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.

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.

3.2

definitely annoying
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
43,219 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 fuel system problems

fuel system problem

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2004 Ford Explorer Owner Comments

problem #3

Aug 152008

Explorer 4WD 6-cyl

  • 60,000 miles

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

The fuel gauge shows a false full and the tank does not fill all the way. The fuel gauge shows a false empty showing you have a half a tank when you may actually have 3 gallons. Running out of fuel on the highway is not safe. The gas stations pump shuts off automatically giving you the impression that the tank is full and is confirmed full by an inaccurate gas gauge which shows full. So you might have 18 gallons in a tank that should have 22.5 gallons and the gauge shows a half tank when you have 3-4 gallons.

- South Jordan, UT, USA

problem #2

Oct 262004

Explorer

  • 11,658 miles
This is a on going problem, our Ford Explorer has trouble with the linkage to the carburetor, the first time we had problem with the Explorer was Oct of 04. Bickford Ford in snohomish wa. Tried to repair it. Then there was two times bickford tried to fix it, the last time we talked to bickford they said that they did not know how to fix the problem and that Ford Motor Co. Did not know how to fix it either. We also tuck it to another auto repair shop and they said that they could not fix it either. We have no chose but to continue to drive it, but we are also afraid it could cause a bad accident. The problem is, when you are stopped or just starting out and give gas it dose not start to go so you give it a little bit more gas and then it will jump forward or backward( if you are backing up) to appoint that it will some times squeal the tires. It all so stalls when you slow down to turn a corner. That is also dangerous in heavy traffic. After four attempts to repair it is still doing the same thing.

- Camano Island, WA, USA

problem #1

Dec 102007

Explorer 6-cyl

  • 58,000 miles
My gas gauge on my 2004 Ford Explorer has failed me many times. I took it to my dealership & they told me to add some fuel additive to my gas tank & this would cure the problem. Well it has not & my warranty is out!!! I'm very concerned for my wife's safety if she runs out of gas, so we have to keep a written log as to the mileage before fill-up's. I'm told the sensor is bad & would cost close to $1,000 to repair. I have complained to Ford & they refuse to repair since the warranty is out. I have also complained to Ford about a back hatch panel that has cracked for no apparent reason directly under the exterior Ford emblem & they will not repair this since it is out of warranty. These are both for sure manufacturer defects, that Ford should be made to repair at their cost.

- Hixson, TN, USA

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