2004 Ford Explorer Sport Trac

IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), FORD STATED CONSUMER REPORTS OF HIGHER THAN EXPECTED EFFORTS WHEN SHIFTING INTO AND OUT OF PARK COULD BE A RESULT OF A GROOVE BEING WORN INTO THE SWING ARM RAMP OF THE STEERING COLUMN. THE SWING ARM IS A COMPONENT BOLTED TO THE STEERING COLUMN THAT ASSISTS IN SHIFTING THROUGH THE TRANSMISSION GEARS.AN ENGINEERING EVALUATION CONDUCTED BY FORD OF RETURNED STEERING COLUMNS FOUND THE GROOVE COULD BE CREATED OVER TIME IF CONSUMER SHIFT MORE QUICKLY FROM THE DRIVE OR REVERSE TO PARK THAN THE BRAKE SHIFT INTERLOCK (BSI) SOLENOID PIN RETRACTS AFTER THE BRAKE PEDAL IS APPLIED. IN NOVEMBER OF 2004, FORD RELEASED A REDESIGNED BSI SOLENOID WITH A SHORTER PIN RETRACTING TIME AS A SERVICEABLE COMPONENT. FORD HAS NOTED THE SHORTER RETRACTION TIME SIGNIFICANTLY LESSENS THE LIKELIHOOD OF BSI SOLENOID PIN TO SWING ARM CONTACT EVEN WITH RAPID CONSUMER SHIFTS.FORD ALSO ISSUED A TECHNICAL SERVICE BULLETIN, TSB 04-22-12, TO INSTRUCT SERVICE TECHNICIANS ON THE PROPER DIAGNOSIS AND VEHICLE REPAIR. REVIEWING COMPLAINTS TO ODI AND DATA SUBMITTED BY FORD, ODI HAS IDENTIFIED 200 ALLEGED INCIDENTS OF UNINTENDED VEHICLE MOVEMENT AFTER CONSUMERS BELIEVE THEY HAVE SHIFTED THE VEHICLE INTO PARK, RESULTING IN 85 ALLEGED CRASHES AND 32 ALLEGED INJURIES.IN ADDITION TO THE REPORTS OF ALLEGED INCIDENTS OF UNINTENDED VEHICLE MOVEMENT, ODI HAS ALSO IDENTIFIED 883 REPORTS OF CONSUMERS ALLEGING DIFFICULTY OR THE INABILITY TO SHIFT THE VEHICLE INTO PARK.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA09-013) TO FURTHER ASSESS THE SCOPE, FREQUENCY AND RISK TO MOTOR VEHICLE SAFETY OF THE ALLEGED DEFECT IN THE SUBJECT VEHICLES.

ON SEPTEMBER 6, 2005, ODI RECEIVED A PETITION REQUESTING THAT THE AGENCY INVESTIGATE ALLEGATIONS OF ENGINE SPARK PLUG EJECTION IN CERTAIN MODEL YEAR 1997 THROUGH 2004 FORD VEHICLES WITH TRITON V-8 AND V-10 ENGINES.ODI RECEIVED A TOTAL OF 474 NON-DUPLICATIVE COMPLAINTS ON THE SUBJECT VEHICLES WHERE THE COMPLAINANT, OR THE DEALER REPAIRING THE VEHICLE, REPORTED THAT A SPARK PLUG DETACHED FROM THE CYLINDER AND/OR EJECTED FROM THE ENGINE.AS OF DECEMBER 8, 2005, ODI IS NOT AWARE OF ANY ALLEGATIONS WHERE THE ALLEGED DEFECT RESULTED IN A LOSS OF VEHICLE CONTROL, A CRASH, AN INJURY, OR A FATALITY IN ANY OF THE 10,319,810 SUBJECT VEHICLES.IN ADDITION, ODI IS AWARE OF ONLY TWO INCIDENTS WHERE THE VEHICLE STALLED WITHOUT RESTART.INFORMATION CONTAINED IN THE ODI CONSUMER COMPLAINTS AND OBTAINED FROM 72 TELEPHONE INTERVIEWS WITH COMPLAINANTS SHOWED THE FOLLOWING:(1) 99% OF THE COMPLAINTS WERE ON MY 1997 TO 2002 SUBJECT VEHICLES.(2) MOST THE COMPLAINANTS REPORTED HEARING A LOUD POP WHILE DRIVING OR UPON STARTING UP THE VEHICLE FOLLOWED BY A LOUD, REPETITIVE CLICKING OR POPPING SOUND.(3) MANY OF THE COMPLAINANTS REPORTED THAT THE POPPING SOUND WAS ACCOMPANIED BY SOME LOSS OF VEHICLE POWER; HOWEVER, IN 99% OF THE INCIDENTS REPORTED, THE VEHICLE DID NOT STALL.IN THE VERY FEW INCIDENTS WHERE THE VEHICLE DID STALL, MOST VEHICLES COULD BE RESTARTED.(4) ONLY A SMALL PERCENTAGE OF THE COMPLAINANTS CITED THAT THEY SMELLED GAS OR A SLIGHT BURNING SMELL WHEN THE INCIDENT OCCURRED.(5) IN ALL BUT A VERY FEW INCIDENTS, VEHICLE DAMAGE WAS LIMITED TO THE ENGINE.IN ONE INCIDENT, THE COMPLAINT REPORTED THAT THE FUEL RAIL WAS DAMAGED AND REPLACED AFTER ONE OF THE SPARK PLUGS EJECTED FROM THE ENGINE; HOWEVER, THE COMPLAINANT REPORTED THAT THE DAMAGE DID NOT RESULT IN ANY TYPE OF FUEL LEAK OR FIRE.IN ANOTHER INCIDENT, THE ONLY INCIDENT WHERE A FIRE WAS ALLEGED, THE COMPLAINANT REPORTED THAT NO FLUID LEAK WAS OBSERVED, BUT THAT A FIRE RESULTED AFTER THE SPARK PLUG HAD EJECTED FROM THE ENGINE AND HE HAD RESTARTED THE VEHICLE AND DRIVEN TO ANOTHER LOCATION.NONE OF THE COMPLAINANTS REPORTED ANY DAMAGE TO THE VEHICLE HOOD.(6) ONLY TWO COMPLAINANTS REPORTED THAT THEY OBSERVED WHAT APPEARED TO BE SOME DROPS OF FUEL COMING FROM THE CYLINDER WHERE THE SPARK PLUG HAD FAILED OR ON THE SPARK PLUG ITSELF; HOWEVER, EACH OF THESE COMPLAINANTS REPORTED THAT THERE WAS NO SMOKE OR FLAMES AS A RESULT OF HIS INCIDENT.AS THE PETITIONER NOTED, AND ODI?S ANALYSIS SHOWED, IT IS POSSIBLE FOR A SPARK PLUG TO DETACH FROM THE ENGINE CYLINDER THREADS IN THE SUBJECT VEHICLES.HOWEVER, ODI?S ANALYSIS OF 474 COMPLAINTS DESCRIBING SUCH INCIDENTS FOUND ONLY A VERY FEW ALLEGED ANY SAFETY-RELATED CONSEQUENCES.NONE OF THESE SHOWED ANY EVIDENCE OF A SERIOUS SAFETY CONSEQUENCE.GIVEN THE LARGE POPULATION AND RELATIVELY LONG EXPOSURE TIME OF THE SUBJECT VEHICLES, THE COMPLAINT ANALYSIS INDICATES THAT THE RISK TO MOTOR VEHICLE SAFETY FROM THE ALLEGED DEFECT IS VERY LOW.IN VIEW OF THE FOREGOING, IT IS UNLIKELY THAT NHTSA WOULD ISSUE AN ORDER FOR THE NOTIFICATION AND REMEDY OF THE ALLEGED DEFECT AT THE CONCLUSION OF THE INVESTIGATION REQUESTED IN THE PETITION.THEREFORE, IN VIEW OF THE NEED TO ALLOCATE AND PRIORITIZE NHTSA?S LIMITED RESOURCES TO BEST ACCOMPLISH THE AGENCY?S SAFETY MISSION, THE PETITION IS DENIED.

All four side curtain airbags deployed while I was driving my car in a parking lot. There was no collision and no reason whatsoever for the airbags to deploy. The airbags in the dash did not deploy. The airbag hit me in the side of the head and shrapnel from the airbag, hit me in the face and eyes and knocked me sideways toward the passenger seat. I was completely stunned and had piercing pain throughout my head and neck. I was able to pull into a parking spot and call police dispatch, and get the car towed. The car will be inspected tomorrow by the insurance company, but because there was no reason for the airbags to deploy, this could be a major problem! Imagine if I was driving on the freeway or in another situation and the airbags just deployed for no reason with no warning. Please take immediate action to get these unsafe airbags off the road. The car will be inspected by the insurance company in the morning and the service provider in the following days. If you would like those reports, I will be happy to send them to you.

NHTSA ID

11592762

Incident

Jun 5, 2024

THE BODY OF MY 2004 FORD EXPLORER SPORT TRAC XLT HAS RIVETS ON THE TOP OF THE ROOF THAT HOLD WATER. INSTEAD OF BEING A FLAT SURFACE WHERE RAIN CAN NATURALLY FALL OFF THE TOP OF THE ROOF IT SITS IN THESE RIVETS AND ACCUMULATES RUST. THIS LEADS TO A LOT MORE PROBLEMS.

NHTSA ID

11299314

Incident

Oct 20, 2017

SEATBELT MECHANISM FOR DRIVER SIDE AND PASSENGER SIDE IS INOPERABLE. IT DOESN'T LOCK AFTER YOU PUT YOUR SEATBELT ON. THE MECHANISM YOU PUT THE SEATBELT BUCKLE IN IS GOOD BUT AFTER THAT THE LOCK MECHANISM FOR THE BELT TO RETRACT ISN'T WORKING PROPERLY. IT DOESN'T MATTER IF YOU ARE DRIVING OR PARKED.

NHTSA ID

11267608

Incident

Sep 11, 2019

Mileage

110,000 mi

TL* THE CONTACT OWNS A 2004 FORD EXPLORER SPORT TRAC. THE CONTACT STATED THAT THE DRIVER AND FRONT PASSENGER SEAT BELTS FAILED TO RETRACT AND LOCK IN POSITION. THE CONTACT CALLED SANDERS FORD (LOCATED AT 1006 W CORBRELT AVE, SWANSBORO, NC 28584, 910-326-1801) AND WAS INFORMED THAT THE SEAT BELTS WERE NO LONGER COVERED UNDER WARRANTY; THEREFORE, THE CONTACT WOULD BE RESPONSIBLE FOR THE DIAGNOSTIC AND REPAIR COST. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 110,000. THE VIN WAS INVALID.

NHTSA ID

11267598

Incident

Jan 1, 2018

Mileage

110,000 mi

DURING NORMAL USE, USUALLY WHEN IN MOTION BUT FREQUENTLY WHEN THE VEHICLE IS NOT IN MOTION, THE DRIVERS SEAT SUDDENLY FLOPS BACKWARDS TO THE RECLINE POSITION. THIS HAS BEEN AN ISSUE SINCE THE TRUCK WAS ABOUT THREE YEARS OLD. I TOOK IT TO THE DEALER ONE TIME BUT THEY SAID THEY WOULD HAVE TO KEEP THE TRUCK; THAT DIDNT WORK FOR ME BECAUSE I WOULD HAVE NO TRANSPORTATION AND I ALWAYS HAVE TO GO TO WORK, THEN AND NOW. I SAW A RECALL ON THE 2010 FOR THIS AND FIGURED I WOULD LET YOU KNOW IT WAS FOR A LOT LONGER THAN THAT. IT MIGHT HELP EXPLAIN SOME DEAD PEOPLE IN SPORT TRACS. I CERTAINLY HAD SOME ANXIOUS MOMENTS AT TIMES IN THE 15 YEARS WITH MY TRUCK..IVE TRIED TO FIX IT SEVERAL TIMES WITH NO REAL SUCCESS, A NEW SEAT IS EXPENSIVE, USED SEATS ARE GOING TO DO THE SAME THING BUT SINCE MY SEAT HAS ALSO COLLAPSED I GUESS I NEED TO REPLACE IT.

NHTSA ID

11267173

Incident

Oct 8, 2019

Mileage

10,000 mi

TL* THE CONTACT OWNED A 2004 FORD EXPLORER SPORT TRAC. WHILE DRIVING 40 MPH IN INCLEMENT WEATHER AND ROAD CONDITIONS, THERE WAS A LOSS OF TRACTION AND STEERING ABILITY. THE VEHICLE SPUN OUT OF CONTROL, ROLLED OVER AT LEAST FIVE TIMES, AND CRASHED INTO A DITCH. THE SEAT BELT RESTRAINED THE DRIVER; HOWEVER, THE AIR BAGS DID NOT DEPLOY. THE DRIVER SUSTAINED EXTENSIVE BRUISING ON THE RIGHT SIDE OF THE BODY, WHICH REQUIRED MEDICAL ATTENTION. A POLICE REPORT WAS FILED. MILLER MOTOR SALES INC (1196 MILWAUKEE AVE, BURLINGTON, WI 53105, (888) 449-0974) WAS NOTIFIED. THE CAUSE OF THE FAILURE WAS NOT DIAGNOSED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS DESTROYED AND TOWED TO A YARD BY THE INSURANCE COMPANY. THE APPROXIMATE FAILURE MILEAGE WAS 204,000.

NHTSA ID

11187003

Incident

Mar 9, 2019

Mileage

204,000 mi

INSTRUMENT PANEL CLUSTER GAUGES AND ODOMETER DROP TO ZERO AT TIMES WHILE DRIVING, AND I DON'T KNOW MY SPEED AND WELL AS RPM'S. AFRAID THE ENGINE MIGHT SLOW DOWN OR STOP CREATING A POSSIBLE FREEWAY ACCIDENT. ON LINE THERE ARE SEVERAL COMPLAINT ABOUT THIS PROBLEM.

NHTSA ID

11132434

Incident

Sep 5, 2018

Mileage

168,000 mi

HAVE HAD 2 OF THESE 2004 FORD SPORT TRAC TRUCKS. ONE WHICH WAS FLIPPED ONTO MY DRIVER SIDE AND TOTALED IN AN ACCIDENT WHERE I WAS HIT DOING 25MPH DOWN A BACK ROAD WHITH A STOP SIGN INTERSECTION, NO AIRBAGS WENT OFF THE ONLY THING THAT SAVED ME WAS MY SEAT BELT FROM WORSE INJURES. MY CURRENT TRUCK WHICH HAS BEEN WELL MAINTAINED AND I STILL HAVE ALL RECEIPTS FOR OVER 5000 WORTH OF WORK DONE, RECENTLY WITH OVER A QUARTER TANK OF GAS TURNING LEFT WILL CUT OUT AND DIE COMPLETELY IN TRAFFIC WHICH HAS ALMOST CAUSE ME TO BE HIT A COUPLE TIMES WITH MY CHILD IN THE CAR. ALSO MY TRANSMISSIONS WENT OUT AND LOST GEARS AT LOW MILEAGE. I TOOK MY CURRENT TRUCK TO RICHARDS TRANSMISSION WHERE THEY TOLD ME THE FORD SPORT TRACK TRANSMISSION NORMALLY DOESN'T LAST PAST 50,000 MILES THAT FORD DID NOT MACHINE THE TRANSMISSION CORRECTLY WHICH IS A KNOWN PROBLEM IN THE FORD SPORT TRAC. BEFORE THE TRANSMISSION STARTED TO SLIP MY O/D WOULD KICK ON AND CAUSE SEVERE JERKING OUT OF FIRST GEAR BUT ONLY WHILE THE O/D WAS ON. I COULD NOT GET IT TO TURN OFF UNLESS I SHUT OFF THE ENGINE. I'VE HAD MY COOLANT AND TRANSMISSION FLUID MIX AND HAVE HAD TO REPLACE THE RADIATOR TWICE BECAUSE OF THIS ABOUT 3000 MILES BEFORE THE TRANSMISSION COMPLETELY LOST SECOND GEAR. I BELIEVE FORD SHOULD FIX THIS, I ENJOY MY TRUCK BUT COULD HAVE BEEN CRITICALLY INJURED A FEW TIMES DUE TO MALFUNCTIONING THAT FORD SHOULD FIX.

NHTSA ID

10984446

Incident

May 27, 2014

Mileage

89,000 mi

NEUTRAL TOW CAPABILITY - SERVICE KIT REQUIREMENTS. *TT

NEUTRAL TOW CAPABILITY -- SERVICE KIT REQUIREMENTS. *TT

IRREGULAR TIRE WEAR. *SC

STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE. *TT

MALFUNCTION INDICATOR LAMP COMING ON WITH DIAGNOSTIC TROUBLE CODES (DTCS) P0171, P0172, P0174 AND/OR P0175 (FUEL SYSTEM TOO RICH OR LEAN). *TT

SAFETY BELT RETRACTION SPEED. *TT