RoadVitals

2004 Ford Expedition Problems

Owner-reported complaints filed with NHTSA, grouped by component

Data refreshed

Owner complaintsComplaints are reports submitted to NHTSA by owners and drivers. NHTSA does not verify most reports before publishing them, and a complaint does not establish that a defect exists. Volume is influenced by how many of a vehicle were sold, how long it has been on the road, and how much attention an issue has received.
296
Latest Mar 5, 2026
Components namedHow many of our component categories appear on at least one report for this model year. One report can name several.
18
Crash or fire reportedComplaints whose submitter recorded that a crash or a fire occurred. These are the reporter's own answers on the NHTSA form, not verified findings.
63

What this page shows

Everything below is an owner-reported complaint submitted to NHTSA about the 2004 Ford Expedition, grouped by the component NHTSA recorded on the report. These are not confirmed defects, and they are not recalls. NHTSA does not verify most reports before publishing them, and a category with more reports in it is not evidence that a part is defective.

Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.

Reports by component

Ranked by how many owner reports name each component category

Percentages are of component mentions. A single complaint can name more than one component, so these do not sum to the total complaint count.

Each component in detail

What the reports in each category say, in the owners' own words

Engine

Reports naming the engine itself — including stalling, misfires, oil consumption, cooling and internal engine components.

55
reports

From owner reports, verbatim

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 · filed Mar 5, 2026

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 · filed Oct 11, 2022
All 55 reports naming engine

Airbags

Reports naming the air-bag system — deployment behaviour, inflators, sensors and warning lights.

45
reports

From owner reports, verbatim

SERVICE AIR BAG LIGHT RANDOMLY CAME ON

NHTSA ID 11242275 · filed Aug 7, 2019

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 · filed Aug 19, 2018
All 45 reports naming airbags

Brakes

Reports naming service brakes, the antilock braking system, brake hoses, master cylinders or the parking brake.

42
reports

From owner reports, verbatim

TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. WHILE THE VEHICLE WAS PARKED, IT ROLLED DOWN AN INCLINE AND STRUCK A BOULDER AT THE END OF THE DRIVEWAY. A POLICE REPORT WAS NOT FILED AND THERE WERE NO INJURIES. THE DEALER WAS NOT CONTACTED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND INFORMED THE CONTACT THAT THE VEHICLE WAS NOT INCLUDED IN A RECALL. NO FURTHER ASSISTANCE WAS OFFERED. THE FAILURE MILEAGE WAS 208,000.

NHTSA ID 11084035 · filed Apr 9, 2018

TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. WHILE INDEPENDENTLY PERFORMING ROUTINE SERVICE ON THE VEHICLE, THE CONTACT NOTICED THAT THE BRAKE LINE WAS CORRODED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE ISSUE. THE FAILURE MILEAGE WAS 107,000.

NHTSA ID 10909737 · filed Sep 26, 2016
All 42 reports naming brakes

Electrical

Reports naming the electrical system — wiring, battery, charging, control modules, infotainment and electrical accessories.

35
reports

From owner reports, verbatim

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 · filed Mar 6, 2025

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 · filed Jan 25, 2022
All 35 reports naming electrical

Tires & wheels

Reports naming tires, wheels, hubs, or the tire-pressure monitoring system.

26
reports

From owner reports, verbatim

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 · filed Mar 6, 2025

TL* THE CONTACT OWNS A 2004 FORD EXPEDITION EQUIPPED WITH B.F. GOODRICH TIRES, SIZE: 265/75R17. THE CONTACT STATED THAT THERE WAS A BUBBLE PROTRUDING FROM THE SIDEWALL AND INTO THE TREAD AREA OF THE TIRE, CAUSING THE TIRE TO DELAMINATE. THE CONTACT REPORTED THE FAILURE TO THE STORE WHERE HE BOUGHT THEM AND THEY INSTRUCTED HIM TO BRING THEM BACK.

NHTSA ID 10479805 · filed Oct 11, 2012
All 26 reports naming tires & wheels

Body & structure

Reports naming the vehicle structure, frame, body panels, doors, hood and trim.

24
reports

From owner reports, verbatim

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 · filed Nov 21, 2022

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 · filed Aug 5, 2020
All 24 reports naming body & structure

Fuel system

Reports naming fuel storage or delivery — tanks, pumps, lines, injectors and fuel leaks.

23
reports

From owner reports, verbatim

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 · filed Dec 2, 2020

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

NHTSA ID 11328057 · filed Jun 9, 2020
All 23 reports naming fuel system

Driver assistance

Reports naming forward-collision avoidance, lane keeping, back-over prevention, cruise control and related electronic driver-assistance systems.

23
reports

From owner reports, verbatim

CAN NOT DRIVE CAR POWER TRAIN AND ENGINE BLEW OUT DONT DRIVE DRIVE FAR ONLY IN MY CITY AND UP TO MAINTENCE AND ALL OF SUDDEN GIRLS STOP SHIFTING ONE DAY WHILE ON ROAD VERY SCARY HAD TO PULL OVER IN MIDDLKE OF INTERSECTION AFTER THT\AT DAY BOUGHT ANOTHER TRANSMISSION AND SAME THING HAPPENED DIDNT LAST MONTH SPENT SO MUCH MONEY ON TRANS THAT CANNOT AFFORD NEW AGIN

NHTSA ID 11035566 · filed Oct 23, 2017

MY VEHICLE, WITHOUT ANY WARNING AT ANY SPEED, INCLUDING HIGHWAY SPEEDS, SHUTS OFF COMPLETELY,WITHOUT ANY WARNING OR INDICATION THAT IT IS ABOUT TO DO THIS. ALWAYS ON A STRAIGHT ROAD WITH ALMOST A FULL TANK OF GAS. THE CAUSE A RELAY SWITCH WHICH IS SOLDIERED INTO THE MEMORY BOARD THAT CONTROLS THE VEHICLE'S BRAIN BOX THAT SHORTS OUT. AFTER DOING RESEARCH ON THE INTERNET, I AM BOTH SHOCKED AND DISGUSTED THAT THE NHSTA HAS NOT INVESTIGATED THIS FAULTY DESIGN BY FORD AND MADE THEM RECALL ALL OF THE 2003- 2008 EXPEDITIONS. YOU ONLY HAVE TO PULL IT UP ON YOU-TUBE OR GOOGLE TO SEE THE 1000'S UPON 1000S OF COMPLAINTS FROM EXPEDITION OWNERS CONCERNING THIS CONSTANT AND DANGEROUS PROBLEM, WHICH CLEARLY ENDANGERS EVERY EXPEDITION OWNER AND THEIR FAMILY. THE WORST PART OF THIS, THE FORD DEALERSHIPS WANT YOU TO SPEND $1000 OF DOLLARS NEEDLESSLY TO TRY AND DIAGNOSE THIS SAME, OLD PROBLEM, BEFORE THEY FINALLY DEAL WITH REPLACING THE ENTIRE FUSE BLOCK PANEL, JUST FOR THE RELAY SWITCH, WHICH IS THE CAUSE, THE SHORTING OUT RELAY SWITCH. THE INTERNET SHOWS AGAIN AND AGAIN, THAT THIS PROBLEM IS SO RAMPANT, THAT IT ISN'T IF IT HAPPENS, BUT WHEN, BECAUSE IT WAS A FAULTY AND DEFECTIVE DESIGN, WHICH ENDANGERS ALL EXPEDITION OWNERS MADE THESE YEARS. THE FAULTY FUSE BLOCK'S FUEL PUMP RELAY SWITCH BURNS OUT AND BETWEEN THAT AND THE THIN WIRES GROUNDING OUT UNDER THE HOOD, DRIVERS, UNSUSPECTINGLY ARE LEFT IN PANIC MODES ON THE HIGHWAY, SCRAMBLING TO GET OUT OF HARMS WAY, AS A RESULT OF YOUR VEHICLE TURNING OFF AT ALL SPEEDS, IE, 70 MPH. IMAGINE A SEMI IS BEHIND YOU AND YOU DON'T HAVE THE SAFE MEANS OF ESCAPING THE DANGEROUS PREDICAMENT YOU ARE NOW LEFT IN TO GET OVER TO THE SIDE OF THE ROAD? A RECALL IS NEEDED ASAP BEFORE TOO MANY PEOPLE ARE NEEDLESSLY KILLED AS A RESULT. EXPEDITION'S ARE FAMILY VEHICLE'S AND USUALLY HAVE LOTS OF CHILDREN IN THEM! THIS IS TOO DANGEROUS TO KEEP OVERLOOKING.

NHTSA ID 11002736 · filed Jul 2, 2017
All 23 reports naming driver assistance

Visibility

Reports naming windshields, glass, wipers, defrosters and mirrors.

15
reports

From owner reports, verbatim

THE REAR A/C ACTUATOR BEGAN MAKING A THUMPING NOISE AND THE REAR A/C NOW ONLY WORKS WHEN IT WANTS TO AND ALSO THE HEAT IN THE REAR. IF YOU TURN ON THE A/C SOMETIMES HEAT WILL COME OUT OF THE VENTS AND IF YOU TURN ON THE HEAT, SOMETIMES A/C WILL COME OUT OF THE VENTS. *TR

NHTSA ID 10436025 · filed Nov 16, 2011

TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 35 MPH, THE CONTACT ATTEMPTED TO ACTIVATE THE FRONT DRIVER SIDE AUTOMATIC WINDOW BUT THE WINDOW REGULATOR FAILED TO RELEASE THE WINDOW IN AN OPEN POSITION. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THEY INFORMED THAT THE WINDOW REGULATOR WOULD NEED TO BE REPLACED TO CORRECT THE PROBLEM. THE FAILURE MILEAGE WAS APPROXIMATELY 100,000. THE VIN WAS UNAVAILABLE.

NHTSA ID 10395441 · filed Apr 11, 2011
All 15 reports naming visibility

Powertrain (other)

Powertrain reports that are not specifically the engine or transmission — driveshafts, axles, transfer cases and differentials.

14
reports

From owner reports, verbatim

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 · filed Mar 5, 2026

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 · filed Nov 21, 2022
All 14 reports naming powertrain (other)

Transmission

Reports naming the automatic or manual transmission, including shifting behaviour, shudder, slipping and transmission control modules.

13
reports

From owner reports, verbatim

SHUTTER/GRINDING NOISE COMING FROM REAR AXLE. *TR

NHTSA ID 10327634 · filed Apr 26, 2010

TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. AFTER HE STARTED THE IGNITION HE APPLIED PRESSURE TO THE ACCELERATOR PEDAL, BUT THE VEHICLE WOULD NOT ACCELERATE. AFTER SEVERAL ATTEMPTS HE WAS ABLE TO DRIVE. HOWEVER WHEN DRIVING THE TRANSMISSION KEPT SLIPPING GEARS. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR DIAGNOSTIC TESTING. THE TECHNICIAN STATED THE FAILURE WAS CONTRIBUTED TO THE FORWARD CLUTCH PISTON SEAL. THE VEHICLE WAS REPAIRED FOR THE MALFUNCTION. THE FAILURE MILEAGE WAS 38,000. THE CURRENT MILEAGE WAS 38,500. THE VEHICLE IDENTIFICATION NUMBER WAS UNAVAILABLE.

NHTSA ID 10290699 · filed Nov 2, 2009
All 13 reports naming transmission

Steering

Reports naming the steering system — racks, columns, power-steering assist and steering linkage.

13
reports

From owner reports, verbatim

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 · filed Nov 21, 2022

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 · filed Jul 3, 2018
All 13 reports naming steering

Suspension

Reports naming suspension components — springs, struts, shocks, control arms and related hardware.

11
reports

From owner reports, verbatim

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 · filed Sep 24, 2018

I BOUGHT FORD EXPEDITION WITH AIRBAGS SUSPENSION AND NOW IT'S BROKEN LIKEWISE AIR COMPRESSOR TOO WAS DAMAGES ,WHICH I DIDN'T KNOW OR ANY IDEA THEY SOLD ME THIS SUV, LOADED WITH THIS AIRBAGS SUSPENSION, IS IT LEGAL HERE IN HAWAII TO SOLD CARS OR SUV'S LOADED WITH AIRBAGS SUSPENSION ? *TR

NHTSA ID 10607939 · filed Jul 3, 2014
All 11 reports naming suspension

Other / unspecified

Reports whose component NHTSA recorded as unknown, or that do not map to one of the categories above.

6
reports

From owner reports, verbatim

TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 20 MPH, HE NOTICED A LOUD VIBRATION COMING FROM THE REAR OF THE VEHICLE. THE WAS VEHICLE TAKEN TO THE DEALER FOR DIAGNOSIS. THE TECHNICIAN STATED THAT BOTH REAR WHEEL HUB ASSEMBLIES WOULD HAVE TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 86,000. *TR

NHTSA ID 10503664 · filed Mar 19, 2013

AN ACCIDENT HAPPEND JULY 18TH TO MY BROTHER AND HIS SON WITH A 2004 FORD EXPEDITION SAUDI ARABIA REGISTRATION HERE IN JORDAN IN AMMAN CITY, FLIPPID OVER FEW TIMES ON THE ROAD , BUT WITH LIABILITY INSSURANCE ONLY ( FORCED MANDATORY INSURRANCE ENTERING JORDAN ) AND THE AIR BAG DID NOT COMEOUT. IS THERE ANY CHANCE TO COMPLAIN AGAINST FORD MOTORS BECAUSE OF THE AIR BAG DID NOT COME OUT. *TR

NHTSA ID 10237969 · filed Aug 13, 2008

Too few reports in this category for a page of its own — they appear in the full complaint list.

Seat belts

Reports naming seat belts, buckles, retractors and pretensioners.

5
reports

From owner reports, verbatim

THE VEHICLE WAS INVOLVED IN A MAJOR FRONT-END ACCIDENT WHICH THE DRIVER SUFFERED A SIGNIFICANT INJURY AND WAS EJECTED FROM THE VEHICLE. THE AIRBAGS FAILED TO DEPLOY, AND THE SEATBELT LATCH NEGLECTED TO KEEP THE DRIVER FROM BEING EJECTED FROM THE VEHICLE. THE DRIVER LOST CONTROL OF THE VEHICLE ON A CITY STREET AND COLLIDED WITH A POWER POLE AND THEN A SIGNAL POLE. UPON HEAD-ON COLLISION WITH THE SIGNAL POLE, THE VEHICLE CAME TO A STOP BUT THE AIRBAGS NEVER DEPLOYED AND THE SEAT BELT LATCH FAILED TO KEEP THE DRIVER IN THE VEHICLE. THE DRIVER WAS EJECTED FROM THE VEHICLE AND SUFFERED MAJOR INJURY.

NHTSA ID 10909463 · filed Sep 24, 2016

TL*THE CONTACT OWNS A 2004 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 50 MPH ON JUNE 23, 2010, A VEHICLE FAILED TO YIELD THE RIGHT OF WAY AND CRASHED INTO THE LEFT SIDE OF THE CONTACTS FRONT END OF THE VEHICLE. THE DRIVERS FRONTAL AIR BAG FAILED TO DEPLOY, AND THE SEAT BELT FAILED TO RESTRAIN THE DRIVER; HOWEVER, THE PASSENGER FRONTAL AIR BAG DEPLOYED. THE CONTACT SUSTAINED INJURIES TO THE CHEST AND BACK. A PASSENGER IN THE OTHER VEHICLE WAS ALSO INJURED. THE INSURANCE COMPANY CONFIRMED THAT THE VEHICLE WAS DESTROYED. THE VEHICLE WAS TOWED TO AN AUCTION LOT. THE MEMPHIS POLICE REPORT NUMBER WAS 10457802. THE MANUFACTURER ALSO FILED REPORT 0503361760. THE FAILURE AND CURRENT MILEAGES WERE 220,000.

NHTSA ID 10344733 · filed Jul 22, 2010

Too few reports in this category for a page of its own — they appear in the full complaint list.

Interior & seats

Reports naming seats, latches, locks, linkages and interior fittings.

5
reports

From owner reports, verbatim

TODAY, I GOT IN THE CAR AND SAT DOWN. THE SEAT SUNK DOWN UNEXPECTEDLY BY ABOUT 3 INCHES. WHEN I GOT OUT OF THE CAR IT POPS BACK UP. IT SINKS SO LOW I AM HAVING TROUBLE SEEING OVER DASH. THIS IS TOO DANGEROUS!

NHTSA ID 10779938 · filed Oct 5, 2015

2004 FORD EXPEDITION; HAD ORIGINAL TIRES PUT BACK ON VEHICLE AFTER HAVE AUTHORIZED TIRES REMOVED. FACTORY TIRES HAD APPROXIMATELY 300 MILES ON THEM. SEVERE VIBRATION IN FRONT END OF CAR BEFORE AND AFTER FACTORY TIRES WERE REINSTALLED. PAID TO HAVE TWO 4-WHEEL ALIGNMENTS, BALANCING ON BOTH SETS OF TIRES (FACTORY AND FORD AUTHORIZED UPGRADES) IN TWO MONTHS. FORD COULD NOT FIND ANY ISSUES WITH THE FRONT END OF THE VEHICLE". VIBRATION EXISTS WITH LESS THAN 1000 TOTAL MILES ON THE FACTORY TIRES. WAS TOLD THAT THEY COULD NOT BE BALANCED AND THAT I NEEDED TO CONTACT THE MANUFACTURER. SECOND INCIDENT IS: THE LEATHER MATERIAL ON THE SEATS HAS CRACKED AND HARDENED. WHEN SITTING, IT BEGINS TO POKE AND SCRATCH AND CAUSE IRRITATION TO THE SKIN. FORD WILL REPLACE PART OF THE LEATHER, BUT REFUSES TO REPLACE ALL OF IT BECAUSE "THE DAMAGE IS NOT BAD ENOUGH". *NM

NHTSA ID 10173429 · filed Nov 14, 2006

Too few reports in this category for a page of its own — they appear in the full complaint list.

Heating & air conditioning

Reports naming the heating, ventilation and air-conditioning system.

3
reports

From owner reports, verbatim

TL*-THE CONTACT OWNS A 2004 FORD EXPEDITION. THE CONTACT STATED THAT WHENEVER SHE TURNED THE REAR AIR CONDITIONING UNIT ON, SHE COULD HEAR A LOUD BANGING NOISE FROM THE REAR OF THE VEHICLE. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALERSHIP WHERE THE CONTACT WAS INFORMED THIS WAS A KNOWN FAILURE. THE CONTACT ALSO MENTIONED SHE EXPERIENCED THE SAME FAILURE A FEW YEARS AGO AND THE VEHICLE HAD THE REAR BLEND DOOR ACTUATOR REPLACED AT AN AUTHORIZED DEALERSHIP. THE FAILURE AND CURRENT MILEAGES WERE APPROXIMATELY 134,000. UPDATED 10/20/10 *BF UPDATED 10/22/10

NHTSA ID 10334260 · filed Jun 2, 2010

REAR A/C ACTUATOR SUDDENLY FAILED WITH NO WARNING. ABS LIGHT CAME ON AND DEALERSHIP SAID THAT AN ANIMAL CHEWED THROUGH THE WIRES TO THE ABS COMPUTER, WHICH WAS ODD BECAUSE I LIVE IN THE CITY OF LOS ANGELES WHERE THIS WAS UNHEARD OFF. COST ME $688 AND THE ABS LIGHT REMAINED ON. I DON'T EVEN HAVE PROOF THAT THEY DID ANYTHING. TRANSMISSION STOPPED SHIFTING INTO OVERDRIVE. DEALERSHIP SAID THAT THE ABS COMPUTER NEEDS TO BE REPLACED. COST ME $450. ABS LIGHT WENT OFF, BUT TRANSMISSION STILL DOESN'T SHIFT INTO OVERDRIVE. DEALERSHIP NOW SAYS THAT MY OVERDRIVE BAND IS WORN. THEY QUOTED ME $3,300 TO FIX. I HAVE ALSO HAD 3 BREAK JOBS WHICH COST $600 A PIECE PERFORMED IN LESS THAN 3 YEARS. WHICH I NEVER HAD THIS PROBLEM WITH ANY VEHICLE I' EVER OWNED. THIS TRUCK IS ONLY 3 YEARS OLD AND HAS HAD A TREMENDOUS AMOUNT OF EXPENSIVE PROBLEMS.*AK

NHTSA ID 10190733 · filed May 15, 2007

Too few reports in this category for a page of its own — they appear in the full complaint list.

Exterior lighting

Reports naming headlights, tail lights, turn signals and other exterior lighting.

3
reports

From owner reports, verbatim

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 · filed Mar 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 · filed Jan 14, 2023

Too few reports in this category for a page of its own — they appear in the full complaint list.

Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers.

Elsewhere on this vehicle

Data sources

Data on this page last refreshed .