The 2004 Ford Expedition has 4 safety recalls and 297 owner complaints on file with NHTSA. The most-reported problem area is air bags (50 complaints).
Recalls4safety recalls
Complaints297filed by owners
Crashes · fires49 · 15reported in complaints
Injuries · deaths60 · 1reported in complaints
2004 Ford Expedition in an NHTSA crash test
Safety recalls
Exterior lighting
NHTSA recall 09E012000 · Apr 7, 2009 · 16,270 vehicles · opened after NHTSA action (OVSC)
Problem: SABERSPORT IS RECALLING 16,270 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.
Risk: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Fix: SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON MAY 11, 2009. OWNERS MAY CONTACT SABERSPORT AT 1-909-598-7589.
Exterior lighting
NHTSA recall 06E064000 · Jul 17, 2006 · 4,029 vehicles · opened after NHTSA action (OVSC)
Problem: CERTAIN TRADESONIC COMBINATION LAMPS SOLD AS REPLACEMENT LAMPS FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. COMBINATION LAMPS NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
Risk: LACK OF AMBER SIDE REFLECTORS IN THE LAMPS WILL DECREASE LIGHTING VISIBILITY TO OTHER DRIVERS AND MAY POSSIBLY RESULT IN A VEHICLE CRASH.
Fix: TRADESONIC WILL NOTIFY OWNERS AND REPLACE THE LAMPS FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING JULY 2006. OWNERS MAY CONTACT TRADESONIC AT 626-934-8884.
Exterior lighting
NHTSA recall 06E026000 · Mar 23, 2006 · 61,944 vehicles · opened after NHTSA action (OVSC)
Problem: 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.
Risk: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
Fix: 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.
Exterior lighting › Headlights
NHTSA recall 06E023000 · Mar 13, 2006 · 292,000 vehicles · opened after NHTSA action (OVSC)
Problem: CERTAIN ANZO COMBINATION HEADLAMP ASSEMBLIES SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES. SOME COMBINATION LAMPS ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS WHICH FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT."
Risk: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH.
Fix: ANZO WILL NOTIFY OWNERS AND REPLACE THE HEADLAMPS FREE OF CHARGE. THE RECALL BEGAN MAY 9, 2006. OWNERS MAY CONTACT ANZO USA AT 909-468-3688.
Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.
Crash test ratings
2004 Ford Expedition 4-DR.
Overall
Not Rated
Frontal crash
Not Rated
Side crash
Not Rated
Rollover
Not Rated
NHTSA 5-Star Safety Ratings (New Car Assessment Program). Ratings are comparable only between vehicles of similar size and weight, and ratings from 2011 on use tougher tests than earlier years. Photos: NHTSA.
Fuel economy
Expedition 2WD
15mpg combined
City / highway
14 / 18 mpg
Fuel
Regular Gasoline
4.6 L · 8 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,450/year to fuel
Expedition 2WD
14mpg combined
City / highway
12 / 16 mpg
Fuel
Regular Gasoline
5.4 L · 8 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,800/year to fuel
Expedition 4WD
14mpg combined
City / highway
12 / 17 mpg
Fuel
Regular Gasoline
4.6 L · 8 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $4,800/year to fuel
Expedition 4WD
13mpg combined
City / highway
12 / 16 mpg
Fuel
Regular Gasoline
5.4 L · 8 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $5,150/year to fuel
EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.
What owners report
Problem area
Complaints
Crashes
Fires
Injuries
Typical mileage*
Air bags Frontal; Side/window
50
33
1
52
87,000 mi
Electrical system 12v/24v/48v battery; Starter assembly › Relay
37
1
2
1
102,500 mi
Service brakes, hydraulic Foundation components › Disc › Pads; Antilock/traction control/electronic limited slip
35
8
2
2
14,596 mi
Engine
29
0
4
0
141,000 mi
Power train Automatic transmission; Automatic transmission › Gear position indication (prndl)
28
1
0
0
31,000 mi
Tires Pressure monitoring and regulating systems; Tread/belt
27
2
0
9
38,650 mi
Engine and engine cooling Engine; Exhaust system › Manifold/header/muffler/tail pipe
26
0
3
1
75,000 mi
Structure Body; Body › Door
25
0
0
0
85,000 mi
Vehicle speed control Cruise control
21
5
3
0
30,060 mi
Fuel/propulsion system
19
0
0
0
138,000 mi
Visibility Power window devices and controls; Glass, side/rear
15
0
0
0
87,500 mi
Steering Hydraulic power assist system; Rack and pinion
14
3
0
2
42,159 mi
*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.
Recent owner complaints
Oct 7, 2026 · crash · 2 injuriesAir bags I was in a collision with another car. The brakes failed.\n Going over 3540 miles per hour, airbag and passenger side and drivers side neither one deployed.
Feb 25, 2026Power train The contact owns a 2004 Ford Expedition. The contact recently purchased the vehicle and stated that while driving at an undisclosed speed, the transmission hesitated before upshifting with the accelerator pedal depressed. Additionally, while stopped at a traffic light, the vehicle rolled backwards when the accelerator pedal was depressed before responding as needed. There was no warning light illuminated. The contact attempted to return the vehicle to the independent dealer where the vehicle was purchased; however, the dealer declined to assist. Recently, the vehicle stalled, and it was towed to an independent mechanic to be diagnosed. The mechanic retrieved fault codes for the engine and…
Feb 6, 2025Electrical system The contact owns a 2004 Ford Expedition. The contact stated that the turn signals, the hazard lights, and the cigarette lighter had become inoperable. The TPMS warning light was illuminated. The dealer and the manufacturer were not notified of the failure. The vehicle was not diagnosed or repaired. The failure mileage was unknown.
Jan 11, 2003Exterior lighting Just bought this truck I have no idea what has or has not been resolved, very poor lighting I noticed and there's a click noise coming from? It just clicks and clicks and clicks. Thanks
Nov 5, 2022 · 110,665 milesSteering The contact owns a 2004 Ford Expedition. The contact stated while driving approximately 10 MPH, the vehicle lunged forward while depressing the accelerator pedal. The contact was unable to drive above 15 MPH because the vehicle became difficult to control. The contact stated that the check engine warning light was illuminated. The contact had taken the vehicle to an independent mechanic who diagnosed and determined that the rear axle was fractured, the rear subframe was severely corroded, and the rear driver's side sway bar and rear differential were corroded. The vehicle had not been repaired. The manufacturer had not been informed of the failure. The failure mileage was 110,665.
Oct 11, 2022 · 127,708 milesEngine The contact owns a 2004 Ford Expedition. The contact stated while driving at 40 MPH, the vehicle shut down completely, and the warning messages indicated check gage and check service engine. The contact was able to pull over on the side of the road. The dealer was not contacted. The manufacturer was not made aware of the failure. The failure mileage was 127,708.
May 14, 2022 · 87,000 milesEngine The contact owns a 2004 Ford Expedition. The contact stated that while her daughter was driving at an undisclosed speed, the vehicle was jerking. The contact stated that one spark plug exploded and then another spark plug exploded and went through the cylinder head. The contact called the local dealer but the vehicle was not diagnosed or repaired. The vehicle was taken to an independent mechanic where the spark plug was replaced. The manufacturer was notified and referred the contact to the NHTSA for assistance. The failure mileage was approximately 87,000.
Jan 24, 2022 · fireElectrical system Electrical fire today. Vehicle was parked outside garage. A clicking noise was heard and noticed the mirror was trying to move/click and car was filled with smoke. Mirror switches didn't work when tried. Knocked mirror off and fire stopped. Wiring Harness around the emergency brake area melted. Fire melted a hole in the dash corner by windshield. Vehicle was last driven about 25 hrs. earlier with no issues. Approx. 128K miles. Glad it wasn't in garage and the clicking was heard or garage/house would have burned. We haven't done anything to it yet.
Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.
NHTSA defect investigations
PE08070 · opened Dec 9, 2008 · closed Apr 15, 2009STEEL WHEEL FRACTURE FORD SPECIAL SERVICE VEHICLE (SSV) EXPEDITIONS USE A STEEL FULL FACE WHEEL DESIGN SIMILAR TO THAT INVESTIGATED IN PE03009, RQ04007, EA04034 (CROWN VICTORIA POLICE INTERCEPTOR) AND PE03026 (GM PICKUPS AND SUVS).A TOTAL OF 8,251 SSVS (2.2% OF TOTAL PRODUCTION) WERE PRODUCED WITHIN MODEL YEARS 2004-2006 AND SOLD PRIMARILY FOR USE BY STATE, FEDERAL, AND MUNICIPAL LAW ENFORCEMENT (LE) AGENCIES.FORD STIPULATES THAT THE SUBJECT VEHICLES ARE NOT SUITABLE FOR HIGH SPEED OR PURSUIT OPERATIONS AND ALSO IDENTIFIED A 2004 NATIONAL INSTITUTE FOR JUSTICE VEHICLE EVALUATION REPORT WHICH ALSO ACKNOWLEDGES THIS LIMITATION. THE FULL FACE WHEEL IS FABRICATED FROM TWO PIECES: A STAMPED OUTER WHEEL DISC AND A FORMED RIM.THE TWO PIECES, WHICH TOGETHER COMPRISE THE OUTER BEAD SEAT, ARE JOINED TOGETHER WITH A CIRCUMFERENTIAL WELD.A CYCLIC BENDING MOMENT OCCURS IN THE OUTER BEAD SEAT AREA AS THE WHEEL ROTATES,…
DP05005 · opened Sep 22, 2005 · closed Jan 4, 2006SPARK PLUG EJECTION FROM CYLINDER HEAD ON SEPTEMBER 6, 2005, ODI RECEIVED A PETITION REQUESTING THAT THE AGENCY INVESTIGATE ALLEGATIONS OF ENGINE SPARK PLUG EJECTION IN CERTAIN MODEL YEAR 1997 THROUGH 2004 FORD VEHICLES WITH TRITON V-8 AND V-10 ENGINES.ODI RECEIVED A TOTAL OF 474 NON-DUPLICATIVE COMPLAINTS ON THE SUBJECT VEHICLES WHERE THE COMPLAINANT, OR THE DEALER REPAIRING THE VEHICLE, REPORTED THAT A SPARK PLUG DETACHED FROM THE CYLINDER AND/OR EJECTED FROM THE ENGINE.AS OF DECEMBER 8, 2005, ODI IS NOT AWARE OF ANY ALLEGATIONS WHERE THE ALLEGED DEFECT RESULTED IN A LOSS OF VEHICLE CONTROL, A CRASH, AN INJURY, OR A FATALITY IN ANY OF THE 10,319,810 SUBJECT VEHICLES.IN ADDITION, ODI IS AWARE OF ONLY TWO INCIDENTS WHERE THE VEHICLE STALLED WITHOUT RESTART.INFORMATION CONTAINED IN THE ODI CONSUMER COMPLAINTS AND OBTAINED FROM 72 TELEPHONE INTERVIEWS WITH COMPLAINANTS SHOWED THE FOLLOWING:(1) 99% OF THE COMPLAINTS WERE ON MY…
