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.
Fuel/propulsion system, Jun 29, 2014
FUEL GAUGE DOESN'T NOTICE WHEN YOU GO FROM AN EMPTY TANK TO FULL. STILL READING NO CHANGE. THEN SLOWLY WILL CLIMB TO THE PROPER AMOUNT OF FUEL WITHIN AN HOUR. THERE IS NO WAY TO ACCURATELY TELL HOW MUCH FUEL IS IN THE VEHICLE. *TR
Structure, Engine, Jun 24, 2014
THE BACK HATCH WINDOW DOESN'T SEEM TO LINE UP WITH THE LATCH. THE BACK HATCH ALSO CRACKED RIGHT NEAR THE FORD LOGO. I HAVE SEEN MANY OF THE EXPLORERS THAT THIS HAS HAPPENED TO. ITS TIME FORD FIXES THIS DEFECT. ALSO WHILE DOING AROUND 60-65 MPH MY TIMING CHAINS BROKE, ALL 3 OF THEM AT THE SAME TIME. I COULD UNDERSTAND 1 MAYBE BUT ALL 3 ? THIS TO HAS TO BE A MANUFACTURER DEFECT. *TR
Visibility, Jun 24, 2014
WHILE OPENING THE SMALLER WINDOW IN THE BACK OF THE CAR, THE WINDOW STARTED TO FALL. LUCKILY THERE WERE TWO PEOPLE TO CATCH IT. I NOTICED THE PASSENGER SIDE HINGE WAS BROKEN. WE USUALLY TAKE OUR INFANT AROUND TO THE BACK OF THE CAR WHILE WE LOAD THINGS. FORTUNATELY, WE HAD ALREADY BUCKLED HER IN. HAD THE GLASS FALLEN OR WE NOT PAID ATTENTION , IT COULD HAVE SERIOUSLY INJURED HER OR US. *TR
Visibility/wiper, Jun 23, 2014
IN WINTER THE BLEND FOR ACTUATOR WENT OUT IN EXPLORER AND LEFT ME WITH NO GREAT SO WHEN I DRIVE I HAVE TO CONTINUE TO TRY AND WIPE FROST OFF OF THE INSIDE OF WINDSHIELD IT IS DANGEROUS TO HAVE TO DRIVE VEHICLE IN WINTER AND ALWAYS WIPING WINDOWS ESPECIALLY WITH KIDS IN THE CAR THERE ARE MANY REPORTS OF THIS HAPPENING IN THIS MODEL AND YEAR OF VEHICLE THIS IS DEFINITELY A SAFETY ISSUE YOU ARE DRIVING DOWN ROAD AT NIGHT AND AS SOON AS YOU PASS A CAR THE CARS HEADLIGHTS MESS WITH FROST ON WINDOW AND IT IS BLINDING NOT TO MENTION WHEN IT RAINS AND THE WINDOWS STEAM UP AND YOU CAN'T SEE THEN EITHER. *TR
Power train, Structure, Jun 18, 2014
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR WHEEL WELLS AND FRAME WERE RUSTED. AND THE REAR HATCH WAS FRACTURED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE MILEAGE WAS 40,000 AND THE CURRENT MILEAGE WAS 100,000. UPDATED 09/30/14*LJ THE CONSUMERS STATED THE TRANSMISSION JERKS INTO GEAR. UPDATED 02/25/2015 *JS
Wheels, Jun 17, 2014
WHEN DRIVING TO WORK I BEGAN TO HEAR A NOISE IN THE FRONT END PART OF THE VEHICLE. AFTER LEAVING WORK AND DRIVING LESS THAN 1 MILE THE NOISE GOT LOUD, SO I PULLED OVER AND WAITED FOR A TOW TRUCK. HAD THE VEHICLE TOWED TO A SHOP AND FIXED. 1 YEAR AND 1 WEEK LATER IT HAD TO BE REPLACED AGAIN. *TR
Wheels, Jun 16, 2014, fire
DAUGHTER DRIVING VEHICLE, RIGHT WHEEL BEARING CEASED, CAUSING REAR END OF VEHICLE TO FISH TAIL, HAD TO DRIVE HOME ON BACK ROAD (NOT HIGHWAY) AS THE VEHICLE WOULD HAVE FLIPPED. CAR WAS SMOKING SO BAD, COULD NOT BE PLACED INTO GARAGE AS IT WOULD HAVE BURNED DOWN THE HOUSE. HAD TO BE TOWED, DAMAGED FROM BEARING TO REAR AXEL AND EMERGENCY BRAKE/CABLES. IF SHE WERE ON THE HIGHWAY SHE WOULD HAVE BEEN KILLED. THERE ARE MULTIPLE COMPLAINTS ABOUT THIS PROBLEM, WHAT WILL IT TAKE? ANYONE HEARD OF ANY CLASS ACTIONS TO MAKE FORD STEP UP TO BAT AND RECALL THESE UNSAFE VEHICLES? *TR
Structure, Jun 13, 2014
WHEN CLOSING REAR PANEL, THE PANEL CRACKED. *JS
Power train, Engine, Jun 12, 2014
WHEN ACCELERATING THE SUV SHAKES, IT HAS A HARD TIME SOMETIMES GOING FROM ONE GEAR INTO ANOTHER. I STARTED THE TRUCK TODAY AND IT MADE A THUMPING SOUND. THE TRANSMISSION IS GOING ON IT AND I TAKE CARE OF IT. I HAVE A HARD TIME GETTING THE TRUCK TO GO INTO GEAR TO GO IN REVERSE. *TR
Suspension, Jun 5, 2014
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THERE WAS AN ABNORMAL NOISE COMING FROM THE FRONT END OF THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN DIAGNOSED THAT THE DOME OVER THE SHOCK ABSORBER WAS RUSTED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE AND CURRENT MILEAGE WAS 117,000. UPDATED 08/11/2014*LJ THE CONSUMER STATED FORD WOULD NOT REPAIR THE VEHICLE. THE VEHICLE WAS TRADED IN TO FORD WITH A REDUCED AMOUNT TO THE TRADE IN ALLOWANCE BECAUSE OF THE FAILURE. UPDATED 08/12/2014 *JS
Power train, May 19, 2014
TL * THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE DRIVING 40 MPH, THE VEHICLE WOULD DECELERATE AUTOMATICALLY TO 20 MPH AND NOT REGAIN SPEED. THE VEHICLE WOULD ALSO NOT SHIFT INTO REVERSE. THE FAILURE OCCURRED TWICE OVER A SIX YEAR PERIOD. THE VEHICLE'S TRANSMISSION HAS BEEN REPLACED TWICE. THE VEHICLE WAS NOT TAKEN TO A DEALER. THE MANUFACTURER WAS NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 22,000.
Structure, May 15, 2014
THE DOORS DON'T OPEN GOOD AND THE DOOR HANDLES BREAK. WE HAVE HAD FIXED TWICE AND THE PREVIOUS OWNER HAD FIXED ALSO! *TR
Structure, May 12, 2014
REAR GLASS LIFT GATE: CRACKS APPEARED IN THE REAR HATCH ON BOTH SIDES OF THE REAR FORD LOGO.( I NOW NOTICE MANY FORD EXPLORERS WITH SAME CRACKS). TOP RIGHT GLASS HINGE TWISTED SIGNIFICANTLY AND TOP LEFT GLASS HINGE TWISTED SLIGHTLY. THE FASTENING BOLTS FOR BOTH GLASS HINGES ARE RUSTED THROUGH. THIS RESULTED IN THE REAR GLASS WINDOW SHIFTING, APPARENTLY CAUSING THE CRACKS IN THE TAIL GATE. I CONTACTED SUNSHINE FORD'S SERVICE DEPT. IN NEWBURGH, NY AND WAS TOLD FORD IS NOT RESPONSIBLE FOR FIXING/REPLACING THIS DEFECT. THEY CHOSE THEIR WORDS CAREFULLY. THEY EMPHASIZED THAT "MY MODEL YEAR" WAS NOT RECALLED FOR THIS DEFECT. I ASKED IF "ANY" EXPLORERS HAD A RECALL FOR THIS DEFECT. THEY WOULD NOT SAY; BUT INSTEAD REPEATED,"MY MODEL YEAR" WAS NOT RECALLED FOR THIS DEFECT. NHTSA HAS ALREADY RECEIVED CONSUMER COMPLAINTS OF INJURIES FROM OWNERS WHOSE LIFT GATE GLASS BROKE OFF ITS MOUNTING HINGE WHILE OPEN, AND CAUSED HEAD INJURIES. IT IS ONLY A MATTER OF TIME BEFORE A REAR LIFT GLASS PANEL DETACHES FROM AN EXPLORER IN MOTION ON A HIGHWAY. THAT COULD EASILY LEAD TO A MULTI VEHICLE ACCIDENT ALONG WITH MULTIPLE FATALITIES. I CHECKED AND FORD HAD A SIMILAR PART RECALL FOR 2002 & 2003 EXPLORERS. FORD CHANGED THE PART THEN AND HAS NOT MET THE # OF COMPLAINTS TO BE FORCED TO RECALL 2004 AND UP EXPLORERS. UNFORTUNATELY, I THINK MANY EXPLORER OWNERS CHECK WITH THE DEALER AS TO WHETHER OR NOT THERE WAS/IS A RECALL AND GIVE UP UPON HEARING NO. WE NEED TO GET ANYONE WE KNOW WITH THIS PROBLEM TO FILE A COMPLAINT WITH THE NHTSA. IT IS ONLY A MATTER OF TIME BEFORE SOME INNOCENT PERSON DIES AS A RESULT OF THIS "KNOWN" DEFECT! AS I UNDERSTAND IT, THIS IS A KNOWN DEFECT FOR WHICH FORD IS NOT WILLING TO TAKE RESPONSIBILITY. FORD SHOULD FIX THIS PROBLEM AT NO COST. *TR
Electrical system, May 12, 2014
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE INDICATOR ON THE INSTRUMENT CLUSTER WOULD NOT PROPERLY SPECIFY WHAT GEAR THE VEHICLE WAS ENGAGED. THE VEHICLE WAS NOT TAKEN TO A DEALER FOR DIAGNOSTIC TESTING. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE AND CURRENT MILEAGE WAS 117,000. THE VIN WAS NOT AVAILABLE.
Power train, May 5, 2014
WHILE DRIVING MY EXPLORER DOWN THE HIGHWAY, THE TRANSMISSION BLEW WITH OUT MUCH WARNING WITH MY BABY IN THE CAR. THE VEHICLE WENT FROM DRIVABLE TO NOT MOVING WITHIN ONE DAY. IT STARTED WITH A HARD SHIFT AND ACCELERATION BEING DELAYED WHEN TRYING TO MAKE A TURN. THEN THE O/D LIGHT CAME ON AND THE VEHICLE LOST ALL POWER WITHIN TEN MILES OF MY HOME LEAVING US STRANDED IN THE DEAD OF WINTER ON THE HIGHWAY WITH VERY LITTLE ROOM TO PULL OVER SO WE COULD HAVE BEEN HIT AT HIGH SPEEDS. *TR
Service brakes, Apr 17, 2014, crash
STOPPING AT RED LIGHT STEPPING ON BRAKE VEHICLE SPEED UP INSTEAD OF STOPPING. CAUSING ME TO SIDE SWIPE FOUR VEHICLES AND GO THROUGH AN INTERSECTION
Power train, Apr 11, 2014
WHILE PARKED, I STARTED UP MY VEHICLE AND PUT THE TRUCK IN REVERSE. HOWEVER, THE TRUCK WOULD NOT REVERSE. I WAS ABLE TO DRIVE FORWARD AND TOOK MY VEHICLE TO MECHANIC. HE STATED THAT THE FORDS WERE "WELL KNOWN" FOR HAVING BAD TRANSMISSION DUE TO CERTAIN PIECES NOT FITTING, ESPECIALLY THE 2002-2006 MODELS. I SEARCHED ONLINE AND REALIZED THIS PROBLEM IS A LOT BIGGER THAN JUST "A FEW" CASES. THIS IS AN EPIDEMIC OF NEGLECT! ADDITIONAL ISSUES INCLUDE THE THROTTLE BODY FOR WHICH YOUR ESTABLISHMENT HAS ALREADY INVESTIGATED BUT LIMITED THE "RECALL" FOR YEARS 2009-2013. THIS SHOULD BE EXTENDED FURTHER TO COVER ALL INCIDENTS WITHIN A CERTAIN MILEAGE. MINE STARTED AROUND FIFTY THOUSAND MILES UNTIL I HAD IT REPLACED FOR $650! I REQUEST AN INVESTIGATION ON THE TRANSMISSION FAILURES, SPECIFICALLY WITH THE INABILITY TO REVERSE. *JS
Vehicle speed control, Mar 29, 2014
I WAS DRIVING AT APPROXIMATELY 45 MPG AND THE VEHICLE STARTED TO SLOW DOWN ON IT'S OWN IN THE MIDDLE OF TRAFFIC. I WAS CLOSE TO HOME AND ABLE TO GET IT INTO MY DRIVEWAY. I HAD TO HAVE IT TOWED TO THE SHOP WHERE THEY DIAGNOSED THAT THE ELECTRONIC THROTTLE BODY MODULE WAS BAD AND REPLACED IT AT A COST OF REPAIR OF $644.00. *TR
Visibility, Mar 24, 2014
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR LIFTGATE GLASS UNEXPECTEDLY SHATTERED WITHOUT ACCESSING THE DOOR. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 69,000. ...UPDATED 04-10-14 *BF UPDATED 04/22/14
Power train, Mar 10, 2014
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED WHILE DRIVING 10 MPH, THE TRANSMISSION FAILED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 130,000. *TR
Structure, Mar 7, 2014
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR LIFT GATE WAS FRACTURED DIRECTLY ON THE LOGO WHERE THE LIFT GATE LOCK WAS LOCATED. THE DEFECT COULD HAVE CAUSED THE REAR LIFT GATE TO OPEN WHILE DRIVING. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 14,000 AND THE CURRENT MILEAGE WAS 16,000. *TR
Structure, Mar 6, 2014
CRACKED PANEL BELOW REAR WINDOW, WENT TO GARAGE AND FOUND THIS, CRACKED ALL THE WAY THRU. *TR
Other or unspecified, Feb 27, 2014
DEFECTIVE BODY MOUNTS AND BUSHINGS. I AM THE OWNER OF A 2004 FORD SPORT TRAC AND WAS ADVISED THAT THE BODY MOUNTS AND BUSHINGS ARE DETERIORATED AND CRUMBLING. AFTER RESEARCHING THE PROBLEM I DISCOVERED THAT THIS IS A COMMON PROBLEM WITH THE SPORT TRAC YEARS 2001-2005. THIS IS A VERY SERIOUS PROBLEM AS WELL AS EXPENSIVE TO REPAIR. I CALLED A BODY SHOP AND THE PARTS ARE $1,695 WITH $720 FOR LABOR. THE FORD DEALERSHIP WANTS $1,882 FOR PARTS AND $400 LABOR TO REPLACE 6 MOUNTS EVEN THOUGH THE VEHICLE HAS EIGHT (8). FORD SHOULD BE MADE TO RECALL THESE VEHICLES AND REPLACE THE PARTS (THAT SHOULD LAST THE LIFE OF THE VEHICLE). EVIDENTLY NOT ENOUGH SERIOUS INJURIES OR DEATH HAS OCCURRED TO MAKE THIS HAPPEN, SO THEY JUST QUIT PRODUCTION AS A CHEAPER WAY OUT. SHAME ON FORD TO NOT TAKE CARE OF THEIR CUSTOMERS.
Seat belts, Structure, Feb 27, 2014
REAR LIFT GATE PLASTIC CRACKED THROUGH FORD LOGO WITH NO CONTACT. THIRD ROW SEATBELT STUCK AND HARD TO RELEASE.
Electrical system, Feb 26, 2014
TL* THE CONTACT OWNS A 2004 FORD EXPLORER SPORT TRAC. THE CONTACT STATED THAT THE IGNITION SWITCH WAS LOOSE. THE CONTACT TOOK THE VEHICLE TO BE DIAGNOSED AND WAS ADVISED BY AN INDEPENDENT MECHANIC THAT THE IGNITION SWITCH WOULD NEED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 112,437.