Problems owners report
Complaints filed with NHTSA about the 2004 Ford Expedition, by the system named in each complaint. One complaint can name several.
- Air bags46
- Electrical system36
- Service brakes, hydraulic34
- Engine29
- Power train27
- Tires26
- Engine and engine cooling26
- Structure24
- Vehicle speed control21
- Fuel/propulsion system19
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 60 injuries and 1 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Fatal crashes in the US
From 2020 to 2023, 116 2004 Expedition vehicles were involved in crashes on US public roads in which someone died; 96 people died inside them, and 48 of the vehicles rolled over. This is a count, not a crash rate: it grows with the number of cars on the road.
NHTSA Fatality Analysis Reporting System (FARS), crash years 2020–2023 (public domain)
New York safety inspections
At its first New York inspection the 2004 Ford Expedition failed the safety check 2.18% of the time — 1% less often than the average 2004 passenger car (2.21%). Median odometer at inspection: 173,735 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
In New Zealand
1 2004 cars are on the New Zealand register; 100% arrived as used imports, 0% were sold new in New Zealand.
NZ Transport Agency Waka Kotahi, Motor Vehicle Register (March 2026) · CC BY 4.0
Fuel consumption
Official Canadian test results for 2 variants: combined 16.7–17.5 L/100 km (about 13–14 mpg US), CO₂ 384–403 g/km.
| Variant | City | Highway | Combined |
|---|---|---|---|
| Expedition 4X4 · Sport utility vehicle · Regular gasoline | 19.0 | 13.9 | 16.7 |
| Expedition 4X4 · Sport utility vehicle · Regular gasoline | 19.7 | 14.9 | 17.5 |
Litres per 100 km. Natural Resources Canada, Fuel consumption ratings (open.canada.ca) · Open Government Licence – Canada
Recalls
No recall campaigns cover the 2004 Ford Expedition.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Ford told its dealers about the 2004 Ford Expedition: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 11005305 | This article supersedes TSB 22-2219 to update the Parts List and Service Procedure to clarify applicable steps by vehicle application. Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 (non-Raptor) vehicles equipped with 4WD may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (IWE). To correct this condition, follow the Service Procedure to remove and cap the vacuum supply line or to reprogram the transfer case control module (TCCM) and replace any worn vacuum and/or IWE components. |
| 10235153 | For 2000-2024 Ford and Lincoln vehicles, swapping a module from a vehicle for diagnosis purposes is likely to cause errors and is not recommended. It is also not recommended to order a replacement module using a vehicle identification number (VIN) from a different vehicle. Most modules on these affected vehicles are VIN/vehicle specific and hardware variations between modules do exist. Swapping a module from a vehicle or ordering a module using a different vehicle/VIN can cause ineffective repairs and additional vehicle down time. Make sure all appropriate Workshop Manual (WSM) procedures are |
| 10214754 | Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 (non-Raptor) vehicles equipped with 4WD may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (IWE). To correct this condition, follow the Service Procedure to remove and cap the vacuum supply line or to reprogram the transfer case control module (TCCM) and replace any worn vacuum and/or IWE components. |
| 10181917 | Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 vehicles equipped with TOD transfer cases may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (IWE). To correct this condition, follow the Service Procedure steps to remove and cap the vacuum supply line. |
| 10177863 | This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/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. |
| 10156863 | 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 |
| 10155551 | 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 | 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 validate a concern. The PCM automatically monitors these inputs more accurately and will set diagnostic trouble codes (DTCs) when appropriate. Using these PIDs for diagnostics will lead to inaccurate results and improper ETB replacements. If a concern is intermittent and no DTCs are present, refer |
| 10028736 | 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 | 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 |
| 10021072 | AIR SUSPENSION PERFORMANCE - HEIGHT SENSOR LINKAGE ARM DISENGAGING. *KB |
| 10020132 | BRAKE SHUDDER. *TT |
| 10019415 | UNINTENDED BRAKE ASSIST. *TT |
| 10019384 | LOW TIRE INDICATOR ON - TPMS SYSTEM SENSOR WAKE UP. *TT |
| 10018938 | VIBRATION DIAGNOSIS - TIRE/WHEEL RUNOUT. *TT |
| 10018745 | WDS COP KIT DIAGNOSTIC TIP - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING. *TT |
| 10018069 | A TINY CRACK, OR CRACKS, AROUND THE TRANSFER CASE DRAIN PLUG HOLE. *TT |
| 10018052 | DRIVERS FRONT POWER SEAT WILL NOT MOVE FORWARD OR REARWARD. *TT |
| 10017892 | REAR AXLE NOISE REPAIR. *TT |
| 10017888 | STEERING WHEEL AT 65 MPH (105 KM/H) OR HIGHER. *TT |
| 10017805 | REAR WINDOW WIPER INOPERATIVE. *TT |
| 10016789 | REAR AXLE NOISE REPAIR. *SC |
| 10014685 | USE OF STAINLESS STEEL EXHAUST STUDS IN SERVICE FOR 5.4L 2V ENGINE. *TT |
| 10014676 | ALUMINUM ALLOY WHEELS PITTING AND OR PEELING CLEANING PROCEDURES. *EH |
| 10014668 | AXLE SEAL LEAKS. *EH |
NHTSA manufacturer communications (public domain)
NHTSA investigations
STEEL WHEEL FRACTURE
SPARK PLUG EJECTION FROM CYLINDER HEAD
NHTSA Office of Defects Investigation