2004 Ford Explorer problems & reliability
1,304 owner complaints filed with NHTSA for the 2004 Ford Explorer. Last verified Aug 7, 2026. Complaints are unverified reports submitted by owners to the federal Office of Defects Investigation.
Each complaint is counted once (by NHTSA case number), even when it names several vehicles.
67 complaints report injuries (83 injured).
Federal crash records (FARS 2020–2023): 2004 Ford Explorer vehicles were involved in 117 fatal crashes with 75 occupant deaths. Involvement counts are not adjusted for how many are on the road and do not imply fault or a vehicle defect.
Most reported problems
| Component | Complaints | Share |
|---|---|---|
| Power Train | 460 | 35% |
| Structure | 426 | 33% |
| Visibility | 100 | 8% |
| Vehicle Speed Control | 76 | 6% |
| Engine and Engine Cooling | 71 | 5% |
| Electrical System | 55 | 4% |
| Engine | 44 | 3% |
| Steering | 41 | 3% |
| Wheels | 41 | 3% |
| Air Bags | 39 | 3% |
Component groups as classified by NHTSA. A complaint can name more than one component, so shares may sum to more than 100%.
Common symptoms owners describe
Keyword analysis of complaint narratives; one complaint can describe several symptoms.
Mileage when problems occurred
Half of the failures with a reported odometer reading occurred by 65,000 miles (middle 50% between 40,000 and 95,000 miles), based on 1,061 complaints that included mileage.
Complaints by incident year
What owners report
“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…”
Service Brakes · filed May 28, 2024
“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…”
Fuel/propulsion System · filed Feb 9, 2024
“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.”
Fuel/propulsion System · filed Apr 22, 2023
Verbatim excerpts from complaints filed with NHTSA. Reports are not independently verified.
Federal defect investigations
- Vehicle Rollaway Allegations
Engineering Analysis EA09013 · opened Aug 18, 2009 · closed Feb 12, 2013
- VEHICLE ROLLAWAY ALLEGATIONS
Preliminary Evaluation PE09020 · opened Apr 21, 2009 · closed Aug 19, 2009
- REAR LIFTGATE GLASS HATCH FAILURE
Recall Query RQ08003 · opened Jun 23, 2008 · closed Oct 24, 2008
- SPARK PLUG EJECTION FROM CYLINDER HEAD
Defect Petition DP05005 · opened Sep 22, 2005 · closed Jan 4, 2006
Technical service bulletins
109 manufacturer communications (TSBs, service campaigns, warranty extensions) are on file with NHTSA for the 2004 Ford Explorer. The 10 most recent:
Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel…
TSB 19-2026 · Service Bulletin/Repair Instructions · issued Feb 7, 2019
Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel…
TSB 19-2026 · Service Bulletin/Repair Instructions · issued Feb 7, 2019
The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a…
SSM 46085 · Service Bulletin/Repair Instructions · issued Sep 21, 2016
Ford/lincoln/mercury: may have sludge buildup in throttle body leading to less airflow or engine idling rpm fluctuation and hard starts or battery disconnect or dead battery after keep alive memory (kam) clear. Models…
TSB-12-8-1 · Service Bulletin/Repair Instructions · issued Aug 1, 2012
Ford/lincoln/mercury: if battery was disconnected or dead, vehicles/trucks may experience hard starts and engine idle rpm fluctuation and exhibit diagnostic trouble codes (dtcs) p0505, p0506, p2111 and p2112. *pe
TSB-12-7-4 · Service Bulletin/Repair Instructions · issued Jul 10, 2012
Ford: some vehicles may exhibit oil separation from the internal lube found in the unitized cartridge seal. Oil separation appears to be and is often misdiagnosed, as an axle lube leak. *pe
TSB-08-19-3 · Service Bulletin/Repair Instructions · issued May 1, 2009
Some 1997-2008 vehicles equipped with a 4.6l 2v, 5.4l 2v, or 6.8l 2v engine--spark plug thread repair procedure--not covered under new vehicle limited warranty. *nj this includes f-53 motorhome chassis. Updated 2/23/10…
07212 · Service Bulletin/Repair Instructions · issued Oct 1, 2007
Neutral tow capability - service kit requirements. *tt
0645 · Service Bulletin/Repair Instructions · issued Jan 1, 2006
Low tire indicator on - tpms system sensor wake up. *tt
0637 · Service Bulletin/Repair Instructions · issued Jan 1, 2006
Malfunction indicator lamp on with pcm diagnostic trouble code p0463 and/or ic diagnostic trouble code b1201 - fuel gauge drops to empty or slow to update after refueling. *tt
05213 · Service Bulletin/Repair Instructions · issued Jan 1, 2006
TSBs are repair guidance manufacturers send to dealers — they are not recalls and repairs are not automatically free. Full documents are available on NHTSA’s site.
Safety recalls
No NHTSA recall campaigns name the 2004 Ford Explorer in our current data. Recalls may apply only to certain VIN ranges — always confirm with a VIN check.
Check whether your specific vehicle is affected
Recall campaigns often cover only certain VIN ranges. Enter your VIN on the official NHTSA site to confirm whether your vehicle is included and whether the repair is still open.
Check VIN on NHTSA →Buying a used 2004 Ford Explorer?
- · Decode the seller’s VIN with our free VIN decoder to confirm the exact year, engine and trim.
- · Check for unrepaired recalls by VIN on NHTSA’s official lookup — recall repairs are free.
- · Owners most often reported problems around 65,000 miles — budget accordingly if the car is approaching that mileage.