Problems owners report
Complaints filed with NHTSA about the 2004 Ford Explorer, by the system named in each complaint. One complaint can name several.
- Power train460
- Structure426
- Visibility100
- Vehicle speed control76
- Engine and engine cooling71
- Electrical system55
- Engine44
- Wheels41
- Steering41
- Air bags39
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 83 injuries and 0 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Fatal crashes in the US
From 2020 to 2023, 117 2004 Explorer vehicles were involved in crashes on US public roads in which someone died; 75 people died inside them, and 50 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 Explorer failed the safety check 2.58% of the time — 17% more often than the average 2004 passenger car (2.21%). Median odometer at inspection: 155,164 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
In the Netherlands
27 first registered in 2004 are on Dutch roads; 56% arrived later as imports. Median list price when new: €55,719.
Most common APK defects
- Overmatige vloeistoflekkage overige vloeistoffen15
- Stuur- of fuseekogel met slijtage kleiner of gelijk 1,0 mm13
- Roestschade dorpel10
- Band(en) aanwezig met een profieldiepte van 1,6 t/m 2,5 mm7
- Fusee(kogel) te veel speling7
- Band onvoldoende profiel7
- Dimlicht onjuist afgesteld6
- Waarschuwingsinrichting controlesysteem bandenspanning geeft6
Colours
RDW Open Data: registered vehicles and APK defects (CC0) · defect descriptions in the RDW's Dutch wording
In the United Kingdom
2 cars built in 2004 were licensed for the road at the end of 2025, and 1 more were declared off the road (SORN).
Department for Transport and DVLA, vehicle licensing statistics (table VEH0124, year of manufacture) · Open Government Licence v3.0
In New Zealand
417 2004 cars are on the New Zealand register; 57% arrived as used imports, 38% 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 3 variants: combined 15.3–20.2 L/100 km (about 12–15 mpg US), CO₂ 323–363 g/km.
| Variant | City | Highway | Combined |
|---|---|---|---|
| Explorer 4X4 FFV · Sport utility vehicle · Regular gasoline | 17.2 | 12.9 | 15.3 |
| Explorer 4X4 · Sport utility vehicle · Regular gasoline | 18.0 | 13.1 | 15.8 |
| Explorer 4X4 FFV · Sport utility vehicle · E85 ethanol | 22.8 | 17.0 | 20.2 |
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 Explorer.
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 Explorer: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 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 |
| 10048099 | 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 EXPEDITION, 05-07 F-150; 2003-06 LS, 06 ZEPHYR, 05-06 NAVIGATOR; 06-08 MILAN. *PE |
| 10045340 | 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 | 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 |
| 10021052 | MIL ON WITH DTC P0463 OR ERRATIC FUEL GAUGE OPERATION. *KB |
| 10021038 | MIL ON WITH P0463 OR ERRATIC FUEL GAUGE OPERATION. *KB |
| 10019947 | NEUTRAL TOW CAPABILITY - SERVICE KIT REQUIREMENTS. *TT |
| 10019384 | LOW TIRE INDICATOR ON - TPMS SYSTEM SENSOR WAKE UP. *TT |
| 10019379 | 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 |
| 10018938 | VIBRATION DIAGNOSIS - TIRE/WHEEL RUNOUT. *TT |
| 10018937 | MIL ON WITH DTC P0191 WITH OR WITHOUT VARIOUS DRIVABILITY SYMPTOMS AND/OR ADDITIONAL DTCS. *TT |
| 10018934 | NEUTRAL TOW CAPABILITY -- SERVICE KIT REQUIREMENTS. *TT |
| 10018745 | WDS COP KIT DIAGNOSTIC TIP - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING. *TT |
| 10018064 | NOISE FROM REAR WHEEL HUB BEARINGS. *TT |
| 10017931 | NO START/HARD START ON COLD SOAK - 4.0L ENGINE. *TT |
| 10017905 | WRENCH LAMP ON AND NO DIAGNOSTIC TROUBLE CODE (DTC) STORED. *TT |
| 10017898 | DELAYED OR HARSH REVERSE ENGAGEMENTS - 5R55S TRANSMISSION - VEHICLES BUILT PRIOR TO 09/23/2004. *TT |
| 10017892 | REAR AXLE NOISE REPAIR. *TT |
| 10017882 | NO START/HARD START ON COLD SOAK. *TT |
| 10017860 | MALFUNCTION INDICATOR LAMP COMING ON WITH DIAGNOSTIC TROUBLE CODES (DTCS) P0171, P0172, P0174 AND/OR P0175 (FUEL SYSTEM TOO RICH OR LEAN). *TT |
| 10016832 | BACKGLASS DIFFICULT TO CLOSE AND AN INTERMITTENT DOOR AJAR LAMP. *TT |
| 10016789 | REAR AXLE NOISE REPAIR. *SC |
NHTSA manufacturer communications (public domain)
NHTSA investigations
Vehicle Rollaway Allegations
VEHICLE ROLLAWAY ALLEGATIONS
REAR LIFTGATE GLASS HATCH FAILURE
SPARK PLUG EJECTION FROM CYLINDER HEAD
NHTSA Office of Defects Investigation