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fairly significant
Typical Repair Cost:
No data
Average Mileage:
102,153 miles
Total Complaints:
12 complaints

Most Common Solutions:

  1. not sure (8 reports)
  2. replace rusted parts (4 reports)
2004 Ford Expedition body / paint problems

body / paint problem

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2004 Ford Expedition Owner Comments

problem #12

Mar 052013

Expedition XLT 5.4L

  • Automatic transmission
  • 97,654 miles


The hood and rear hatchback door have oxidized and the paint has peeled, especially around the edges.

- , Miami, FL, USA

problem #11

Sep 162015

Expedition LXT V6

  • Automatic transmission
  • 144,000 miles

The bottom underside of my Expedition is quickly deteriorating to the point that my local dealer felt it unsafe to drive. It has been garaged and well maintained since we purchased it in 2004 with followed maintenance. The underside is rotted away and not something one would notice by just looking at the car. From the outside the car looks fine but it will not pass an inspection now. The current estimate to properly repair it is over $4000. When I spoke to Ford they said it has not been recalled and is out of warranty and thus can't do anything. This should not be happening and I have never seen such severe rust on the underside.

- , Dover, MA, USA

problem #10

Jul 142015

Expedition XLS 4.6L

  • Automatic transmission
  • 83,823 miles
  1. Found it 7/14/15 mi: 83,823 measuring for new running boards.
  2. If there any electoral lines running through here you in trouble. 3 Consider this base model from 03 & up & if you had a rear hatch short well we all know were it is coming from. cost of hatch pair $275
  3. I when at time Ford Hatch failures I reported my 04 Expedition.
  4. I'm still looking for manual yellow pull release in case vehicle ever crashed into a river or pond, or worse if there was a fire in front of truck disable battery! I hope the 2015 model has these updates

- , Yarmouth Port, MA, USA

problem #9

Aug 012014

Expedition Eddie Bauer 5.4L

  • Automatic transmission
  • 94,778 miles


Started noticing bubbling on the hood and back hatch last year. Very annoying!

- , Edmonton, AB, Canada

problem #8

Apr 012014

Expedition Eddie Bauer 5.4L

  • Automatic transmission
  • 186,000 miles

I wasn't aware of the rusting above my running boards underneath my doors until I took my vehicle in for an estimate. The mechanic informed me of the damage to both sides of my vehicle. This problem is going to cost me more monies on top of my other repairs!

- , Cincinnati, OH, USA

problem #7

Jan 012013

Expedition Eddie Bauer 4.8L

  • Automatic transmission
  • 85,000 miles

I noticed the rust developing under the passengers door jamb right above the running boards when I was replacing the brakes. I checked the drivers side and noticed no rust, yet on that side. The problem seems to be that the area rusting is exposed to elements because there are finger sized holes running the length of the vehicle and salt and water can get trapped in these spaces. I literally pushed my finger through to reveal a 3 inch hole. The rust runs another 2 feet towards the rear doors. Have no idea what I am going to do.

- , Stafford, VA, USA

problem #6

Jun 222013

Expedition Eddie Bauer V6

  • Automatic transmission
  • 95,000 miles


Afraid it might start leaking. If it does, then that's a lot of electrical stuff getting wet. And to use the roof racks, forget it, my stuff would be all over the road.

- , Melbourne, FL, USA

problem #5

Nov 012012


  • Automatic transmission
  • 75,000 miles

This trunk has 75,000 babied miles (wife's truck)' has never gone four wheeling or anything, just drove around town. The truck is only 8 years old and should have another 8. I can't believe it because the truck is in mint condition until you look under the door jam frame above the factory installed running boards. One would think that having the running boards would help to protect this area. The rust through warranty is for 5 years unlimited miles which does me know good. I don't really know when the rust through started as I never thought I would have this problem because of the running board, I noticed the rust through when I had to retrieve my daughters ball from under the truck and I was like what the hell. Could poke my finger right through the rusty metal. Has any one experienced this? Do I have any recourse?

Please help.



- , Randolph, MA, USA

problem #4

Mar 152012

Expedition XLT 5.4L V8

  • Automatic transmission
  • 160,000 miles

Paint on roof is coming off at the body joints. The area has started rusting.

- , Kings Mountain, NC, USA

problem #3

Aug 092008

Expedition Eddie Bauer

  • Automatic transmission
  • 80,000 miles

Bought this Ford Expedition with 20000 mi. on it, fairly new, two yrs after, that piece of crap ford is a rusted bucket of crap. Grooves on roof have 1/2" holes of rust on them. Never again Ford.......

- , Miramar, FL, USA

problem #2

Nov 112009

Expedition Eddie Bauer V8

  • Automatic transmission
  • 40,000 miles

click to see larger images

body is rusting body is rusting body is rusting

The roof in my Expedition is rusting out and the dealer says they want $3,000 to repair. It is so bad that it is starting to leak even. FORD AJOKE, They know there crap metal is rusting out they could care less. I'll never by antoher FORD thats for sure.. They SUCK..

- , Boynton Beach, FL, USA

problem #1

Dec 042008

Expedition 4.6L

  • Automatic transmission
  • 84,578 miles

I have found rust on the roof in the grooves. A body shop said it appears to be a problem with manufacturing. It appears that water settles in these groves and the rust has penetrated the paint coat in each groove.

- , Okc, OK, USA

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