISSION AND DRIVE SHAFT AREA WHEN BETWEEN 30 AND 50 MPH. DEALER HAS VERIFIED NOISE AND IS CONSIDERING A NEW DRIVE SHAFT. CAR IS NEW AND HAS LESS THAN 3000 MILES.