2004 Ford Explorer Owner Complaints

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 after paying $539.95 for power steering low pressure and brake line. Wife's Eddie Bauer 2004 v8 was reported to FORD Motor Co. Case# [XXX] defective copper brake lines on suv. No good will offered no warrantee fue to latent defective brake line copper tubing coming from ABS modular. ABS LIGHT COMES ON AT TIMES. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11591062

Incident

May 8, 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 at a Ford dealership, no help. That's a big safety problem. Ford provided the contacts phone number to the junkyards but the contact doesn't want the gas tank from a junkyard who probably put holes in them to drain the gasoline out of the tank.

NHTSA ID

11570989

Incident

Feb 8, 2024

Smoke for a good 5 mins under the hood oil leeking

NHTSA ID

11533148

Incident

Jul 16, 2023

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.

NHTSA ID

11518469

Incident

Jan 19, 2023

The contact's son owned a 2004 Ford Explorer. The contact stated that while her son was driving in the rain at approximately 35 MPH, the vehicle hydroplaned as he rounded a corner. The vehicle slid into a ditch and hit a tree on the passenger side of the vehicle. The air bags did not deploy upon impact. The contact's son and his friend were both transported to the hospital for their injuries. Her son was treated for soreness in various parts of his body and was released the same day. Her son's friend had to remain in the hospital overnight and his injuries were unknown. A police report was filed. The vehicle was towed from the independent collision center where it remained in their possession. The dealer nor the manufacturer had yet to be notified of the failure. The vehicle had yet to be repaired or destroyed. The failure mileage was approximately 153,000.

NHTSA ID

11482255

Incident

Aug 29, 2022

Mileage

153,000 mi

On two incidents this week when steering wheel is cut to maximum left or right in tight parking lot and narrow road while making tight turns at legal speeds the engine (V8 4.6L) stalls. Brought to non-Ford mechanic for inspection(NYS ANNUAL) and passes but mechanic looked for a power steering pressure sending sensor or switch that is to give signal to EMC to increase idle to compensate for more power steer demands. Part is $35 at Partgeek but mechanics dont know where the harness the sending switch is located, if one exists or is it in power steering pump. Call Ford NADA! Call two local Ford dealers. One says dont work on cars 15 years old, other says go to liabary to get diagrams, Ford says obsolete parts in 10 years.Bummer! Husband ordered 8/10/20 New 2021 Bronco. Pushed into 2022 due to supply chain. Found out Bronco built at MAP same as Ranger, will not get stronger 10r80 transmission,but Explorer 10r60, 25% weaker ; and gets Explorer 2.3L EgoBoost non- Ranger improved 4×4 engine , although they say same transmission and improved engine as Ranger in ads. Ford Buit Tought? MY2022! PLEASE INVESTIGATE THIS HIGHWAY TRAFFIC SAFETY ISDUE. NO BRAKING NOR STEERING WHEN SENSON IN POWER STEERING STALLS 4.6L ENGINE. Cannot apply gas and brake to keep from stalling when making sharp turns. I am 75 years old and with COPD. Serpertine belt replace before incidents.

NHTSA ID

11440207

Incident

Nov 4, 2021

on 5/6/21 at Ramp Ford 4869 Nesconset Hwy.,Pt. Jeff.Sts.,NY at 10:00am dealer sevice Mgr. met with NYSDMV Auto Facilities Inspector on a claim against Mavis Discount Tire,556 Route 25A, Mt Sinai,NY case 1Pi-01937 on a right rear wheel. Ramp removed R/R wheel to inspect with state inspector, appears like axle nut on r/r has not been removed r/0361772. On 7/12/21 Mt. Sina Tire r/0 7828-18 when fixing a tire flat, found r/r one broken stud,one addition lug nut missing from r/r wheel. Immediately Ramo service manager denied his tech improperly reassembled r/r wheel nuts on all five wheel assembly studs. With three studs the Ford vehicle was in inimanent highway danger. Such lost of 40% of wheel nuts may have caused lost of life. Mt. Sinai tire replaced fourth missing nut, fixed flat and scheduled fifth wheel assembly stud. Ramp 's general manager was imformed of poor and dangerios service and stated he was not a mechanic! Reimbursement for 5/6/21 were denied by dealer! Dealers .denies any warantees of labor since customer signed their disclaimer. All repairs are provided by the dealer facility1520504 AS IS WITHOUT ANY WARRANTY OF GUARANTEE! This disclaimer was only signed by non-owner after inspector left dealer. Inspector has pictures and stated he did not see the reassembly of r/r brakes, calebre, wheel nuts after inspection was completed. This was a dangerious omission of not properly torquing nut to Ford Motor spec. FORD MOTOR denies any warantee of repairs by Ramp.

NHTSA ID

11424544

Incident

Jul 13, 2021

MICHELIN CROSSTERRAIN TIRES SUFFERING TREAD SEPARATION. THREE OUT OF FOUR SO FAR. HAD I NOT BEEN PAYING ATTENTION TO THIS PROBLEM IT WOULD HAVE HAPPENED ON THE HIGHWAY..

NHTSA ID

11413513

Incident

Apr 21, 2021

Mileage

96,125 mi

TIRES! TIRES! TIRES! AGAIN! A SECOND TIRE HAS SUFFERED TREAD SEPARATION AND FAILED COMPLETELY. WHY CAN'T I GET ANYONE TO TAKE THIS PROBLEM SERIOUSLY?

NHTSA ID

11407982

Incident

Mar 26, 2021

Mileage

96,200 mi

ENGINE DIES WHEN DRIVING WITH CRUISE CONTROL OPERATING AND HEADING DOWN SLIGHT HILL AT SPEED OF AROUND 35 MPH. CRUISE IS DESIGNED TO MAINTAIN DRIVING SPEED GOING DOWN THE HILL (UP OR DOWN HILL FOR THAT MATTER). THE TACHOMETER INDICATES A SLOWING OF ENGINE RPM. AT HIGHER SPEEDS, THE SLOWING OF RPM DOES NOT FALL TOO LOW. HOWEVER, AT THE SLOWER SPEED AROUND 35MPH, THE RPM DROPS BELOW 500 RPM AND THE ENGINE STALLS. I LOSE POWER STEERING AND BREAKS. I HAVE A DIFFICULT TIME STEERING AND BREAKING. THIS IS A SAFETY PROBLEM ON A CURVE OR IF A RED LIGHT IS AHEAD. I CAN'T STEER THE CAR ON THE CURVE. I MAY NOT BE ABLE TO STOP THE CAR AT THE TRAFFIC LIGHT AND END UP IN AN INTERSECTION AND BE HIT BY VEHICLES WITH A GREEN LIGHT. I MAY HIT A CAR IN FRONT OF ME THAT HAS STOPPED AT A LIGHT OR STOP SIGN. I MAY NOT BE ABLE TO STOP FOR A PEDESTRIAN CROSSING AT THE INTERSECTION (WITH THE LIGHT). I MAY NOT BE ABLE TO AVOID A CHILD ... WHO DARTS INTO THE ROADWAY. THIS IS A PROBLEM FOR MANY OWNERS OF THE 2004 EXPLORER. THERE ARE MANY COMPLAINTS ABOUT IT ON THE WEB. IT IS A PROBLEM THAT HAS BEEN NOTED FOR YEARS. I COMPLAINED ABOUT IT TO DEALERS SEVERAL TIMES. DEALERS DISMISSED IT AS NOTHING CAN BE FOUND, REPLICATED OR JUST NOT A PROBLEM. IT IS TIME TO RECALLL THE VEHICLE TO FIX THIS SAFETY PROBLEM. THIS IS AN ONGOING PROBLEM. I TRY TO AVOID USING CRUISE CONTROL CONTROL AT THE 35MPH RANGE. IT SEEMS OK AT HIGHWAY SPEEDS. THE LAST OF MANY INSTANCES WAS IN NOVEMBER 2020. THE PROBLEM FIRST HAPPENED WHEN THERE ABOUT 30,000 MILES ON THE CAR.

NHTSA ID

11395422

Incident

Nov 12, 2020

Mileage

220,000 mi

WHILE DRIVING HOME FROM WORK LAST WEEK I NOTICED A SLIGHT 'BUMPING' FEEL LIKE AN UNBALANCED TIRE, SO I TOOK A LOOK WHEN I GOT TO MY DRIVEWAY BUT FOUND NOTHING. THE NEXT DAY ON MY WAY TO WORK THE "BUMPING' WAS MUCH WORSE SO I STOPPED TO CHECK AND FOUND A LARGE BULGE ON THE TREAD OF THE RIGHT FRONT TIRE. AFTER SLOWLY RETURNING HOME I REMOVED IT AND SET IT ASIDE. A FEW HOURS LATER THE THREADS WERE SEPARATING BADLY SO I LET THE AIR OUT BEFORE IT BLEW APART. I ORDERED A REPLACEMENT TIRE (DIFFERENT BRAND) BUT I'VE STILL GOT THREE MORE OF THESE ON THE VEHICLE .THEY HAVE 36K MILES ON THEM AND A 60K WARRANTY WITH ONLY MODEST THREAD WEAR BUT I STILL CHECK THEM EVERY DAY. I DON'T FEEL SAFE.*DT CONSUMER STATED HE STILL HAS A DEFECTIVE TIRE.*JB

NHTSA ID

11389077

Incident

Jan 13, 2021

Mileage

94,000 mi

THIS PAST WEEKEND I WAS DRIVING AN 04 FORD EXPLORER WHEN BOTH SIDE AIRBAGS SPONTANEOUSLY DEPLOYED. I WAS NOT IN AN ACCIDENT. I WAS DRIVING DOWN A TWO-LANE ROAD AT LESS THAN 35 MILES PER HOUR WHEN THE AIRBAGS DEPLOYED. I WAS ABLE TO PULL OVER BUT NOT BEFORE SUSTAINING AN INJURY TO MY EAR AND NOT BEFORE THE PASSENGER SUSTAINED AN INJURY TO HER RIGHT ARM. I REPORTED THIS TO FORD, WHICH ADVISED TO CARRY THE VEHICLE TO A DEALERSHIP. TOOK IT TO THE DEALERSHIP, WHERE THE SERVICE MANAGER WAS UNCONCERNED WITH THE FACT THAT THE AIRBAGS SPONTANEOUSLY DEPLOYED. HE LOOKED AT THE VEHICLE FOR TWO DAYS ONLY TO REPORT HE WAS NOT AWARE OF WHY THE AIRBAGS DEPLOYED AND STATED THERE WAS NOTHING HE COULD DO ABOUT IT. I REPEAT, I WAS NOT IN AN ACCIDENT AND THE AIRBAGS DEPLOYED WHILE DRIVING. THIS IS OF COURSE QUITE CONCERNING TO ME BUT FORD DOES NOT SEEM TO CARE. PLEASE FOLLOW-UP ON THE SAFETY OF FORD'S VEHICLES.

NHTSA ID

11337948

Incident

Jul 5, 2020

Mileage

62,000 mi

TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE WHEEL STUDS DETACHED ON MULTIPLE TIRES WHILE DRIVING. THE FAILURE RECURRED THREE TIMES ON MULTIPLE WHEELS ON DIFFERENT OCCASIONS. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN ONCE TO AN INDEPENDENT MECHANIC WHERE THE STUDS WERE REPLACED; HOWEVER, THE FAILURE CONTINUED. THE CONTACT ALSO STATED THAT SHE REPLACED MULTIPLE STUDS HERSELF. THE MANUFACTURER AND DEALER WERE NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 120,000.

NHTSA ID

11286314

Incident

May 10, 2017

Mileage

120,000 mi

THE VEHICLE WAS MOVING AT A SLOW RATE OF SPEED (APPROX 5-10 MPH) ON A BUMPY ROAD. THE DRIVER WAS LOOKING FOR A PARKING SPACE. THE SIDE AIRBAGS DEPLOYED. THE INSURANCE COMPANY HAS DETERMINED THAT THERE WAS NO COLLISION OR REASON FOR THE AIRBAGS TO DEPLOY AND THEREFORE THEY WILL NOT COVER THE DAMAGE.

NHTSA ID

11265739

Incident

Apr 14, 2019

Mileage

225,000 mi

MY 2004 FORD EXPLORER HAS RECENTLY AND QUICKLY BEGAN SHIFTING VERY BADLY. I ALWAYS COME TO A COMPLETE STOP AND SHIFT INTO NEUTRAL BEFORE SHIFTING INTO REVERSE OR DRIVE BECAUSE WHEN SHIFTING INTO REVERSE FROM P OR D, IT ALWAYS TAKES A WHILE, THEN CLUNKS AGGRESSIVELY INTO PLACE. WHILE DRIVING SOMETIMES DOWNSHIFTING WILL ALSO CLUNK INTO PLACE. THIS ISSUE HAS BEEN REPORTED BY COUNTLESS OTHER DRIVERS AND HAS CAUSED MANY POTENTIALLY DANGEROUS SITUATIONS. FROM ACCELERATING SLOWLY THEN BANGING GEARS AND TAKING OFF, TO STUTTERING WHILE TRYING TO ACCELERATE, OR EVEN SWITCHING INTO REVERSE WHILE PARKING, AND HAVING THE CAR TRY TO JUMP BACK A FEW INCHES IS ONLY A FEW ISSUES THIS PROBLEM HAS CAUSED MYSELF AND COUNTLESS OTHERS. PEOPLE ARE REPLACING TRANSMISSIONS LEFT AND RIGHT TO NO AVAIL, ONLY A FEW 10 THOUSAND MILES AFTER INSTALLING NEW TRANSMISSIONS, THEIR CAR STARTS TO EXPERIENCE THE SAME ISSUES AS BEFORE. AT LOW SPEEDS AND IN PARKING LOTS THIS BECOMES A GAME OF LUCK AS YOU ACCELERATE MORE THAN NECESSARY TO TRY TO GET GOING, THEN STOPPING AND WAITING A FEW SECONDS WHILE YOU SHIFT TO NEUTRAL BEFORE SHIFTING TO REVERSE AS FEAR OF IT BANGING INTO GEAR AS YOU TRY TO MANEUVER YOUR CAR AROUND PEOPLE AND OTHER PARKED CARS BECOMES A MORE DANGEROUS TASK THAN IT SHOULD BE. IN SUM, WHILE STATIONARY, SLOW SPEED, OR JUST CRUISING, THE TRANSMISSION WHILE SHIFTING GEARS, OR SHIFTING INTO REVERSE/DRIVE, SOMETIMES WANTS TO BANG INTO GEAR OR LOSE POWER, OR DELAY SHIFTING ONLY TO BANG INTO GEAR MOMENTS LATER. SOME ISSUES WHEN TAKING CARS INTO REPAIR IS FINDING METAL TRANSMISSION SHAVINGS WHERE THEY SHOULDNT BE! FINALLY, THE EXCESSIVE BANGING CAN ALSO DAMAGE THE ENGINE OVER TIME IN ADDITION TO THE TRANSMISSION. PLEASE REFERENCE THE FOLLOWING LINK TO GET A BETTER IDEA OF THE ISSUES: HTTPS://WWW.CARCOMPLAINTS.COM/FORD/EXPLORER/2004/TRANSMISSION/TRANSMISSION_SLIPPING_SHIFTS_HARD.SHTML THANKYOU

NHTSA ID

11258464

Incident

Sep 24, 2019

THE IGNITION KEYS LOSES THE PROGRAM AND I CONSTANTLY HAVE TO HAVE NOTH REPROGRAMED. I WAS TOLD THIS WAS A RECALL THAT FORD KNOWS ABOUT. THE CAUSE THE CAR INABILITY TO START

NHTSA ID

11245234

Incident

Aug 18, 2019

Mileage

164,400 mi

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 . THIS IS UNSAFE AND FORD MOTOR KNOWS OF COMPLAINST. PART ARE NOT AVAILBLE. THIS IS A HIGHWAY SAFETY ISSUE. THE MODEL WAS THE EDDIE BAUER TOP OF THE LINE $40,,835 CAR FMV $5000 ONLY 54000 MILES PRI LEVEL CODE 450240U74 SHIP WGT 4357

NHTSA ID

11233554

Incident

Jan 1, 2014

Mileage

50,000 mi

TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. THE CONTACT STATED THAT THE BRAKE LAMPS, TURN SIGNALS, AND EMERGENCY FLASHERS FAILED TO OPERATE PROPERLY. THIS WAS A DISTRACTION TO THE CONTACT'S DRIVING BECAUSE HE COULD NOT NOTIFY OTHER DRIVERS OF THE VEHICLE'S MOVEMENTS. THE VEHICLE WAS DRIVEN TO AN INDEPENDENT MECHANIC, BUT THEY DID NOT HAVE TIME TO DIAGNOSE THE VEHICLE. THE CONTACT CALLED A FORD CUSTOMER SERVICE LINE, BUT THEY DID NOT ASSIST. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 264,000.

NHTSA ID

11228959

Incident

Jun 20, 2019

Mileage

264,000 mi

MY STEERING COLUMN BROKE RIGHT OFF! TRYING TO PUT IT IN DRIVE @99,735 MI. HAD TO TOW IT TO SHOP, AND REPLACE THE STEERING COLUMN. I SEE OTHER PEOPLE HAD THIS SAME PROBLEM. THERE SHOULD BE A RECALL FOR THIS!!! I ALSO HAD TO REPLACE THE TRANSMISSION @ 103,000 MILES IT WOULD SKIP 3RD GEAR. SEEMS EVERYONE ELSE HAS TO REPLACE THE TRANSMISSION. ALSO BACK BEARINGS!! WHAT A DISGRACE. RECALL THIS DISGRACEFUL WORKMANSHIP! NO HONOR!

NHTSA ID

11221524

Incident

Aug 24, 2017

Mileage

99,735 mi

I WAS GETTING STUFF OUT OF MY BACK SEAT AND MY REAR WINDOW JUST BLEW OUT SHATTERING GLASS ALL OVER .THE BOTTOM PIECE THAT SECURES THE GLASS TO THE DOOR WARPRED ABOUT 6 INCHED ON EACH SIDE EXPLODING THE GLASS

NHTSA ID

11174673

Incident

Feb 5, 2019

Mileage

170,000 mi

I HAVE CRACKS IN THE PLASTIC ON THE OUTSIDE OF MY LIFT GATE . EACH TIME I USE THE HANDLE TO LIFT THE CRACKS BECOME WORSE. THERE ARE SEVERAL POSTS ONLINE ASKING ABOUT THE SAME PROBLEM. EVERY ONE I SEE IN A PARKING LOT OR ON THE ROAD HAS THE SAME PROBLEM. FORD REPORTS THAT IT AFFECTS 1997-2007 EXPLORERS. I DON'T UNDERSTAND WHY THIS HASN'T BEEN ADDRESSED. I CALLED FORD AND THEY REFERRED ME TO YOUR ORGANIZATION. SOME OF THESE CRACKS I HAVE SEEN REACH TO THE BACK WINDOW WHICH I BELIEVE WOULD BE A SAFETY HAZARD.

NHTSA ID

11174477

Incident

Nov 6, 2009

Mileage

61,000 mi

TL* THE CONTACT OWNED A 2004 FORD EXPLORER. WHILE THE CONTACT'S SON WAS DRIVING 40 MPH, HE LOST CONTROL OF THE VEHICLE AND STRUCK A TREE, A LIGHT POST, AND AN ELECTRICAL BOX. THE AIR BAGS DID NOT DEPLOY. THE CONTACT'S SON WAS NOT INJURED. A POLICE REPORT WAS FILED AND THE VEHICLE WAS TOWED TO A TOW YARD. THE VEHICLE WAS NOT TAKEN TO A DEALER TO BE DIAGNOSED AND WAS DEEMED A TOTAL LOSS BY THE TOW COMPANY. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 291,000.

NHTSA ID

11170037

Incident

Dec 23, 2018

Mileage

291,000 mi

TL* THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE DRIVING AND ATTEMPTING TO SHIFT GEARS, THE CONTACT'S SON PULLED TOO HARD AND FRACTURED THE GEAR SHIFTER. THE CONTACT STATED THAT THE GEAR SHIFTER WAS CURRENTLY TOO LOOSE AND WOULD NOT SHIFT INTO ANY GEAR. THE DEALER AND MANUFACTURER WERE NOT CONTACTED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE MILEAGE AND VIN WERE UNKNOWN.

NHTSA ID

11163755

Incident

Dec 12, 2018

TL* THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE REVERSING, THE CONTACT'S VEHICLE ACCELERATED ON ITS OWN AND CRASHED INTO A CHEVROLET COBALT. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE AIR BAGS DID NOT DEPLOY. THERE WERE NO INJURIES. A POLICE REPORT WAS FILED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, BUT THE FAILURE COULD NOT BE DIAGNOSED. THE LOCAL DEALER AND MANUFACTURER WERE NOT CONTACTED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE RECURRED MULTIPLE TIMES, RESULTING IN THE CONTACT CRASHING INTO A TREE AND OTHER UNKNOWN VEHICLES. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE AIR BAGS DID NOT DEPLOY. THERE WERE NO INJURIES. A POLICE REPORT WAS FILED. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE. THE LOCAL DEALER WAS NOT CONTACTED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS CONTACTED AND DID NOT ASSIST. THE FAILURE MILEAGE WAS 175,000. THE VIN WAS UNKNOWN. *TT VIN IS NOT VALID *JB

NHTSA ID

11150300

Incident

Aug 13, 2018

Mileage

181,000 mi

THE DRIVERS SEAT BELT HAS COME UNLOCKED ON SEVERAL OCCASIONS. IT HAS HAPPENED SO MANY TIMES I TUG HARD EVERY TIME I BUCKLE UP TO MAKE SURE IT'S CLICKED AND IT HAS UNLOCKED WHILE DRIVING EVEN THOUGH I DOUBLE CHECK IT.

NHTSA ID

11145262

Incident

Nov 3, 2018

Mileage

189,000 mi