CarComplaints.com 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.
10.0
really awful
Crashes / Fires:
2 / 0
Injuries / Deaths:
9 / 0
Average Mileage:
70,906 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.
The hatch of our 2004 Ford Explorer cracked on its own and then 2 weeks later another crack appeared now the glass is starting to shift. I have seen multiple Explorer with the same defect. The Ford body shop told us that he has seen over 500 Explorer within the last 3 months with the same problem. But they refuse to fix it. If it does not get fixed the window could fall out during driving and be a danger to others on the road. If there are that many vehicles that "mysteriously" crack there has got to be a problem.
Manufacturers defect: 2004 Ford Explorer; 6" plastic panel below rear window running across the car has cracked top to bottom because of cold weather. A very common problem but Ford does not consider it a safety problem and therefore will not cover the total cost of replacing it.
On my roof I noticed that the paint is peeling just to the outside of both sides of the roof rack. The paint is cracked and peeling uniformly on both side which indicated it is a defect in the painting process.
The back panel under the window on my 2004 Ford Explorer cracked by the emblem. I contacted Ford on Dec 1, 2008 and was told that nobody has filed a complaint. Since then I've noticed over 15 Ford Explorer with the same problem and numerous complaints on the internet, however Ford denys there is a problem and has refused to provide me with assistance in getting this resolved.
- Bellevue, NE, USA
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The plastic piece below the rear hatch glass has cracked between the window and the top of the tail gate. I have contacted Ford with no response. I have see many Explorer with the same problem. Some say the damage is cased by water getting behind the plastic and freezing, causing the plastic to crack. This could allow more water into the panel causing more problems.
Four weeks ago I discovery an crack just below my rear window of my 2004 Ford Explorer XLT 4.0 V6...later I have seen this damage on three other cars at traffic lights and in parking lots. Just today I notice I this problem in yet another Explorer, and I was able to speak with the owner, and he said it just happen two week earlier. I also have had the hinge of my 2004 Explorer to break also, I had read that this was an problem with the 2003- 2003 mode. Well to me it looks like it and problem with the 2004 model also. It cost me 80 dollars to get the hinges placed with labor. I have read the it will cost between 300 to 600 dollars to repair the crack.
Tailgate, plastic which run around "Ford" the width of the gate cracked. Cold weather the crack gets large, hot weather it closes up. It cracked on its own.
I have a 2004 eddie bauer Explorer and piece below tailgate window cracked from top to bottom contacted my dealership and told me he would go 20/80 I figured that was better than nothing even though Ford should have paid it all.
The rear hatch door cracked on my 2004 Explorer, next to the Ford emblem, for no apparent reason. Concerned safety of glass now. Dealer says to bad that they might fix it for around $250 I still have a warranty but not for the body.
2004 Ford Explorer rear tailgate plastic panel cracked by the Ford logo. I've notice other Ford Explorer with the same problem. Also many complaints on the internet. Ford will do nothing!!!!!!
I own a 2004 Explorer and a few weeks ago I noticed a crack in the back hatchback. I went to the Ford dealership to ask for a estimate and when I told the service attendant what the problem was, he stated that the cold weather contributed to the crack and he said that it has happened to at least 75% of the Explorer. I asked is it the Explorer only and he said "yes." My warranty has expired and therefore they do not want to pay for the repairs. It cost $350 and when I called the Ford company they referred me to the dealership where I purchased the vehicle and the service manager said" we deal with those on a case by case basis" which to me meant if you still have a warranty then you are covered. They didn't do a recall because if it is not broken then don't fix it. Unfortunately this crack occurred after my warranty expired. I would not have a problem repair the vehicle if it was due to negligence on my behalf or something that I did to cause the problem but this should not have happened even with everyday wear and tear on a vehicle. Could you please assist me in attempting to get the Ford company to repair my vehicle? I am concerned with the crack and moisture or water getting inside and possibly creating additional problems to the vehicle.
This morning present on the backside of my 2004 Ford Explorer back hatch is a crack in the metal beginning under the back window proceeding vertically down to bottom where it stopped above my back license plate. The crack is 8-10 inches in length. It was not present prior to this morning when I approached my car to go to work. Research on the internet reveals 100's of complaints with the exact description. Ford is not addressing this defect since all the vehicles are past the mileage warranty. My sister also owns a Ford Explorer and she has the same crack in the back of her hatch. Both cracks are located to the left of the Ford emblem on the back hatch. Continues use of this vehicle will cause the metal crack to widen, thus impacting the back hatch window making it unable to close properly.
The contact owns a 2004 Ford Explorer. While cleaning the rear window of the vehicle, the contact noticed a crack between the window and the handle. The vehicle was driven to the dealer and they referred him to a local body shop. After arriving at the body shop, the mechanic stated that there were several Ford Explorer with this defect. The manufacturer stated that they were not liable for the repairs. The current mileage was 14,136 and failure mileage was 13,636.
Have 2004 eddie bauer Explorer with crack in the rear gate. Needs to be recalled. I was online and foudn at least 200 people with the same crack. Ford will not replace.
Plastic applique on liftgate cracked while vehicle was parked and liftgate was not being used. This is the second time this has happened since we purchased the vehicle five years ago. The crack continued to spread until now the piece is in two separate pieces. The pieces are loose and could possibly come off while driving which could be a dangerous situation. Ford refuses to fix this even though it is clearly a design flaw in all 2002-2005 Explorer. We have seen many Explorer on the road and on used car lots with this same defect.
I bought it brand new in 2004 and have taken very good care of this vehicle, but it hasn't returned the favor. I have had multiple transmission problems that Ford says that they all do it and won't fix it. My tailgate cracked next to the Ford symbol, once again won't fix it. My paint on my hood is peeling off. I only have 50,000 easy miles on it but looking at it and driving it you would think that it had 150,000 on it. I will never buy Ford again!
2004 Ford Explorer right rear liftgate glass hatch hinge has failed. Glass hatch did not fall but is hanging by remaining hinge and is unstable or unsafe. Issue same as NHTSA action number: RQ08003.
A D V E R T I S E M E N T S
- Clermont, FL, USA