2004 Ford Explorer problems, complaints & recalls
Most-reported problem areas: Power Train:automatic Transmission (281) · Structure:body (182) · Power Train (71)
🧭 Reliability snapshot
Compared against other Ford Explorer model years — complaint volume vs the model's median year, recalls and severity. How we score →
🛣️ Complaints by mileage
1,087 NHTSA complaints that reported an odometer reading.
Safety recalls (0)
No recalls on record for this model year (campaigns announced since 2010).
Service bulletins (109)
Technical service bulletins are repair instructions manufacturers send dealers for known issues. Unlike recalls, the fix is not automatically free — but naming the bulletin at the service desk can save diagnosis time and support goodwill repairs.
Structure 2019-02-07 · TSB 19-2026 · Service Bulletin/Repair Instructions
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 replacement is recommended. follow the service procedure steps to correct the condition
Structure 2019-02-07 · TSB 19-2026 · Service Bulletin/Repair Instructions
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 replacement is recommended. follow the service procedure steps to correct the condition
Engine And Engine Cooling:exhaust System:manifold/Header/Muffler/Tail Pipe 2016-09-21 · SSM 46085 · Service Bulletin/Repair Instructions
the powertrain control/emissions diagnosis (pc/ed) manual has been revised for diagnosing electronic throttle bodies (etbs). the etc_act and etc_dsd pids should not used to diagnose possible etb concerns. the ids has a limited refresh rate when reading these pids and cannot display quickly enough to
Engine 2012-08-01 · TSB-12-8-1 · Service Bulletin/Repair Instructions
ford/lincoln/mercury: may have sludge buildup in throttle body leading to less airflow or engine idling rpm fluctuation and hard starts or battery disconnect or dead battery after keep alive memory (kam) clear. models 2003-05 thunderbird, 05-06 mustang, 06-08 fusion, 04-05 explorer, 05-06 expedit
Engine 2012-07-10 · TSB-12-7-4 · Service Bulletin/Repair Instructions
ford/lincoln/mercury: if battery was disconnected or dead, vehicles/trucks may experience hard starts and engine idle rpm fluctuation and exhibit diagnostic trouble codes (dtcs) p0505, p0506, p2111 and p2112. *pe
Power Train:axle Assembly:axle Shaft:seal 2009-05-01 · TSB-08-19-3 · Service Bulletin/Repair Instructions
ford: some vehicles may exhibit oil separation from the internal lube found in the unitized cartridge seal. oil separation appears to be and is often misdiagnosed, as an axle lube leak. *pe
Showing the 6 most recent of 109 bulletins. Search all of them free at nhtsa.gov.
What owners report
2024-05-28 · Service Brakes“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 …”
2024-02-09 · Fuel/Propulsion System“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.…”
2023-07-19 · Fuel/Propulsion System · 🔥 fire“smoke for a good 5 mins under the hood oil leeking…”
2023-04-22 · Structure:body“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.…”
2022-08-31 · Air Bags · 153,000 mi · 💥 crash“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 tr…”
2021-11-12 · Steering“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…”
2021-07-13 · Wheels“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/036177…”
2021-04-23 · Tires · 96,125 mi“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..…”
2021-04-13 · Unknown Or Other · 96,200 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?…”
2021-02-09 · Vehicle Speed Control · 220,000 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 sp…”
Excerpts of consumer complaints filed with NHTSA, lightly truncated. They are owner statements, not verified findings.