NHTSA lists 1,322 complaints for the 2004 Ford Explorer, 61 of them mention a crash and 15 mention a fire. 71 complaints mention an injury, with 87 injuries and 0 deaths reported.
Data build 2026-10-08.
NHTSA lists this vehicle as FORD EXPLORER.
Model-generated complaint tags: This model year has not been tagged.
Investigations
4 investigations; 0 open.
EA09013
Opened: 2009-08-18. Closed: 2013-02-12.
Vehicle Rollaway Allegations
This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for an
Systems: POWER TRAIN, STEERING.
Linked campaign numbers: None listed.
PE09020
Opened: 2009-04-21. Closed: 2009-08-19.
VEHICLE ROLLAWAY ALLEGATIONS
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
Systems: STEERING.
Linked campaign numbers: None listed.
RQ08003
Opened: 2008-06-23. Closed: 2008-10-24.
REAR LIFTGATE GLASS HATCH FAILURE
THIS INVESTIGATION WAS OPENED ON JUNE 23, 2008, BASED ON 34 COMPLAINTS INVOLVING EIGHT INJURIES IN WHICH THE REAR LIFTGATE GLASS HATCH ON MODEL YEAR 2004 FORD EXPLORERS OR MERCURY MOUNTAINEERS BROKE OFF AND FELL, USUALLY WHILE INDIVIDUALS WERE OPERATING THE GLASS HATCH OR LOADING OR UNLOADING ITEMS FROM THE REAR OF THE VEHICLE.FORD CONDUCTED RECALL 04V-442 IN 2004 TO ADDRESS SIMILAR PROBLEMS ON MO
Systems: STRUCTURE, VISIBILITY.
Linked campaign numbers: None listed.
DP05005
Opened: 2005-09-22. Closed: 2006-01-04.
SPARK PLUG EJECTION FROM CYLINDER HEAD
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 CY
Systems: ENGINE AND ENGINE COOLING.
Linked campaign numbers: None listed.
Manufacturer communications
109 manufacturer communications.
Communications by system| System | Count |
|---|
| POWER TRAIN | 30 |
|---|
| ELECTRICAL SYSTEM | 21 |
|---|
| ENGINE AND ENGINE COOLING | 18 |
|---|
| FUEL SYSTEM, OTHER | 7 |
|---|
| STRUCTURE | 7 |
|---|
| VISIBILITY | 6 |
|---|
| TIRES | 5 |
|---|
| ENGINE | 3 |
|---|
10155551
Date: 2019-02-07. Type: Service Bulletin/Repair Instructions. Systems: STRUCTURE.
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
10156863
Date: 2019-02-07. Type: Service Bulletin/Repair Instructions. Systems: EQUIPMENT, STRUCTURE.
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
10109070
Date: 2016-09-21. Type: Service Bulletin/Repair Instructions. Systems: ENGINE, ENGINE AND ENGINE COOLING.
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
10048099
Date: 2012-08-01. Type: Service Bulletin/Repair Instructions. Systems: ELECTRICAL SYSTEM, ENGINE.
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
10045340
Date: 2012-07-10. Type: Service Bulletin/Repair Instructions. Systems: ENGINE.
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
10028736
Date: 2009-05-01. Type: Service Bulletin/Repair Instructions. Systems: POWER TRAIN.
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
10023943
Date: 2007-10-01. Type: Service Bulletin/Repair Instructions. Systems: ENGINE AND ENGINE COOLING.
SOME 1997-2008 VEHICLES EQUIPPED WITH A 4.6L 2V, 5.4L 2V, OR 6.8L 2V ENGINE--SPARK PLUG THREAD REPAIR PROCEDURE--NOT COVERED UNDER NEW VEHICLE LIMITED WARRANTY. *NJ THIS INCLUDES F-53 MOTORHOME CHASSIS. UPDATED 2/23/10. *PE
10019379
Date: 2006-01-01. Type: Service Bulletin/Repair Instructions. Systems: FUEL SYSTEM, OTHER.
MALFUNCTION INDICATOR LAMP ON WITH PCM DIAGNOSTIC TROUBLE CODE P0463 AND/OR IC DIAGNOSTIC TROUBLE CODE B1201 - FUEL GAUGE DROPS TO EMPTY OR SLOW TO UPDATE AFTER REFUELING. *TT
10019384
Date: 2006-01-01. Type: Service Bulletin/Repair Instructions. Systems: TIRES.
LOW TIRE INDICATOR ON - TPMS SYSTEM SENSOR WAKE UP. *TT
10019947
Date: 2006-01-01. Type: Service Bulletin/Repair Instructions. Systems: POWER TRAIN.
NEUTRAL TOW CAPABILITY - SERVICE KIT REQUIREMENTS. *TT