2004 Ford Expedition Owner Complaints

The contact owns a 2004 Ford Expedition. The contact recently purchased the vehicle and stated that while driving at an undisclosed speed, the transmission hesitated before upshifting with the accelerator pedal depressed. Additionally, while stopped at a traffic light, the vehicle rolled backwards when the accelerator pedal was depressed before responding as needed. There was no warning light illuminated. The contact attempted to return the vehicle to the independent dealer where the vehicle was purchased; however, the dealer declined to assist. Recently, the vehicle stalled, and it was towed to an independent mechanic to be diagnosed. The mechanic retrieved fault codes for the engine and stated that the TCM needed to be replaced. The vehicle was not repaired. The manufacturer was not informed of the failure. The failure mileage was unknown.

NHTSA ID

11722224

Incident

Feb 25, 2026

The contact owns a 2004 Ford Expedition. The contact stated that the turn signals, the hazard lights, and the cigarette lighter had become inoperable. The TPMS warning light was illuminated. The dealer and the manufacturer were not notified of the failure. The vehicle was not diagnosed or repaired. The failure mileage was unknown.

NHTSA ID

11646759

Incident

Feb 6, 2025

Just bought this truck I have no idea what has or has not been resolved, very poor lighting I noticed and there's a click noise coming from? It just clicks and clicks and clicks. Thanks

NHTSA ID

11501797

Incident

Jan 11, 2003

The contact owns a 2004 Ford Expedition. The contact stated while driving approximately 10 MPH, the vehicle lunged forward while depressing the accelerator pedal. The contact was unable to drive above 15 MPH because the vehicle became difficult to control. The contact stated that the check engine warning light was illuminated. The contact had taken the vehicle to an independent mechanic who diagnosed and determined that the rear axle was fractured, the rear subframe was severely corroded, and the rear driver's side sway bar and rear differential were corroded. The vehicle had not been repaired. The manufacturer had not been informed of the failure. The failure mileage was 110,665.

NHTSA ID

11494447

Incident

Nov 5, 2022

Mileage

110,665 mi

The contact owns a 2004 Ford Expedition. The contact stated while driving at 40 MPH, the vehicle shut down completely, and the warning messages indicated check gage and check service engine. The contact was able to pull over on the side of the road. The dealer was not contacted. The manufacturer was not made aware of the failure. The failure mileage was 127,708.

NHTSA ID

11488840

Incident

Oct 11, 2022

Mileage

127,708 mi

The contact owns a 2004 Ford Expedition. The contact stated that while her daughter was driving at an undisclosed speed, the vehicle was jerking. The contact stated that one spark plug exploded and then another spark plug exploded and went through the cylinder head. The contact called the local dealer but the vehicle was not diagnosed or repaired. The vehicle was taken to an independent mechanic where the spark plug was replaced. The manufacturer was notified and referred the contact to the NHTSA for assistance. The failure mileage was approximately 87,000.

NHTSA ID

11465508

Incident

May 14, 2022

Mileage

87,000 mi

Electrical fire today. Vehicle was parked outside garage. A clicking noise was heard and noticed the mirror was trying to move/click and car was filled with smoke. Mirror switches didn't work when tried. Knocked mirror off and fire stopped. Wiring Harness around the emergency brake area melted. Fire melted a hole in the dash corner by windshield. Vehicle was last driven about 25 hrs. earlier with no issues. Approx. 128K miles. Glad it wasn't in garage and the clicking was heard or garage/house would have burned. We haven't done anything to it yet.

NHTSA ID

11448740

Incident

Jan 24, 2022

Unknown, transmition left me stranded on busy highway. Managed to get it moved off the road before being hit. After getting it home and not driving for a period of time it can be started and moved with no issue. Drive to town no problem parked it to take care of some business and when I went to leave I couldn't back out of the parking place. Got it home and let it sit again. Needed to move it out of the way all was good started it and moved it across the yard and backed it in no problem. Had K&O auto look at it and was told it needs a transmission. I see allot of complaints about this issue from others without Ford being held responsible to correct the problem. Nice vehical said I can't afford to get it fixed, now driving a 500.00 used vehicle to get around, it is an eye sore but gets me around ok. Would rather enjoy the expidition if Ford would fix the issue that 1000's have had.

NHTSA ID

11429658

Incident

Aug 18, 2021

The contact owns a 2004 Ford Expedition. The contact stated while driving at various speeds, the vehicle lost motive power without warning and the steering wheel became difficult to steer on several occasions. The vehicle was taken to an independent mechanic, but the failure could not be replicated. The throttle was replaced however, the failure recurred. The manufacturer was not made aware of the failure. The failure mileage was 216,000. The Vin was not available.

NHTSA ID

11425528

Incident

Jul 12, 2021

Mileage

216,000 mi

VEHICLE LOST POWER FOR 3-5 SECONDS AT HIGHWAY SPEEDS APPROXIMATELY 65 MPH ON THREE SEPARATE EVENTS. VEHICLE SLOWED DOWN DUE TO POWER LOSS WHILE IN HEAVY TRAFFIC. THREE OTHER TIMES AT IDLE SPEED IN DRIVE AND IN PARK ENGINE STALLED AND IMMEDIATELY RESTARTED. LOSS OF POWER STEERING DUE TO ENGINE NOT RUNNING WHEN STALL EVENT HAPPENED. I PERFORMED INSPECTION OF FUEL PUMP RELAY WHICH IS INTERNAL TO PASSENGER SIDE FUSE BLOCK. FOUND INADEQUATE SOLDER JOINT ON INTEGRATED RELAY PRINTED CIRCUIT AND BURN MARKS ON OUTSIDE OF FUEL PUMP RELAY. LOCATED SALVAGE FUSE BLOCK SAME MAKE AND MODEL AND INSPECTED. SAME DAMAGE ON SALVAGE FUSE BLOCK ASSEMBLY. REPLACED WITH AFTERMARKET FUSE BLOCK WITH REVISED SOLDER JOINT AND UPDATED RELAY.

NHTSA ID

11377472

Incident

Oct 13, 2020

Mileage

158,612 mi

THE FRAME IS RUSTING. SEE PHOTOS. THE BODY IS RUSTING AWAY ALSO THE BRAKE LINES. THE ENTIRE VEHICLE IS RUSTING AWAY. WHY HAS THIS 2004 FORD NOT INCLUDED IN A RECALL FOR RUST.

NHTSA ID

11343564

Incident

Feb 11, 2015

Mileage

85,000 mi

TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. THE CONTACT STATED WHILE VEHICLE WAS IN A STAND STILL THE VEHICLE WAS LEAKING OIL ON THE MUFFLER SYSTEM AND STARTER. THE CONTACT ALSO STATED WHILE DRIVING 25 MPH, A BURNING ODOR WAS DETECTED COMING FROM THE MUFFLER AREA. THE CONTACT STATED THE CHECK ENGINE WARNING LIGHT WAS ILLUMINATED. THE CONTACT STATED A LOCAL DEALER WAS CONTACTED HOWEVER THE FAILURE HAD NOT BEEN DIAGNOSED OR REPAIRED. THE CONTACT STATED THAT HEAD GASKET WOULD NEED TO BE REPLACED. THE CONTACT STATED THAT THE FAILURE OCCURRED AT 75,000 MILES AND HE REPLACED THE HEAD GASKET. THE MANUFACTURER HAD BEEN INFORMED OF THE FAILURE AND REFERRED THE CONTACT TO NHTSA. THE FAILURE MILEAGE WAS APPROXIMATELY 210,000.

NHTSA ID

11330124

Incident

Jun 15, 2020

THE GAS GAUGE NEVER WORKS AND SOMETIMES THE VEHICLE THINKS THAT IT DOESNT HAVE GAS WHEN IT DOES. *TR

NHTSA ID

11328057

Incident

Jun 3, 2020

CHATTER WHEN WHEEL TURNED AT LOW SPEED. LOW SPEED TURNING , SHAKING AND VIBRATION. *TR

NHTSA ID

11328015

Incident

Dec 16, 2019

Mileage

115,000 mi

TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE SUDDENLY STALLED AND SHUT OFF. LATER, AFTER RESTARTING THE ENGINE, THE VEHICLE OPERATED NORMALLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FUEL PUMP RELAY CIRCUIT BOARD HAD MALFUNCTIONED AND BURNT OUT. THE CIRCUIT BOARD WAS REPLACED AND THE FAILURE WAS REMEDIED. AN UNKNOWN LOCAL DEALER WAS CONTACTED. THE MANUFACTURER WAS NOT CONTACTED. THE FAILURE MILEAGE WAS 180,000.

NHTSA ID

11258060

Incident

Sep 1, 2019

Mileage

180,000 mi

WHILE DRIVING A 2004 FORD EXPEDITION 178,000 KEPT STALLING ON THE HIGHWAY AND STREETS. I HAD IT TOWED SEVERAL TIMES BECAUSE IT WON'T START BACK ON THE NEXT DAY IT WOULD TURN ON. HAD THE FUEL PUMP REPLACED AND STILL HAVING THE SAME PROBLEMS IT TURN OFF ON MY 18 YEAR OLD SON LIKE 5 TIMES GOING TO SCHOOL AND WORK WHERE IT ALMOST GOT TO THE POINT WHERE WE FELT IT WASN'T A RELIABLE DUE THE FACT IT STALLS WHILE ON THE ROAD OR EVEN JUST TURNING AND ALMOST CAUSED MY SONS LIFE . FINALLY WE FOUND OUT IT'S THE RELAY GETS HOT AND IT CAUSES FOR THE CAR TO STOP AND I'M AWARE THAT FORD KNOWS ABOUT THIS VERY FRUSTRATING AND DISAPPOINTING THEY HAVE NOT DONE A RECALL ON THIS THE RELAY CAN NOT BE CHANGE BY ITS SELF HAS TO BE THE WHOLE CIRCUIT BOARD

NHTSA ID

11254548

Incident

Sep 10, 2019

SERVICE AIR BAG LIGHT RANDOMLY CAME ON

NHTSA ID

11242275

Incident

Aug 1, 2019

Mileage

185,000 mi

FRAME WAS BROKEN AND RIGGED AND PAINTED UNSAFE AND I AM CONCERNED WHEN HE PUTS MY KIDS IN THE CAR IT IS NOT SAFE

NHTSA ID

11223108

Incident

Jun 10, 2016

MY DASH VENTS ARE NOT SENDING ANY A/C OUT THE FRONT VENTS, AND I ALSO FEEL HEAT FROM THE FLOOR BOARD OF MY CAR ALONG WITH EXHAUST EMISSIONS. I KNOW THAT THE SAN DIEGO POLICE HAD THE SAME PROBLEM WITH THEIR EXPEDITIONS AND THEY WERE RECALLED AND REPAIRED,NOW THEY CHANGED TO FORD EXPLORERS . IS THERE ANYTHING STILL ON THE BOOKS FOR THE EXPEDITIONS? THE VEHICLE CAN BE IN ANY FUNCTION,IT IS JUST NOT WORKING, AND ALSO I HEAR A TUMPPING NOISE IN MY RIGHT REAR PANEL. I AM UNABLE TO SEND ANY PICTURES BECAUSE EVERYTHING IS COVERED.

NHTSA ID

11219895

Incident

Jun 11, 2019

Mileage

137,135 mi

TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. WHILE DRIVING 60 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE CONTACT WAS ABLE TO RESTART THE VEHICLE AFTER WAITING SEVERAL MINUTES. THE VEHICLE WAS TAKEN TO COWLES PARKWAY FORD (LOCATED AT 13779 NOBLEWOOD PLAZA, WOODBRIDGE, VA 22193, (703) 986-5500) WHERE IT WAS DIAGNOSED THAT THE FUEL PUMP NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED, BUT THE FAILURE RECURRED A DAY LATER. AFTER FURTHER RESEARCH, THE CONTACT BECAME AWARE THAT THE FUEL PUMP RELAY NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED. THE APPROXIMATE FAILURE MILEAGE WAS 188,000.

NHTSA ID

11164162

Incident

Nov 30, 2018

Mileage

188,000 mi

RUSTED OUT ROCKER PANELS, BRAKE LINES, FRONT END RADIATOR MOUNTS, FENDER MOUNTS. THE ENTIRE UNDER CARRIAGE IS RUSTING AWAY. WE HAVE HAD TO REPLACE ALL THE BRAKE LINES AS THEY HAVE RUSTED AWAY, REDID THE ROCKER PANELS RUST AWAY. NOW WE HAVE TO REPLACE THE ENTIRE FRONT END BECAUSE OF RUST. WILL NOT PASS PA STATE INSPECTION DUE TO RUST. IS THE EXPEDITION IN THE RECALL FOR RUST?

NHTSA ID

11130883

Incident

Aug 15, 2018

Mileage

125,000 mi

HEAD ON COLLISION WITH FORD F-250 AND NEITHER AIR BAGS DEPLOYED. WE DID NOT HAVE ANY RECALLS ON OUR FORD EXPEDITION. MY HUSBAND AND SON ARE VERY LUCKY I WILL NEVER OWN A FORD EVER AGAIN.

NHTSA ID

11120927

Incident

Jul 20, 2018

Mileage

136,000 mi

TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE STALLED WITHOUT WARNING. THE CONTACT STATED THAT THE VEHICLE WOULD RESTART ERRATICALLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE THE CONTACT WAS INFORMED THAT THE FUSE BOX NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED, BUT THE FAILURE RECURRED MULTIPLE TIMES. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 187,000. THE VIN WAS NOT AVAILABLE.

NHTSA ID

11115203

Incident

Feb 1, 2017

Mileage

187,000 mi

THE ROD THAT DETACHES TO THE BACK OF THE TIRE HADE BROKE OFF CAUSING MY TIRE TO STAY OUT WORDS ON A CITY STREET

NHTSA ID

11105316

Incident

Jul 2, 2018

Mileage

230,851 mi

I WAS DRIVING ABOUT 35 - 40 MPH DOWN SPACECENTER BLVD AND WITHOUT WARNING AND FOR NO REASON MY SIDE AIRBAGS SUDDENLY DEPLOYED.

NHTSA ID

11100311

Incident

Jun 6, 2018

Mileage

147,824 mi