The 2004 Ford Explorer has 4 safety recalls and 1,304 owner complaints on file with NHTSA. The most-reported problem area is power train (473 complaints).
Recalls4safety recalls
Complaints1,304filed by owners
Crashes · fires58 · 15reported in complaints
Injuries · deaths83 · 0reported in complaints
2004 Ford Explorer in an NHTSA crash test
Safety recalls
Exterior lighting › Headlights
NHTSA recall 09E025000 · May 11, 2009 · 42,540 vehicles · opened after NHTSA action (OVSC)
Problem: 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.
Risk: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Fix: 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.
Visibility › Glass, side/rear
NHTSA recall 07E104000 · Dec 11, 2007 · 1,657 vehicles
Problem: 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."
Risk: IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT(S) MAY BE SERIOUSLY INJURED BY SHATTERED GLASS.
Fix: 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.
Exterior lighting
NHTSA recall 06E049000 · May 24, 2006 · 27,176 vehicles · opened after NHTSA action (OVSC)
Problem: 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.
Risk: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
Fix: 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.
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.
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
NHTSA side barrier crash test
2004 Ford Explorer 4-DR.
Overall
Not Rated
Frontal crash
Not Rated
Side crash
Not Rated
Rollover
★★★★★
Rollover risk
22.8%
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
Explorer 4WD FFV FFV
16mpg combined
City / highway
14 / 19 mpg
Fuel
Regular Gasoline
4 L · 6 cyl · Automatic 5-spd · 4-Wheel or All-Wheel Drive · about $4,200/year to fuel
Explorer 2WD FFV FFV
16mpg combined
City / highway
14 / 20 mpg
Fuel
Regular Gasoline
4 L · 6 cyl · Automatic 5-spd · Rear-Wheel Drive · about $4,200/year to fuel
Explorer 2WD
16mpg combined
City / highway
14 / 19 mpg
Fuel
Regular Gasoline
4 L · 6 cyl · Automatic 5-spd · Rear-Wheel Drive · about $4,200/year to fuel
Explorer 4WD
16mpg combined
City / highway
14 / 19 mpg
Fuel
Regular Gasoline
4 L · 6 cyl · Automatic 5-spd · 4-Wheel or All-Wheel Drive · about $4,200/year to fuel
Explorer 2WD
15mpg combined
City / highway
13 / 18 mpg
Fuel
Regular Gasoline
4.6 L · 8 cyl · Automatic 5-spd · Rear-Wheel Drive · about $4,450/year to fuel
Explorer 4WD
15mpg combined
City / highway
13 / 18 mpg
Fuel
Regular Gasoline
4.6 L · 8 cyl · Automatic 5-spd · 4-Wheel or All-Wheel Drive · about $4,450/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*
Power train Automatic transmission; Automatic transmission › Lever and linkage › Column shift
473
18
2
6
50,000 mi
Structure Body; Body › Hatchback/liftgate › Hinge and attachments
439
2
1
24
72,000 mi
Visibility Glass, side/rear; Power window devices and controls
102
0
0
8
67,226 mi
Vehicle speed control Cruise control; Accelerator pedal
76
10
5
6
73,500 mi
Engine and engine cooling Engine; Cooling system
72
1
5
1
55,150 mi
Electrical system Starter assembly; Instrument cluster/panel
57
1
1
0
51,000 mi
Engine
44
1
1
2
114,500 mi
Steering Hydraulic power assist system; Linkages › Tie rod assembly
42
2
1
1
88,385 mi
Wheels Lugs/nuts/bolts/studs; Rim
42
3
2
2
83,913 mi
Suspension Rear; Front
40
0
0
1
64,900 mi
Air bags Side/window; Frontal
39
21
0
33
109,000 mi
Unknown or other
35
1
0
2
91,515 mi
*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.
Recent owner complaints
May 8, 2024Service brakes on [XXX] brought to local shop on power steering leak. Week before, Paid $50 for inspection. on [XXX] appointment was line and replaced. But tech said get pass brake line was rotted and was bad leak of brake fluid. On [XXX] my wife's Explorer was reinspected and rear driver side brake copper line also reported rotted after paying $539.95 for power steering low pressure and brake line. Wife's Eddie Bauer 2004 v8 was reported to FORD Motor Co. Case# [XXX] defective copper brake lines on suv. No good will offered no warrantee fue to latent defective brake line copper tubing coming from ABS modular. ABS LIGHT COMES ON AT TIMES. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT…
Feb 8, 2024Fuel/propulsion system I need a new gas tank for my vehicle and Ford stopped making the gas tank for my vehicle. That is a very big safety issue. I called Ford and they were helping to find one from junkyard's I don't want one from a junkyard that I have to repair. I asked for Ford to make a gas tank or pay for them to have mine fixed right at a Ford dealership, no help. That's a big safety problem. Ford provided the contacts phone number to the junkyards but the contact doesn't want the gas tank from a junkyard who probably put holes in them to drain the gasoline out of the tank.
Jul 16, 2023 · fireFuel/propulsion system Smoke for a good 5 mins under the hood oil leeking
Jan 19, 2023Engine Back windows fell off track and windows fell down, cannot roll them up. AC and Heater broke and won't work at all. Fuel system is too lean. Transmission is going out Timing Chain and tensioners making loud knocking noise. Burning oil.
Aug 29, 2022 · 153,000 miles · crash · 2 injuriesAir bags The contact's son owned a 2004 Ford Explorer. The contact stated that while her son was driving in the rain at approximately 35 MPH, the vehicle hydroplaned as he rounded a corner. The vehicle slid into a ditch and hit a tree on the passenger side of the vehicle. The air bags did not deploy upon impact. The contact's son and his friend were both transported to the hospital for their injuries. Her son was treated for soreness in various parts of his body and was released the same day. Her son's friend had to remain in the hospital overnight and his injuries were unknown. A police report was filed. The vehicle was towed from the independent collision center where it remained in their…
Nov 4, 2021Steering On two incidents this week when steering wheel is cut to maximum left or right in tight parking lot and narrow road while making tight turns at legal speeds the engine (V8 4.6L) stalls. Brought to non-Ford mechanic for inspection(NYS ANNUAL) and passes but mechanic looked for a power steering pressure sending sensor or switch that is to give signal to EMC to increase idle to compensate for more power steer demands. Part is $35 at Partgeek but mechanics dont know where the harness the sending switch is located, if one exists or is it in power steering pump. Call Ford NADA! Call two local Ford dealers. One says dont work on cars 15 years old, other says go to liabary to get diagrams, Ford…
Jul 13, 2021Wheels on 5/6/21 at Ramp Ford 4869 Nesconset Hwy.,Pt. Jeff.Sts.,NY at 10:00am dealer sevice Mgr. met with NYSDMV Auto Facilities Inspector on a claim against Mavis Discount Tire,556 Route 25A, Mt Sinai,NY case 1Pi-01937 on a right rear wheel. Ramp removed R/R wheel to inspect with state inspector, appears like axle nut on r/r has not been removed r/0361772. On 7/12/21 Mt. Sina Tire r/0 7828-18 when fixing a tire flat, found r/r one broken stud,one addition lug nut missing from r/r wheel. Immediately Ramo service manager denied his tech improperly reassembled r/r wheel nuts on all five wheel assembly studs. With three studs the Ford vehicle was in inimanent highway danger. Such lost of 40% of wheel…
Apr 21, 2021 · 96,125 milesTires MICHELIN CROSSTERRAIN TIRES SUFFERING TREAD SEPARATION. THREE OUT OF FOUR SO FAR. HAD I NOT BEEN PAYING ATTENTION TO THIS PROBLEM IT WOULD HAVE HAPPENED ON THE HIGHWAY..
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
EA09013 · opened Aug 18, 2009 · closed Feb 12, 2013Vehicle Rollaway Allegations This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for any particular failure mechanism, the failure of the Automatic Transmission Parking System, was 4.4/100K.The next-highest failure rate was for the BSI System, at 3.4/100K.For all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent years.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.For additional information…
PE09020 · opened Apr 21, 2009 · closed Aug 19, 2009VEHICLE ROLLAWAY ALLEGATIONS IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), FORD STATED CONSUMER REPORTS OF HIGHER THAN EXPECTED EFFORTS WHEN SHIFTING INTO AND OUT OF PARK COULD BE A RESULT OF A GROOVE BEING WORN INTO THE SWING ARM RAMP OF THE STEERING COLUMN. THE SWING ARM IS A COMPONENT BOLTED TO THE STEERING COLUMN THAT ASSISTS IN SHIFTING THROUGH THE TRANSMISSION GEARS.AN ENGINEERING EVALUATION CONDUCTED BY FORD OF RETURNED STEERING COLUMNS FOUND THE GROOVE COULD BE CREATED OVER TIME IF CONSUMER SHIFT MORE QUICKLY FROM THE DRIVE OR REVERSE TO PARK THAN THE BRAKE SHIFT INTERLOCK (BSI) SOLENOID PIN RETRACTS AFTER THE BRAKE PEDAL IS APPLIED. IN NOVEMBER OF 2004, FORD RELEASED A REDESIGNED BSI SOLENOID WITH A SHORTER PIN RETRACTING TIME AS A SERVICEABLE COMPONENT. FORD HAS NOTED THE SHORTER RETRACTION TIME SIGNIFICANTLY LESSENS THE LIKELIHOOD OF BSI SOLENOID PIN…
RQ08003 · opened Jun 23, 2008 · closed Oct 24, 2008REAR LIFTGATE GLASS HATCH FAILURE THIS INVESTIGATION WAS OPENED ON JUNE 23, 2008, BASED ON 34 COMPLAINTS INVOLVING EIGHT INJURIES IN WHICH THE REAR LIFTGATE GLASS HATCH ON MODEL YEAR 2004 FORD EXPLORERS OR MERCURY MOUNTAINEERS BROKE OFF AND FELL, USUALLY WHILE INDIVIDUALS WERE OPERATING THE GLASS HATCH OR LOADING OR UNLOADING ITEMS FROM THE REAR OF THE VEHICLE.FORD CONDUCTED RECALL 04V-442 IN 2004 TO ADDRESS SIMILAR PROBLEMS ON MODEL YEAR 2002 AND CERTAIN MODEL YEAR 2003 FORD EXPLORERS AND MERCURY MOUNTAINEERS.THE INFORMATION FORD PROVIDED IN RESPONSE TO ODI'S INFORMATION REQUEST LETTER INDICATED THAT FAILURES WITH 2004 VEHICLES WERE PRIMARILY LIFTGATE GLASS HATCH HINGE FAILURES RELATED TO CORROSION AT THE HINGE PIN, WHEREAS THE FAILURES THAT PROMPTED THE RECALL WITH THE EARLIER MODELS WERE PRIMARILY RELATED TO PROBLEMS WITH THE GLASS HATCH'S STRUTS OR FRACTURE OF A PRIOR HINGE DESIGN AT THE BOSS/BOLT CONNECTION AT THE…
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…
