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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:
1 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
123,002 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 electrical problems

electrical problem

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2004 Ford Explorer Owner Comments (Page 1 of 3)

problem #46

Jan 012014

Explorer

  • 50,000 miles

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

Plastice parts are deteriorating, desolving in front inside drive sun visor-lighted visor broke off; centerl rear A/C and heat moon roof light console falls off-plastice clips desolved and will not fasten into roof assembly, causing blocked eyesight and at time on right turn hitting head or eyes. This is unsafe and Ford motor knows of complainst. Part are not availble. This is a highway safety issue. The model was the eddie bauer top of the line $40, ,835 car fmv $5000 only 54000 miles pri level code 450240U74 ship wgt 4357

- Miller Place, NY, USA

problem #45

Jun 172016

Explorer

  • miles
All four seals where leaking including pinion seals. Clunking noise 40 to 50mph when you let go of the gas, holds back, heater gauge+mph gauge don't work most.of the time.paint chipping away all over.replaced all seals 5 times +yoke cvhalf shaft. Replaced front differential still making the noise.poor lighting at night.it has a miss fire gave it a tuneup and still is doing it. Radio volume won't turn down it goes louder when turning down.

- Blairsville, PA, USA

problem #44

Nov 022017

Explorer

  • 108,000 miles
Brake lights came on by themselves, both while driving and at a standstill. I could pull the on the brake peddle but when I shut the door the brake lights would come on. When driving it must have been confusing to people behind me thinking I kept applying the brakes. I took it to a shop to have the brake light switch replace and found that there wasn't a replacement switch available and a different one hd to be wired in at the cost of over $180.

- Sioux Falls, SD, USA

problem #43

Aug 162016

Explorer

  • 180,000 miles

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

While driving down the street I activated the cruise control feature, but when I deexcellerated using the the steering wheel cruise control buttons down to a speed below 40, the engine shut off and power steering off, while I was still in motion on the street. I had to put the vehicle into park and crank up again (which almost didn't crank back up), to get back running. This is the first time using my cruise control feature and have read other horror stories of their Ford Explorer shutting off mid drive due to using the decel button during cruise control. Must be recalled for highway and interstate safety hazard immediately.

- Milton, FL, USA

problem #42

Jun 032016

Explorer

  • 31,155 miles
The throttle would not respond after starting. Electronic throttle control and engine service warning lights lit on dash. Engine would not rev over 1000 RPM. Had to get electronic throttle body replaced at a cost of $875 plus $65 towing. Electronic throttle control failure has been common Ford going back to 2002. Ford has replaced over 1.6 million units under their consumer satisfaction program. However, there was no recall. Called Ford, and was assigned a case #, however, Ford would not assist with payment. Vehicle out of warranty. 31,155 actual mileage

- Chicago, IL, USA

problem #41

Sep 022013

Explorer

  • 90,000 miles
My SUV shuts off, at full speed!!! I've been in contact with Ford's corporate office, dealerships and other mechanics..... it is an issue that tens of thousands of Ford Explorer owners have had. There are thousands of complaints online! it is so common that mechanics know what you're talking about, before you finish a description of the problem. It's alsoi common for individuals to replace motors and continue to have their vehicles shut off on them, at full speed!!!. I am afraid for my child's safety, as well as my own.

- Waynesboro, GA, USA

problem #40

May 172015

Explorer

  • 109,000 miles

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

Complete engine failure while driving. Service engine soon light appeared 2 days previous but did not yet make it to the mechanic. Computer reading suggested a sensor problem. Engine shut down, lost power steering and all systems. Engine restarted but now idles rough.

- Ann Arbor, MI, USA

problem #39

Jan 302015

Explorer 4WD 6-cyl

  • 135,000 miles
Driving down the road at 10:52 pm and with no warning the entire truck shut down/off. All lights inside and out shut off, engine shut off, no power to the entire vehicle. Coasted to a stop, put it in park and turned the key off and then back on - the truck started right up with out a problem.

- Kennett Square, PA, USA

problem #38

Jan 282015

Explorer 6-cyl

  • 105,000 miles
Good morning, my car was parked in the driveway, not running, 11:15pm, when horn started to continuously and would not stop. Smelt wires burning. I started the car and was attempting to move it out of my neighborhood and upon driving, I tapped the horn and it stopped. Smell of wires burning. It happened again, yesterday am and today am, on the way to go, and I hit the horn and it stopped. Can this be airbag related"?" I am scared to drive my car, fearing the airbag will open or a fire is going to start.

- Boca Raton, FL, USA

problem #37

Oct 172014

Explorer

  • 140,817 miles
The contact owns a 2004 Ford Explorer. The contact stated that the service engine and the battery warning lights illuminated. The contact also stated that the vehicle jerked and made a loud noise. The vehicle was taken to a dealer who replaced the front driver side hub and wheel bearing, the rear springs, the three passenger gear calipers, four rear driver side calipers, the battery, five rear brake pads, and six rear rotors plus an oil change. Three weeks after the repairs, the vehicle stalled without warning. In addition, the brake pedal hesitated to respond. The vehicle was towed back to the dealer, who diagnosed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 140,817.

- Hornell, NY, USA

problem #36

Dec 022014

Explorer 4WD 6-cyl

  • 39,000 miles

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

The car is in parking condition at work and after a long awhile it would not start even the full battery. I have attempted to make lots of checks for all component like relays, fuses and wiring connection they are all fine, in good condition. But finding out the starter relay had no power, no current flowing through it. I belief that the faulty is ( PCM unit ) power train control module that blocked a current from the starter relay.

- Cedar Park, TX, USA

problem #35

Oct 092014

Explorer 8-cyl

  • 124,000 miles
I was at a stoplight and when the light turned green my car would not move. The car was in drive and it would just rev. The cars behind me started honking. I put it in the lower gears and finally started moving forward and drove it to the dealership. As I was driving to the dealership in the lower gears the car shifted out of gear while in traffic, I put it in neutral and back into 3 and it started moving forward again. This is very dangerous since the car will just shift in and out of gear and stop moving forward. At the dealership the car would not move while in drive or reverse. They told me the transmission needs to be replaced at a cost of $4,200, this is after I just had the throttle body replaced two months ago at a cost of $1,800. Ford need to do a recall in these transmissions it could lead to an accident.

- Tucson, AZ, USA

problem #34

Sep 092014

Explorer

  • 150,000 miles
My vehicle burned through another alternator, everything on the vehicle is 100% factory so I don't know what is causing that. Immediately after I replaced the alternator for the second time in 6 months, the power steering has vanished. I checked all the belts made sure everything is running properly and in the correct place. The power steering pump seems to be pumping but not working.

- Fitchburg, MA, USA

problem #33

Apr 122014

Explorer

  • 117,000 miles
The contact owns a 2004 Ford Explorer. The contact stated that the indicator on the instrument cluster would not properly specify what gear the vehicle was engaged. The vehicle was not taken to a dealer for diagnostic testing. The manufacturer was not notified of the failure. The vehicle was not repaired. The approximate failure and current mileage was 117,000. The VIN was not available.

- Hedgesville, WV, USA

problem #32

Dec 202012

Explorer

  • 140,000 miles
On the body the tailgate panel keeps cracking this makes my truck look bad compared to the money I put into it. My engine or transmission acts as if something is wrong it is not shifting gear right. On the electrical tire pressure light keeps coming on and it also keeps leaking water from somewhere. Ford needs to go out of business for selling these pieces of junk. It makes no sense.

- Columbus , GA, USA

problem #31

Aug 222013

Explorer

  • 190,000 miles
The contact owns a 2004 Ford Explorer. The contact stated that the vehicle failed to start. The contact mentioned that the anti-theft alarm engaged automatically while attempting to start the vehicle. The vehicle was not taken to a dealer for a diagnostic. The manufacturer was notified of the failure. The vehicle was not repaired. The approximate failure and current mileage was 190,000.

- Wheatley Heights, NY, USA

problem #30

Jul 292005

Explorer 6-cyl

  • 2,000,000 miles
My car won't shift in to gear any more.

- Lomita, CA, USA

problem #29

May 222012

Explorer

  • 131,000 miles
The contact owns a 2004 Ford Explorer. The contact was driving 2 mph in reverse when the back up sensor failed and the contact crashed into another vehicle. The crash caused no injuries and the police were contacted. The vehicle was not taken to the dealer for inspection of the failure or repairs. The manufacturer was not contacted. The failure and the current mileage was 131,000.

- Brookville , IN, USA

problem #28

Mar 092012

Explorer

  • 900,000 miles
After starting vehicle and moving shift lever from park to reverse - rotating shift handle mount broke off- required towing and $1800 repair cost. Have seen similar instances on consumer complaint boards - Ford fails to recognize as being a safety manufacturing defect.

- Mcdonough, GA, USA

problem #27

Jun 232007

Explorer 6-cyl

  • 19,000 miles
Cruise control is intermittent, sometimes accelerates unexpectedly especially when pushing the button to turn it off. So far have been able to stop car, but it is a scary situation. Also, rear warning indicator works only occasionally. Could run over or into someone if depending on it.

- Paradise, CA, USA

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