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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.

2004 Ford Explorer body / paint problems

body / paint problem

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2004 Ford Explorer Owner Comments (Page 4 of 11)

« Read the previous 20 complaints

problem #148

Aug 182012

Explorer 6-cyl

  • 92,900 miles

A D V E R T I S E M E N T S

The hinge on the right side of the rear liftgate glass is falling off. I purchased this vehicle used in August 2012. The hinge seemed to be in tact then but has slowly been corroding and falling off. The glass makes an awful noise when I drive over pot holes, bumps, etc. I do not use the glass in fear it will fall on me. There have been times when I turn my vehicle on and the message center says "rear liftgate ajar" only to find that somehow the glass liftgate is not latched. Nobody uses it so unsure if the corrosion and broken hinge is causing the glass to ajar from the latch. I called a local Ford dealership to see if this has been recalled on my vehicle, as it has on numerous other 2004 Ford Explorer. I was told it was not recalled and the part is $50/piece. The left hinge is starting to do the same as well. I am scared that this will eventually fall off while I am driving the vehicle and think this should be recalled as it is a huge safety issue.

- Tremont, IL, USA

problem #147

Nov 102012

Explorer 6-cyl

  • 77,614 miles
After a day of shopping I pulled into my driveway and parked my SUV. I went to open the rear window hatch when the left side came apart from the vehicle and landed on top of me. Fortunately the right side of the window was able to stay intact while my husband was able to run to my aid to lift the door up. I am four months pregnant and my three year old son was standing by my side. I have read that many complaints about this issue have been made to the Ford corporation regarding this problem but they continue not to rectify the issue at hand; while leaving vehicle owners helpless when this situation occurs. I read that this was a good avenue to report this issue since Ford continues to ignore the problem and wonder if my husband would not have been in shouting distance what would've happen to my son, unborn child and myself!!!!!

- North Olmsted, OH, USA

problem #146

Oct 192012

Explorer 6-cyl

  • 112,000 miles
Rear hatch window hinge (left side) broke and released the glass while driving. Window fell to one side. I had to make an immediate emergency stop. It was difficult to prop window to a safe position and lock down. It must remain locked down until I can fix it.

- Chico, CA, USA

problem #145

Oct 232012

Explorer 8-cyl

  • 115,000 miles

A D V E R T I S E M E N T S

The rear liftgate window hinge broke off and the entire rear window fell on my wife. The hinges are made of a white type of metal that has corroded and sheared off. The pins inside apparently broke and it didn't appear to be falling off, it just came off. The window hit my wife in the arm and leg. We were lucky it wasn't one of our kids closing the gate at the time or that they weren't inside when it happened or this could have been a lot worse. After searching online for information about this issue I found thousands of complaints about this exact issue and hundreds of post of injuries incurred from this. Ford recalled other vehicles with the same issue with the same part and yet the 2004 was never included. Something needs to be done. A part over time shouldn't break off and cause a safety hazard.

- Muskego, WI, USA

problem #144

Sep 262012

Explorer 6-cyl

  • miles
When closing the rear window hatch, the left hinge that holds the glass completely let go of the glass. Fortunatley my husband was the one closing it and was able to catch the glass before it broke the other hinge and pulled the glass off completely. The right hinge was also bent, as the window will now not sit level to be put back into place. This should be recalled, as there is a large hazard of th window falling. What if my daughter had been standing underneath as usual, or he had not been able to catch the window and it broke and sen "exploding" glass pieces everywhere. I see that this appears to be a very widespead issue when looking through complaints. Also, the tailgate in my Explorer has also experienced the same mysterious crack that so many other vehicles have had. One day it was fine, then it was cracked. Could these issues be somehow releated? or is the entire hatch just full of flaws.

- Naples, FL, USA

problem #143

May 162012

Explorer 6-cyl

  • 92,000 miles
The pins on the liftgate window are breaking through the hinge. The driver side has broken clean through and the passenger side is beginning to break through even though I haven't used it since the other one broke. There is also a crack under the window on the back lift door.

- Indianapolis, IN, USA

problem #142

Jul 232012

Explorer

  • 160,000 miles

A D V E R T I S E M E N T S

The contact owns a 2004 Ford Explorer. The contact stated that the hinges on the rear liftgate broke and the window fell down on the contact's shoulder, resulting in a shoulder injury. The contact took the vehicle to the dealer and was informed that the hinges on the rear liftgate needed to be replaced. The dealer also stated that the vehicle was not included in the recall associated with NHTSA campaign id number: 04V442000 (structure: Body: Hatchback/lifgate: Hinge and attachments). The failure and current mileages were 160,000.

- Monticello, NY, USA

problem #141

Jul 052012

Explorer 6-cyl

  • 61,800 miles
The hinges that hold on the rear window are starting to break. The 02 and 03 model Explorer were recalled for this but Ford refuses to issue a recall for the 2004 models even though this appears to be a huge issue affecting a large numbers of Explorer. I have caught it before total failure but many people have had the glass come loose and injure them. It is a huge safety issue.

- Denver, CO, USA

problem #140

Jun 112012

Explorer

  • 69,000 miles
The contact owns a Ford 2004 Ford Explorer. The contact stated that the lower portion of the lift gate glass exhibited a long stress crack. The vehicle was taken to an authorized dealer and the vehicle was not repaired. The approximate failure mileage was 69,000. The VIN was unavailable.

- Covington, FL, USA

problem #139

Jun 062012

Explorer 6-cyl

  • 92,000 miles
The plastic piece of molding underneath the rear glass window cracked and fell off. Nothing was done to prompt this. I have read that thousands of other vehicles have this same issue.

- Sparta, MI, USA

problem #138

May 192012

Explorer 6-cyl

  • 120,000 miles

A D V E R T I S E M E N T S

The left rear lift gate window hinge broke causing the window to fall and bruise my daughter's arm. Terrible design and fraught with peril.

- Austin, TX, USA

problem #137

Apr 222012

Explorer 6-cyl

  • 134,000 miles
My 11 year old daughter went to close the rear window gate and the right hinge broke off at where the hinge attaches to the window. My wife and daughter tried to get it lined up with the hinge again but was not able to do anything with it and had to drive home with the windows hanging by the struts. Later when I got home I noticed that the right strut was not decompressing as well which probably put some pressure on the hinge. I tried to push it back up manually it wouldn't budge. I was able to remove the right strut and close and latch the window but now it's crooked and obviously not working. I did research and see there are tons of complaints about this same thing happening on 04 Explorer. I am very concerned that the window will fall off and this almost caused bodily harm to my daughter when it failed and fell.

- Chapel Hill, NC, USA

problem #136

Feb 162012

Explorer

  • 70,000 miles
The contact owns a 2004 Ford Explorer. The contact stated that there was a 6-inch crack from the base of the rear window to the license plate. The dealer was not contacted. The manufacturer was contacted, but denied any assistance with repairs to the failure. The vehicle was not repaired. The approximate failure and current mileage was 70,000. The VIN was unavailable.

- Trussville, AL, USA

problem #135

Jan 222012

Explorer 6-cyl

  • miles
After a cold spell in January the panel under the rear window fractured from the window down. We took the car to the Ford dealer and was told this is very common and it would be around $400 dollars to fix. If this is common why is Ford not correcting this without the customer having to pay out of pocket. It seems this is a manufacturing problem not a consumers!

- Canton, OH, USA

problem #134

Dec 082011

Explorer 6-cyl

  • miles
Rear body panel applique Ford series part #402A30.

- Greensboro, NC, USA

problem #133

Dec 212011

Explorer 6-cyl

  • 103,000 miles
When we had the cold snap a few weeks ago, a plastic panel, under the rear window cracked. The cost to repair this is about $450 to $550. Searching on line, this seems to be a problem over a number of model years, as there are several hundred reports. In the past week, I have seen 7 more Explorer with a similar crack. Ford customer service says there is no recall. It is not a safety issue, but it is expensive to repair.

- West Palm Beach, FL, USA

problem #132

Jan 182012

Explorer

  • miles
Update on rear cracked panel: Rear back panel replaced twice. Ford service told me it would cost approx $800 to replace cracked panel again then suggested I take my '04 Ford Explorer to a body shop for a repair at a cost of approx $200 which I did. That repair lasted about 3 months...panel has cracked again. If the glass falls out someone is going to get hurt. It is ridiculous that Ford will not take full responsibility for this defective part.

- San Lorenzo, CA, USA

problem #131

Nov 092010

Explorer

  • miles
The contact owns a 2004 Ford Explorer. The contact stated that the rear liftgate exhibited a fracture that started from the top of the manufacturing emblem and down to the bottom of the liftgate. The contact spoke with the manufacturer but was advised that there was nothing that could be done to assist. The vehicle was not repaired. The current mileage was 89,000 and the failure mileage was unknown.

- Borlingbrook, IL, USA

problem #130

Oct 212011

Explorer 6-cyl

  • 130,000 miles
The rear passenger window hinge broke causing the glass to fall on top of me and hit me in the head and knock me down to the ground.

- Wichita, KS, USA

problem #129

Nov 142011

Explorer 6-cyl

  • 51,000 miles
Cracked panel below rear window. Also, rear window appears loose.

- Paradise, CA, USA

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