Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety. Notes: The 2004 Ford Explorer one of our worst vehicles on record. "Avoid like the plague" is putting it lightly.

The 2002-2005 Explorer has a very well-established record of expensive transmission failure at under 100k miles. The Explorer has an enclosed transmission which is typically replaced with a rebuilt transmission at a cost of almost $3,000.

Another common problem for the 2002-2005 Explorer is wheel bearing failure at around 90k miles, with a typical repair bill of $500 to $1000 depending on how many wheel bearings failed.

Adding insult to injury, the 2002-2005 Explorer also has a massive problem with the rear panel cracking. While it's a minor annoyance compared to transmission failure, ironically the crack usually goes right through the Ford logo.


fairly significant
Typical Repair Cost:
Average Mileage:
75,168 miles
Total Complaints:
749 complaints

Most Common Solutions:

  1. waiting for Ford to recall (292 reports)
  2. not sure (200 reports)
  3. replace panel (111 reports)
  4. possible class action lawsuit (62 reports)
  5. call Ford motor company 1-800-241-3673 (27 reports)
  6. do not buy Ford again (25 reports)
2004 Ford Explorer body / paint problems

body / paint problem

Find something helpful? Spread the word.
Get notified about new defects, investigations, recalls & lawsuits for the 2004 Ford Explorer:

Unsubscribe any time. We don't sell/share your email.

2004 Ford Explorer Owner Comments (Page 25 of 38)

« Read the previous 20 complaints

problem #269

Nov 232009


  • Automatic transmission
  • 58,000 miles


I can't believe that I Googled this problem and saw SOOOO many people with the same complaint!! What is required by us as consumers for FORD to fix this? I saw another Explorer with the same problem driving to work this morning!! Something needs to be done!

- , Virginia Beach, VA, USA

problem #268

Jan 092010

Explorer Eddie Bauer 4.0L V6

  • Automatic transmission
  • 66,350 miles

Have been a loyal Ford owner for many years & am disappointed they haven't had a recall for this. When I first noticed the crack I thought my Explorer had been vandalized and almost filed a police report. Then I came across this website & am glad it saved me from that embarrassment. Funny how once your car has this defect, you notice just how many other Explorers out there have the same issue!

Update from Mar 10, 2010: Ford dealer will fix it for $400 but will not guarantee it won't happen again. He told me that at least it won't rust since it's plastic.

- , Mt. Healthy, OH, USA

problem #267

Sep 012009

Explorer LX V6

  • Automatic transmission
  • 109,000 miles

I will never buy another Ford. I am truly unhappy about my truck tearing to pieces and everyone from the people I bought it from to the insurance company giving me the run-around abour why they can't fix it. My panel in the back under the window is tearing to pieces and no one seems to care. I don't want to have ti dish out more money to pay for myself. What happens when it tears up again? Built Ford Tough? LOL, I don't think so. Built tough enough to drive off the lot, then you are own your own with the fixing all their f-ups!

- , Florence, AL, USA

problem #266

Jan 122010

Explorer XLT V6

  • Automatic transmission
  • 100,000 miles


Same as all the other posters, just went to open the hatch and there the horrible crack was, right through the middle of the Ford emblem, from the glass to the bottom. The Explorer has been garaged since day 1, there was no impact or slamming of the hatch -- it just cracked by itself. Horrible! Ford should definitely recall this part!

- , Belmont, NC, USA

problem #265

Jan 132010


  • Automatic transmission
  • 124,000 miles

i walked outside today at work and noticed a HUGE crack in my door rear panel door !!!!!!!!!!!!!!!!!! not only is this awful looking i cant afford to get it fixed . is there any recall on this or a lawsuit i can sign up for ?

- , Columbia, TN, USA

problem #264

Jan 112010


  • Automatic transmission
  • 59,129 miles

Called Ford cause this is a defect that they should take care of, but instead they said try your insurance company! Well this is Fords defect not mine or my insurance company. Ford should stand up and take care of this what kind of car just cracks? Where is ford? Never again will I purchase a ford..........

- , Cumming, GA, USA

problem #263

Jan 012010

Explorer Eddie Bauer 4.0L V6

  • Automatic transmission
  • 60,000 miles


Neighbor's Exploder has the same problem. Mine is always parked in the garage (we work from home). Can't believe there isn't a secret recall on this one. This is an excellent vehicle, but Ford must learn to stand behind their products. Back to Toyota for me.

- , Garland, TX, USA

problem #262

Jan 082010

Explorer XLT 4.0L V6

  • Automatic transmission
  • 110,000 miles

does anyone know where i can buy a new panel? if you have info. please e-mail me the info.


- , Chattanooga, TN, USA

problem #261

Jan 082010

Explorer XLT 4.0L V6

  • Automatic transmission
  • 78,652 miles

click to see larger images

cracked panel below the rear window cracked panel below the rear window

Just came out this morning and it was cracked. Same as everyone els including my neighbor's who's cracked two weeks ago and same as everyone else. just to the left of the ford emblem and with around 70,000 miles.

Has to be a defect for it to occur in so many and at the same place.



Germantown, TN

- , Germantown, TN, USA

problem #260

Jan 042010

Explorer V6

  • Automatic transmission
  • 85,000 miles

FORD YOU NEED TO FIX THIS PROBLEM! Over 200 complaintes should be your first clue that your company is using cheap stuff to make it's cars wih. I went outside one morning and there it was, a huge crack in the SUV!

- , Fort Bragg, NC, USA

problem #259

Nov 272009

Explorer V8

  • Automatic transmission
  • 185,000 miles


I have a 2004 Eddie Bauer Ford Explorer V-8. I recently noticed while walking around the vehicle on a cold morning that a crack had developed around the Ford emblem and had cracked completely through! I thought no way this is happening to my car! I have noticed this in passing other Fords explorers too. As this is clearly a defect either in the placing of the emblem during manufactering of the vehicle or a defect in the materials used to make the door, why haven't this been recalled in ALL Ford explorers. It seems that this part could break off at any time. This is obviously no fault of the owner. What does it take before the coorporations recall something? This problem and other issues I have encountered with this year make and model has left a less than desirable taste in my mouth as to future purchases of anything made by Ford. Was this a bad year or what?

- , Starke, FL, USA

problem #258

Dec 282009

Explorer XLT 4.6L V8

  • Automatic transmission
  • 97,000 miles

Problem just showed up one day. Crack goes all the way between the back window and the bottom of the panel. Window still latches but looks awful. Definitely will affect resale value.

- , Williamston, SC, USA

problem #257

Oct 172009

Explorer XLT V6

  • Automatic transmission
  • 80,000 miles

I dont believe I should have to pay to fix this. It is a faulty factory part. I didnt breakit and I will continue to write in until ford pays for this panel to be fixed. If writing in I will start contacting the news channels and new papers I know there are plenty of others who would be glad to send in complaints about this. I would appreciate ford to replace this panel at no cost to me since it is no fault of mine. thank you very much

- , Ladson, SC, USA

problem #256

Dec 092009

Explorer LX V6

  • Automatic transmission
  • 51,298 miles

I'm done with Ford, with only 50,000 miles the thing is falling apart. It's never pulled a trailer...OMG, can you imagine if it was ever used as a work horse????

- , Grass Valley, Califirnia, USA

problem #255

Nov 182008

Explorer XLT 4.0L V6

  • Automatic transmission
  • 60,200 miles

Never noticed how many were broken, till it happened to mine.

- , Sparta, TN, USA

problem #254

May 132007

Explorer Eddie Bauer V6

  • Automatic transmission
  • 44,000 miles

After owning several American cars over the years with absolutely no luck at all, problems up the yin yang, I decided to purchase a used Explorer for my wife. Perfect condition and low mileage a big plus. A couple of months into owning the vehicle I saw the cracked lift gate. I immediately questioned my wife on what she had done. This was news to her. The crack was way too high for someone to have hit her. I come to find out, through Ford, that this is a common problem that they are aware of, but will not fix unless I pay an ungodly amount of money.

I'd like to know how they sleep at night knowing they sold a piece of junk and will not own up to it. This is definitely not helping my perception of American car makers!

- , Arlington Heights, IL, USA

problem #253

Oct 022009

Explorer Eddie Bauer V8

  • Automatic transmission
  • 60,000 miles

I woke up one morning to find a hideous crack to the left of the Ford emblem on the liftgate. Ford would be happy to repair if I had purchased an extended warranty. What a racket!! My last Ford. Hello Toyota!!

- , Woodbridge, VA, USA

problem #252

Sep 012008

Explorer V6

  • Automatic transmission
  • 48,000 miles

Waited for chance to look for recall and was suprised to find none, found this site and hope more people will wiite complants about the panels that cracking in half, just like most of the same modelsl I see on the road with the same problem.

- , Porter Ranch, CA, USA

problem #251

Dec 112009

Explorer LX

  • Automatic transmission
  • 54,000 miles

On December 11, I went shopping and when I went to place items in the back of my vehicle, I noticed a crack all the way from the back window to the bottom of the panel. I take very good care of my vehicle. There was no indication that the vehicle had been hit as there were no damages. I asked my mechanic to look at the crack and tell me what he thought. He did some research and found that this problem is very common with Ford Explorers. He checked with the local Ford Dealership (Hilbish in Kannapolis, NC and they told him it was not under warranty, but it was such a common occurrence, they gave him a quote for repairs without even looking at the vehicle. I also have 1499 for an extended Platinum Warranty (6 years/72,000 miles. My vehicle only has about 54,000 miles and the 6 years are not up, but I have been told this is not covered by the warranty.

I do not understand why Ford has not issued a recall for this problem. It certainly seems to be a widespread problem. I will file a complaint with Ford and with Better Business and everyone else who has this problem should do the same.

- , Davidson, NC, USA

problem #250

Dec 142009


  • Automatic transmission
  • 50,000 miles

Same complaint as others. Walked out to my explorer (my baby, low mileage, well cared for, no wrecks) to find the panel under the rear window cracked. Crack starts at bottom of window, extends to Ford symbol, and then starts again next to Ford symbol and extends downward. Clearly a stress crack. So angry!!!! Called Ford and logged complaint. They say there is no recall and it is not covered under warranty. Going to log complaint with National Highway Traffic Safety Admin and Better Business Bureau.

Interestingly, we are a Ford family and are having problems with our 2003 Expedition as well. We have had to replace SIX catalytic converters and need another!!! Ford is taking no responsibility. And now this. We are disgusted!

- , Jacksonville, NC, USA

Read the next 20 complaints »

Not what you are looking for?