VehicleVerdict

2004 Ford Explorer problems

Verdict · NHTSA data

One of the years to avoid

With 1,647 complaints filed to NHTSA — about 2.1 times the median Explorer year — the 2004 model ranks #11 of 44 Explorer years for complaint volume. It lands on the years-to-avoid list. Complainants reported 100 injuries in total across these filings.

Transmission leads the complaint categories with 473 reports (29% of the total).

1,647

NHTSA complaints

4

Recalls

4

Investigations

69

Crash-involved

21

Fires reported

100

Injuries

0

Deaths

—

NCAP overall

How does 2004 compare to other Explorer years?

Explorer NHTSA complaints by model year, 2004 highlighted4,096 complaints1977: 2 complaints1984: 1 complaints1985: 1 complaints1986: 3 complaints1987: 3 complaints1988: 7 complaints1989: 1 complaints1990: 12 complaints1991: 764 complaints1992: 848 complaints1993: 1,151 complaints1994: 1,531 complaints1995: 1,048 complaints1996: 1,818 complaints1997: 2,150 complaints1998: 2,374 complaints1999: 1,737 complaints2000: 1,203 complaints2001: 503 complaints2002: 4,096 complaints2003: 1,369 complaints2004: 1,647 complaints2005: 604 complaints2006: 788 complaints2007: 271 complaints2008: 216 complaints2009: 49 complaints2010: 155 complaints2011: 1,494 complaints2012: 1,027 complaints2013: 2,781 complaints2014: 2,038 complaints2015: 2,187 complaints2016: 3,004 complaints2017: 2,010 complaints2018: 859 complaints2019: 327 complaints2020: 1,617 complaints2021: 525 complaints2022: 339 complaints2023: 143 complaints2024: 26 complaints2025: 132 complaints2026: 25 complaints
Explorer NHTSA complaints by model year, 2004 highlighted. Red bars are years to avoid.

See all Explorer years to avoid →

What are the most common 2004 Ford Explorer problems?

ComponentComplaintsShare
Transmission47329%
Body & Structure43927%
Engine1167%
Visibility & Wipers1147%
Speed Control765%
Electrical System614%
Tires & Wheels614%
Brakes543%
Other463%
Steering423%
Suspension402%
Airbags392%
Fuel System362%
Latches & Locks231%
Lighting91%
Seats70%
Seat Belts70%
Climate Control (A/C & Heat)30%
Trailer Hitch10%

Does the 2004 Ford Explorer have recalls?

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

09E025000LightingMay 11, 2009 · 42,540 units

Defect

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.

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

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.

07E104000Visibility & WipersDecember 11, 2007 · 1,657 units

Defect

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."

Consequence

IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT(S) MAY BE SERIOUSLY INJURED BY SHATTERED GLASS.

Remedy

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.

06E049000LightingMay 24, 2006 · 27,176 units

Defect

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.

Consequence

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

Remedy

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.

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.

Consumer complaints filed with NHTSA

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

“HAVE A 2004 FORD EXPLORER WITH BAD TRANSMISSION. DELAY IN SHIFTING IN REVERSE AND A JOLT INTO GEAR CAUSED BE TO SLAM INTO ITEMS IN MY GARAGE. ALTHOUGH NO ONE WAS HURT, IT CAN HAPPEN. FORD HAS KNOW OF THIS ISSUE AS WELL AS 2-3 GEARS SLIPPING WHICH CAN CAUSE A SLOWING OF THE VEHICLE IN TRAFFIC. *TR”

Complaint filed with NHTSA · Transmission · September 17, 2009 · crash

“MY 2004 FORD EXPLORER'S REAR TRIM UNDERNEATH THE REAR WINDOW BLEW OFF THE TRUCK AT 60MPH. THE (WHOLE TRIM) SHOT THROUGH THE SKY LIKE A BOOMERANG. IT SENT A MOTORCYCLIST BEHIND ME OFF ROADING. IT VERY WELL COULD HAVE LEAD TO HIS DEATH AS THERE WERE TREE'S A FEW FEET AWAY. I HAVE NOT REPLACED ANY…”

Complaint filed with NHTSA · Body & Structure · May 9, 2011 · crash

“ON 1/17/12 DRIVING ON HIGHWAY AND NOTICED A BURNING SMELL. IT WAS A STRONG SMELL. NOTICED A GLOW UNDER THE DASHBOARD AND PULLED INTO A EMPTY PARKING LOT. THE TRUCK WENT UP IN FLAMES. CALLED FORD AND THEY SAID PROVE WHAT HAPPENED. NOT SURE BUT THE VEHICLE WAS IN VERY GOOD CONDITION WITH NO PROBLEMS…”

Complaint filed with NHTSA · Engine · January 17, 2011 · fire

“TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT AFTER OPENING THE REAR GLASS LIFT GATE WINDOW, THE TWO PLASTIC HINGES ATTACHED TO THE WINDOW FRACTURED CAUSING THE WINDOW TO FALL AND SEPARATE FROM THE VEHICLE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS…”

Complaint filed with NHTSA · Visibility & Wipers · August 2, 2014

“WHILE TURNING LEFT AT LOW SPEED, WITHOUT WARNING THE VEHICLE ACCELERATED. THE DRIVER WAS NOT ABLE TO CONTROL THE VEHICLE AND COLLIDED INTO A GARAGE. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION. THE MECHANIC CAN NOT DUPLICATE THE PROBLEM. *NM CONSUMER WAS TURNING LEFT TOWARDS GARAGE WHEN…”

Complaint filed with NHTSA · Speed Control · May 25, 2004 · crash

2004 Ford Explorer — common questions

Is the 2004 Ford Explorer reliable?

NHTSA data argues against it: 1,647 complaints put the 2004 model at #11 of 44 Explorer years. It is one of the Explorer years to avoid.

What are the most common 2004 Explorer problems?

According to NHTSA complaint data, the leading problem areas are transmission (473 complaints), body & structure (439 complaints), engine (116 complaints).

Does the 2004 Ford Explorer have recalls?

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

Is the 2004 Ford Explorer under NHTSA investigation?

NHTSA opened 4 investigations into this model year; all are now closed.

Which Ford Explorer years should you avoid?

Based on complaint rates and open investigations, the Explorer years to avoid are 2002, 2016, 2013, 1998, 2015, 1997, 2014, 2017, 1996, 1999, 2004, 2020, 1994, 2011, 2003, 2000, 1993, 1995, 2018, 1992, 1991. The cleanest record among Explorer years belongs to 1989.

Related

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