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hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
78,964 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Ford Expedition electrical problems

electrical problem

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2004 Ford Expedition Owner Comments

problem #20

Jun 272015


  • 126,000 miles


The contact owns a 2004 Ford Expedition. While driving at various speeds, the vehicle stalled without warning. The vehicle was restarted and taken to a dealer and an independent mechanic; however, the cause of the failure was unable to be determined. The contact mentioned that the alternator, battery, transmission, fuel pump, and fuel bypass switch were replaced; however, the failure recurred. The manufacturer was notified of the failure. The failure mileage was 126,000.

- Valley Grove, WV, USA

problem #19

Jul 232015


  • 231,000 miles
This has occurred a three times in last month...first being in July. I park my vehicle, turn ignition off and pull out key and the air conditioner is still blowing and radio is still going for a couple seconds after key is pulled out...only a couple seconds and immediately shuts itself off. This is definitely an electrical or ignition issue.I do know radio will stay on until door opened, thats a feature of the vehicle, but this is different, air stays blowing"? not sure if this is related to above issue but also having an problem with electrical(") under the hood, at times the vehicle while sitting at a light or drive thru tries to die so much so that you can see the instrument panel lights trying to go out as the car attempts to die. I have put a brand new battery in a couple months ago but its not that, its a weird issue like while holding brake down, it just attempts to die and this is only at times, not every time. When on gas, never an issue at all. Car runs great but seems to have an electrical problem somewhere.

- Weatherford, TX, USA

problem #18

Aug 142012


  • 156,000 miles
The contact owns a 2004 Ford Expedition. The contact stated that while driving approximately 50 mph, the vehicle stalled without warning. The contact stated the failure occurred sporadically. The vehicle was taken to an independent mechanic. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 156,000.

- Delano, MN, USA

problem #17

Oct 012012


  • 100,000 miles


I am the 2nd owner of this vehicle. Had problem w/ drivers seat & mirror fuse blowing out since I purchased truck in August 2011. Some time in 2012 I started having additional problems w/ my truck like radio &/or heating/air not coming on when started. Check engine light going on & off & back windshield wiper stopped working. Then it was the vehicle was dying quickly by leaving the radio on for 10 min after vehicle was turned off. We replaced the battery & terminals that connect at the positive & negative. We had plenty of other issues like the entire brake lines needing replacing due to rusting. There is now rusting on other parts of the truck. Blew fuse to air conditioner 2X. Things seem to be ok after battery was replaced until the truck shut off several times while driving it over the past year. Sometimes if you waited 5-10 minutes it would restart. Vehicle has been in shop & nothing comes back on diagnostic test. We have had the alternator & fuel pump tested. The cables to the battery were just found rotted & replaced but something is still killing my battery. The fuse box has been making loud click noises when the truck struggles to start. Today it wouldn't start again until jumped & now the radio wouldn't go on. At the shop again & the mechanic is stumped but working on it! from research it seems to be either a fuel pump relay that is apparently sodder into the fuse box & almost impossible to replace w/ replacing the whole box or it is the fuse box itself. I am also seeing claims of water leaking down windshield & getting into fuse box. All I know is Ford should acknowledge & recall before someone gets killed! my children were in the car several times now when it staled while I was driving or stuck in parking lot & even a severe thunderstorm when it won't start. And now I'm reading the fuse box has caught fire in some of these cars! I rely on this vehicle!

- Atco, NJ, USA

problem #16

Sep 012014


  • 105,000 miles
The contact owns a 2004 Ford Expedition. The contact stated that while driving approximately 30 mph, the vehicle stalled without warning. The vehicle was able to restart, but the failure occurred on numerous occasions. The vehicle was taken to a dealer where it was diagnosed that the wiring harness and the ECU needed to be replaced. The vehicle was repaired however, the failure persisted. The manufacturer was not made aware of the failure. The approximate failure mileage was 105,000.

- St Petersburg, FL, USA

problem #15

Nov 132013


  • 98,000 miles
Battery drains, took fuse to radio out and fixed the problem for a while but then the locks started to act on there own no way to fix dealers keep saying they never heard of the problem or they want to try things but all they end up dong is costing me more money. But I have found hundreds of people on the internet with the same problems.

- Council Bluffs, IA, USA

problem #14

Dec 152013

Expedition 8-cyl

  • 109,089 miles


We have had a down pour not long ago on Saturday. The next day after using the Expedition once when it was turned off the power locks repeatedly lock and unlock (we had to take the fuse out to get it to stop). There is a clicking noise in the fuse box/on the passenger side where the fuse box is located. When the locks function on their own with every click the dash lights faintly flicker. With the power locks fuse removed the dash lights still flicker making the gauges jump with every flicker. It eventually stops. I've read on many forums of these similar problems. But Ford seems to turn the other way with these reported problems. I've called Ford already and there is no recalls. On the forums with these similar and same issues it says it was diagnosed as a leak into the fuse box by bad manufacturing windshield sealant. Some vehicles seem to function on their own even at night and there had been some that burst into flames and the loss of the vehicle was the result. This is the manufacturer's responsibility due to faulty put together and product causing electrical problems when water drips down into the fuse box. Please help us! we cannot afford the $1000's of dollars for this particular repair that is an ongoing issue for many other Ford Expedition and Ford F-150 and Ford Taurus vehicles!!!

- Fort Stewart, GA, USA

problem #13

Nov 092011

Expedition 8-cyl

  • miles
After owning the vehicle for about 3 months the battery went dead, I put a new battery in it and it worked fine for about 2 weeks then it was dead again. I hooked it to a diagnostic machine and no codes. I then replaced the alternator and now there is a code but since the 1st incident I had to disconnect the battery every time I turn the engine off or after 4 to 8 hours the battery is dead again. I haven't had the codes check yet but I will soon.

- Council Bluffs, IA, USA

problem #12

Jan 012006


  • 25,000 miles
The contact owns a 2004 Ford Expedition. The contact stated that while the air conditioning system was activated, an abnormal noise was heard from the rear passenger's side. The vehicle was taken to the dealer, who replaced the air conditioning compressor however, the failure was not corrected. The manufacturer was made aware of the failure. The approximate failure mileage was 25,000 and the current mileage was 89,000.

- Anaheim, CA, USA

problem #11

Jul 022013

Expedition 8-cyl

  • 149,000 miles
The contact owns a 2004 Ford Expedition. The contact stated that after turning the vehicle on and shifting into drive, numerous electrical systems failed. The radio powered off and on independently, the windshield wipers seized, the air conditioning system would not power off, and the windshield wiper and 4X4 lights on the instrument panel illuminated. The vehicle was taken to the dealer for diagnosis but they were unable to duplicate the problem. The manufacturer was not notified. The approximate failure mileage was 149,000.

- Pennsauken, NJ, USA

problem #10

Oct 132011

Expedition 8-cyl

  • 120,000 miles


Was driving down the road and my Expedition just shut down. All power off and steering wheel locked up. Was stuck in middle of the road. Had it towed to Ford dealership who replaced the main fuse. It happened again 6 months later. Once again had to have it towed. Once again main fuse blew and my SUV lost all power. Ford dealership gave us extra fuses. Since then it has happened twice, once about a month ago and we replaced the main fuse. The last time which was Thursday, January 17th, my teenage son was driving and he ran off the road into a ditch. Wheel rim bent but he thankfully was just shook up and not injured.this time it was not the fuse but the SUV just lost power and steering locked and he went off the road. Missed a tree by a few feet. When this first began to happen I called Ford and wrote them multiple letters. They were polite, but stated is was not their problem since car had 120,000 miles on it.

- Seneca, SC, USA

problem #9

Nov 142011


  • 52,000 miles
The contact owns a 2004 Ford Expedition. The contact stated that sporadically with the key in the ignition, the vehicle would start without being engaged. The air conditioner would also exhibit the same failure. In addition, the temperature gauge would fail intermittently. The vehicle was taken to a local mechanic where the contact was awaiting diagnosis. The manufacturer was notified of the failure, but denied any assistance with repairs to the defect. The dealer was not contacted and the vehicle was not repaired. The failure mileage was 52,000 and the current mileage was 52,200.

- Hazlet, NJ, USA

problem #8

Feb 222011


  • 129,999 miles
The contact owns a 2004 Ford Expedition. The contact inserted the key in the ignition and the vehicle would not start. The contact stated there was a code in the owners manual for the security alarm system to deactivate and believed that to be the cause of the failure. The contact entered the code and after waiting a few minutes the vehicle restarted. The failure recurred a second time. The contact used the same code but the vehicle would not start until the following day. The dealer was contacted and informed the contact that he would need to bring the vehicle in for diagnostic testing. The vehicle was not repaired. The approximate failure mileage was 129,999.

- Newburn, NC, USA

problem #7

Jan 212011


  • 81,700 miles
The contact owns a 2004 Ford Expedition. While driving approximately 60 mph, the traction control system, ABS and air bag warning indicators illuminated spontaneously. In addition, the headlights became dimmer. The contact was able to continue driving with caution to the residence. The vehicle was taken to an independent mechanic for diagnostic testing where they detected two trouble codes related to the wiring harness and computer system. There was a technical service bulletin under NHTSA item number 10009329 (electrical system). The vehicle was in the process of being repaired. The failure mileage was approximately 81,700.

- Foster City , CA, USA

problem #6

Jan 192009

Expedition 4WD 8-cyl

  • Automatic transmission
  • miles
The contact owns a 2004 Ford Expedition. The contact turned the engine off and exited the vehicle. Suddenly, a fan blowing noise came from underneath the hood area and the interior lights blinked continuously. The engine was restarted and turned off. However, the failure continued to occur. When the battery cable was disconnected the failures stopped. The failures occurred under rainy conditions on several separate occasions. The vehicle was taken to an authorized dealer for inspection. The technician stated the failure was contributed to water leaking into the smart junction box apart of the electrical system. The contact scheduled an appointment for diagnostic testing. The vehicle had not been repaired at the time of the complaint. The failure mileage was unknown. Updated 7/16/10 the consumer stated the failure has been corrected, even though she had to pay out of pocket. Updated 07/22/10

- Pinetown, NC, USA

problem #5

Dec 142009


  • 31,000 miles
2004 Ford Expedition shuts down with out warning at highway speed!!

- Bronx, NY, USA

problem #4

Jul 122009


  • miles
Driving my 2004 Ford Expedition down the highway when we herd a load pop coming from the engine, pulled over thought it was a blown head gasket. Pulled of the highway and looked at it again turns out that the engine spit out the spark plug and shredded the rubber boot on the coil pack. This a pears to be a safety issue, if it went any farther up it could have hit and ruptured the fuel rail and ignited.the good thing is that I have engine knowledge and knew to disconnect the coil pack and the injector for that cylinder. I was 56 miles away from home and putted back home. Drop it of at the dealer tonight will wait to here from them tomorrow.

- Merrit Island, FL, USA

problem #3

Jun 252008


  • 56,000 miles
I have had problems with my 2004 Ford Expedition with the electrical system. It seems any time it rains or I wash the car there is some kind of electrical short that shuts it down. I've heard there is a problem in the windshield that water leaks to the electrical box causing problems. I am having the same problems, but what worries me is that I smell something burning. I am concerned that this problem my eventually cause a fire while driving.

- Tucson, AZ, USA

problem #2

Jan 042005

Expedition 4WD 8-cyl

  • Automatic transmission
  • 8,100 miles
Vehicle fails to start. Multiple squeaks and rattles from dash - into dealer three times to repair - unable to resolve at dealeship level.

- Canton, MI, USA

problem #1

Jan 232004

Expedition 4WD 8-cyl

  • Automatic transmission
  • 1,400 miles
[29 day's new] 2004 Ford Expedition 4X4 eddie B.- I started the car and attempted to back up out of a parking space. I noticed the steering was stiff and the brake pedal was heavy. I then noticed all the warning lights were on. The car had rolled back out of an inclined parking spot, so I tried to put the car in drive and place it back in its previous spot. I could put the vehicle in drive, but it wouldn't move forward; I cycled from park to drive a couple of times to be sure it was properly in drive. The engine was running fine the whole time this was happening. I turned the engine off, restarted it, and had the same results. This was a major malfunction, so I called the Ford towing service. While waiting for the tow driver, I started the car again and the vehicle returned to a normal running state, with no warning lights etc. The dealer has had the car for almost a week and can not recreate the problem or produce any fault codes.

- Riverside, CA, USA

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