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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 6 of 11)

« Read the previous 20 complaints

problem #108

Jan 292011

Explorer

  • 53,000 miles

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

2004 Ford Explorer: Engine seized for no apparent or obvious reason at 53,000 miles. Not repairable. Also, rear plastic panel beneath window cracked. Just read that this is a very common occurrence.

- Chantilly, VA, USA

problem #107

Apr 162010

Explorer

  • 40,000 miles
The contact owns a 2004 Ford Explorer. The contact noticed that the rear plastic tailgate strip was cracked in the center. The vehicle was taken to an authorized dealer for inspection. The technician informed that the manufacturer would be responsible for the expense of replacing the plastic strip for vehicles that do not exceed 36,000 miled. The vehicle was not repaired because the contact exceeded the required mileage. The failure mileage was approximately 40,000. The VIN was unavailable.

- Weymouth, MA, USA

problem #106

Jan 222011

Explorer

  • miles
I am the owner of a 2004 Ford Explorer, with apprx. 50,000 highway miles. In 2007 I walked outside to find the rear back panel under the window with the Ford emblem was cracked. I took it to the Ford dealership, it was still under warranty. The total cost for repair was $403.47, I had to pay $250 & the warranty covered the difference of $153.47. Here it is 2011, I walk outside to find the rear panel under the window with the Ford emblem cracked again, the only difference this time is, I have no warranty. This apparently is a defect on Ford part, the same crack 2 times on the same vehicle after being replaced and Ford has not recalled yet. Their is not one day you drive and not find Ford Explorer owners driving around with cracks on the rear panel. Come on Ford own up or lose consumers.

- Frederick, MD, USA

problem #105

Dec 242010

Explorer

  • 92,000 miles

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

Crack appeared on plastic panel just to the left of Ford emblem the car had 92K miles when occurred. Body shop estimate $500 to repair.

- Cold Spring, NY, USA

problem #104

Oct 252010

Explorer

  • 46,673 miles
Vertical crack in the plastic tailgate attached to the rear window left of the Ford emblem. Ford dealer said they have seen many of these, so I feel this is a design flaw & Ford should fix for free. Ford giving me run a round. So much for Ford tough. Who should I contact to get this fixed for free? or should I take it to the news station about just how tough Ford trucks are.... they crack like easter eggs....... I have never had this off road and keep it in a garage.

- St. Peters, MO, USA

problem #103

Dec 252010

Explorer

  • 82,000 miles
The tail gate on the 2004 Explorer should be recalled, it will only get worse and lots of people will die when the back windows just start falling out. Every Explorer I see it like this! built Ford tough..lol.....I guess it's ok for a few hundred to die until Ford maybe recall it, it's there responsibility!!!!!!! I will never buy another Ford till this gets fixed. Think of all the lawsuits in the making Ford..bad business!!! fix my found on road...before you get sued...my back window will fall out soon and guess who`S getting sued. Fix your junk Ford you lied to me quality is job 1000 making money and lying is job 1..your sickling boycott Ford I already have 3000 plus with this problem just wait Ford you'll get yours...

- Mechanicburg, PA, USA

problem #102

Jan 302009

Explorer

  • 45,000 miles

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

Noticed a number of cracked rear panels on late model Ford Explorer (2004-2006)- this problem is widespread on the Ford Explorer- Ford has failed to acknowledge that this defect in workmanship exist- Ford should recall these vehicles or offer a goodwill repair these Ford Explorer owners.

- Greensboro, NC, USA

problem #101

Nov 252010

Explorer 8-cyl

  • 79,000 miles
Rear panel vertical crack below window.

- Fort Washington, MD, USA

problem #100

Nov 192010

Explorer 6-cyl

  • 106,090 miles
The hatch below my rear window has cracked on both sides of the Ford logo on my Explorer. It seemed to have happened over night. I am concerned that it may not be strong enough to hold the window in while driving. Ford has had three years of models with this some problem and hasn't made it right by it's owners.

- Milton, WA, USA

problem #99

Oct 072010

Explorer

  • 98,000 miles
The contact owns a 2004 Ford Explorer. The contact noticed two cracks below the rear window on the tailgate. The contact called the manufacturer who offered no assistance. The failure mileage was approximately 98,000.

- North Little Rock, AR, USA

problem #98

Jul 012010

Explorer 6-cyl

  • 50,000 miles

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

2004 Ford Explorer has a cracked rear panel splitting the entire back panel. I contacted Ford and they will not do anything about it. I think it could be a safety concern as the whole panel could break off by the rear window. I've researched this on line and this appears to be a common issue with my year Explorer. Ford should take responsibility for their faulty product.

- Tigard, OR, USA

problem #97

Nov 092010

Explorer

  • 56,242 miles
Crack suddenly appeared in the rear panel below the window, from the glass to the bottom of the hatch.

- Weymouth, MA, USA

problem #96

Nov 062010

Explorer

  • 47,000 miles
The contact owns a 2004 Ford Explorer. The contact stated that the rear lift gate panel was fractured below the glass. The vehicle was never involved in a crash. The vehicle was not taken to a dealer for repairs nor was the manufacturer notified of the failure. The failure mileage was 47,000.

- Spring Valley, NY, USA

problem #95

May 012005

Explorer 6-cyl

  • 32,000 miles
Ford 2004 Explorer paint bubbling at front of aluminum hood. Clearly a defect. Took to dealer where the body shop manager said he repainted 70 so far this year but Ford will not take care of it. Asked to meet with the district supervisor. Set up a meeting when he would be in town. He would not even come out to talk to me and sent someone else out to tell me Ford will not fix it because in my warranty it reads, "rust must permanent from the inside out". I argued that it is an aluminum hood and will never rust! I then wrote Ford Motor Company and have never heard back from them. I keep checking for recalls and have seen nothing to date. My wife and I see many of the same vehicles with this same problem all the time. Shame on Ford!! I would like to see something taken care of with this. This is clearly a defect and not something any of us consumers ever did to make this happen.

- Saginaw, MI, USA

problem #94

Oct 202010

Explorer 6-cyl

  • 75,000 miles
10/20/2010 - spokane, Washington - rear panel under back glass around Ford logo cracked after a cool morning 32-35 degrees. The crack extends from the window all the way to the bottom of the panel.

- Spokane Valley, WA, USA

problem #93

Oct 072010

Explorer

  • 57,000 miles
The contact owns a 2004 Ford Explorer. On October 7, 2010, the contact noticed that the rear liftgate glass had a crack in the panel. The dealer stated that there were no related recalls. The contact called the manufacturer who stated she might be eligible for reimbursement, if there failure became a recall. The current and failure mileages were approximately 57,000.

- Riverview, FL, USA

problem #92

Oct 152010

Explorer 6-cyl

  • 52,000 miles
2004 Ford Explorer cracked panel below the rear window.

- South St Paul, MN, USA

problem #91

Sep 202010

Explorer

  • 74,000 miles
A crack has formed in the rear lift gate panel. It occurred overnight while not in use about 2 weeks ago. I didn't think much of it until I began noticing many other Explorer and Mercury Mountaineer of about the same year (2002-2004) with the same defect. I decided to see if there was a recall, but all I could find was a lot of people complaining and no action from Ford. I don't know how many others have filed a complaint with you, but at one website there are at least 290 other owners who have posted a complaint. If your interested, here is the link: www.carcomplaints.com/Ford/Explorer/2004/body_paint/cracked_panel_below_the_rear_window.shtml.

- Lewistown, PA, USA

problem #90

Sep 132010

Explorer 4WD 6-cyl

  • miles
There is a crack in the rear panel under the windshield of my 2004 Ford Explorer XLT. Aside from being unsightly, I'm afraid that this crack will weaken the panel which is integral to keeping the rear windshield seated properly.

- Glen Allen, VA, USA

problem #89

Sep 082010

Explorer

  • 111,000 miles
Panel beneath rear glass cracks on Ford Explorer. Several reports of same occurrence on internet and 3 (including myself) where I work. Almost all same description, "panel breaks near Ford emblem".

- Franklin, KY, USA

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