2004 Ford Explorer structure problems

426 owner complaints filed with NHTSA name the structure on the 2004 Ford Explorer — 33% of all complaints for this model year.

426

Structure complaints

33%

share of all complaints

72,000 mi

median reported incident mileage

2 / 1

crash / fire reports

What owners report

“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.”
filed Apr 22, 2023
“Plastice parts are deteriorating, desolving in front inside drive sun visor-lighted visor broke off; centerl rear a/c and heat moon roof light console falls off-plastice clips desolved and will not fasten into roof assembly, causing blocked eyesight and at time on right turn hitting head or eyes …”
filed Jul 20, 2019

Verbatim excerpts from complaints filed with NHTSA. Reports are not independently verified.

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