VehicleVerdict

2004 Ford Expedition problems

Verdict · NHTSA data

One of the years to avoid

With 381 complaints filed to NHTSA — about 1.9 times the median Expedition year — the 2004 model ranks #14 of 36 Expedition years for complaint volume. It lands on the years-to-avoid list. Reports tied to this model year include one death and 70 injuries, per the complaint records themselves.

No single system dominates the record — complaints spread across engine (55), airbags (49), and brakes (43), which usually points to general build quality rather than one defect.

381

NHTSA complaints

4

Recalls

2

Investigations

57

Crash-involved

16

Fires reported

70

Injuries

1

Deaths

—

NCAP overall

How does 2004 compare to other Expedition years?

Expedition NHTSA complaints by model year, 2004 highlighted1,137 complaints1991: 1 complaints1993: 1 complaints1994: 4 complaints1995: 1 complaints1996: 3 complaints1997: 1,065 complaints1998: 1,022 complaints1999: 1,137 complaints2000: 1,134 complaints2001: 739 complaints2002: 415 complaints2003: 800 complaints2004: 381 complaints2005: 452 complaints2006: 395 complaints2007: 267 complaints2008: 179 complaints2009: 42 complaints2010: 74 complaints2011: 92 complaints2012: 163 complaints2013: 114 complaints2014: 96 complaints2015: 229 complaints2016: 274 complaints2017: 474 complaints2018: 452 complaints2019: 581 complaints2020: 473 complaints2021: 270 complaints2022: 156 complaints2023: 87 complaints2024: 106 complaints2025: 47 complaints2026: 13 complaints2027: 0 complaints
Expedition NHTSA complaints by model year, 2004 highlighted. Red bars are years to avoid.

See all Expedition years to avoid →

What are the most common 2004 Ford Expedition problems?

ComponentComplaintsShare
Engine5514%
Airbags4913%
Brakes4311%
Electrical System3910%
Tires & Wheels308%
Transmission287%
Body & Structure257%
Fuel System236%
Speed Control216%
Visibility & Wipers154%
Other144%
Steering133%
Suspension113%
Seats51%
Seat Belts51%
Lighting31%
Climate Control (A/C & Heat)21%

Does the 2004 Ford Expedition have recalls?

4 NHTSA recall campaigns on file. Recall repairs are free at franchised dealers.

09E012000LightingApril 7, 2009 · 16,270 units

Defect

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.

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

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.

06E064000LightingJuly 17, 2006 · 4,029 units

Defect

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.

Consequence

LACK OF AMBER SIDE REFLECTORS IN THE LAMPS WILL DECREASE LIGHTING VISIBILITY TO OTHER DRIVERS AND MAY POSSIBLY RESULT IN A VEHICLE CRASH.

Remedy

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.

06E026000LightingMarch 23, 2006 · 61,944 units

Defect

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.

Consequence

WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.

Remedy

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.

06E023000LightingMarch 13, 2006 · 292,000 units

Defect

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."

Consequence

WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH.

Remedy

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.

Consumer complaints filed with NHTSA

Representative excerpts, cleaned of personal information. These are consumer statements, not verified defects.

“TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. THE CONTACT WAS INFORMED BY A NEIGHBOR THAT HER VEHICLE WAS ON FIRE. THE FIRE DEPARTMENT WAS CALLED TO EXTINGUISH THE FIRE. THERE WERE NO INJURIES REPORTED. THE VEHICLE WAS NOT DESTROYED NOR WAS IT TAKEN FOR INSPECTION OR REPAIRS. THE CAUSE OF THE FIRE…”

Complaint filed with NHTSA · Engine · April 14, 2012 · fire

“WHILE DRIVING 40 MPH VEHICLE WAS INVOLVED IN A FRONTAL COLLISION. UPON IMPACT, BOTH FRONTAL AIR BAGS FAILED TO DEPLOY. DRIVER SUSTAINED MINOR INJURIES, AND WAS TRANSPORTED TO A HOSPITAL. VEHICLE WAS TOWED TO A GARAGE FOR INSPECTION. THE CAUSE HAD NOT BEEN DETERMINED AT THIS TIME. THIS INFORMATION…”

Complaint filed with NHTSA · Airbags · April 15, 2005 · crash

“WE WERE INVOLVED IN AN ACCIDENT. OUR 2004 FORD EXPEDITION SEAMED TO FAIL TO RESPOND TO SLAMMING ON THE BRAKES TO AVOID COLLISION. WE REAR ENDED A CAR, NO ONE HURT. NO AIR BAG DEPLOYMENT AT ALL. #0-35 MPH SPEED. HIT CAR IN FRONT OF US AFTER HE STOPPED IN ROAD FOR NO REASON. MAJOR DAMAGE TO OUR…”

Complaint filed with NHTSA · Brakes · March 30, 2010 · crash

“WHILE THE VEHICLE WAS PARKED IT CAUGHT ON FIRE UNDER HOOD. CONSUMER CALLED THE FIRE AND POLICE DEPARTMENTS. THE FIRE WAS EXTINGUISHED, AND THERE WERE NO INJURIES. VEHICLE WAS TOWED TO DEALER FOR INSPECTION. *AK”

Complaint filed with NHTSA · Electrical System · September 13, 2004 · fire

“1. WE WERE DRIVING TO GO ON VACATION ON I-95 IN GEORGIA WHEN THE CAR BECAME OUT OF CONTROL WE SPUN AND HIT A GUARD RAIL BEFORE WE CAME TO A STOP. THE CAR HAD TO BE TOWED. THERE WAS OVER 6500.00 IN DAMAGE TO MY VEHICLE. THE INSURANCE PAID FOR 3 TIRES BUT NOT THE ONE THAT CAUSED THE ACCIDENT. *TR”

Complaint filed with NHTSA · Tires & Wheels · August 3, 2008 · crash

2004 Ford Expedition — common questions

Is the 2004 Ford Expedition reliable?

NHTSA data argues against it: 381 complaints put the 2004 model at #14 of 36 Expedition years. It is one of the Expedition years to avoid.

What are the most common 2004 Expedition problems?

According to NHTSA complaint data, the leading problem areas are engine (55 complaints), airbags (49 complaints), brakes (43 complaints).

Does the 2004 Ford Expedition have recalls?

Yes — NHTSA lists 4 recall campaigns affecting the 2004 Ford Expedition. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Is the 2004 Ford Expedition under NHTSA investigation?

NHTSA opened 2 investigations into this model year; all are now closed.

Which Ford Expedition years should you avoid?

Based on complaint rates and open investigations, the Expedition years to avoid are 1999, 2000, 1997, 1998, 2003, 2001, 2019, 2017, 2020, 2018, 2005, 2002, 2006, 2004, 2021. The cleanest record among Expedition years belongs to 2027.

Related

Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.

Compiled by Sharon Ben-Moshe, Founder.