hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
73,994 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 Expedition body / paint problems

body / paint problem

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2004 Ford Expedition Owner Comments

problem #11

Feb 022016


  • 66,000 miles


The contact owns a 2004 Ford Expedition. The contact stated that while driving at various speeds, there was an abnormal noise coming from the vehicle. The vehicle was taken to the dealer where it was diagnosed that the passenger side rear frame rail section had rusted through and separated. The dealer also diagnosed that the wheel bearing and hub assembly needed to be replaced as well. The contact stated that the dealer stated that the vehicle was no longer road worthy due to rust of the frame and should not be driven. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was 66,000.

- Yorktown Heights, NY, USA

problem #10

Apr 072014


  • 180,000 miles
The contact owns a 2004 Ford Expedition. The contact stated that upon inspection, it was found that the sub frame was rusted. The contact also indicated that the radiator mounts detached from the vehicle. The vehicle was taken to an independent mechanic who confirmed the failure. The manufacturer was notified. The VIN was not available. The failure mileage was 180,000.

- Beloit, WI, USA

problem #9

Aug 012013


  • 103,000 miles
My truck has started making a very loud noise coming from the front under side of the vehicle. Upon further investigation we have discovered that there was excessive rust and corrosion on the frame. This has caused parts of the engine to shift and rub/ collide with other parts and cause the noises. Our mechanic and my husband both feel that the rust and corrosion have made the vehicle unsafe to drive. There is no way to tell when any part of the engine/vehicle could break free, possibly causing more damage and or an accident while driving. Our vehicle is very well maintained and the amount of rust and corrosion is excessive for the year and mileage on the vehicle. The lack of ability to tell when or where the framework may give out makes it unsafe in our opinion to drive. Especially with children in the vehicle most of the time. The corrosion is also so excessive we believe it is not repairable by any body shop. My frustration with this is that we had not planned on getting a new vehicle and were planning on driving it for quite awhile longer. Other then the rust and corrosion the vehicle is in fairly good condition.. I believe that the rust and corrosion sounds very similar to that described on the Windstar and should be investigated along with the Windstar problems. Finally there is also excessive bubbling of the paint in various locations of the vehicle.

- Oak Ridge, NJ, USA

problem #8

Oct 142012

Expedition 8-cyl

  • 107,000 miles


Observed significant rust-through and deterioration of the body structure at the two front body to frame mounting points. Metal structure supporting the air conditioning condenser coil has completely disintegrated and the coil has dropped approximately 1" from its designed position. Metal structure supporting the radiator is almost completely disintegrated. Surrounding metal supporting the body to frame sown significant deterioration and rust-through. Concerned with safety and structural integrity of the body to frame connection and support of components.

- Ridgewood, NJ, USA

problem #7

Jul 302007

Expedition 8-cyl

  • 38,938 miles
Roof canel rust, had repaired it 4 times since 2007. Ford is unwilling to take ownership of the defect and with each repair, the roof is weaker. Spoke to two dealerships and this defect keeps them in business since this is all they do.

- Pembroke Pines, FL, USA

problem #6

Mar 012007

Expedition 8-cyl

  • miles
Paint peeling, creating corrotion on the roof.

- Hialeah, FL, USA

problem #5

Nov 082010


  • miles


Bubbling paint on rear tail gate. Clearly a paint preparation issue, otherwise paint on the rest of the car is near perfect.

- Mechanicsburg, PA, USA

problem #4

Sep 222011


  • 67,000 miles
The contact owns a 2004 Ford Expedition. While driving in rainy weather conditions approximately 30 mph, the interior dome light began leaking a small amount of water. The vehicle was taken to an authorized dealer and they recommended the vehicle be taken to an auto collision center for inspection. The vehicle was taken to an auto collision center and the technician stated the roof of the vehicle would need to be replaced and also informed the contact that eventually, the water leakage would result in electrical issues. The manufacturer was made aware of the problem. The approximate failure mileage was 67,000.

- Sarasota, FL, USA

problem #3

Sep 192008


  • 97,000 miles
The contact owns a 2004 Ford Expedition. The contact stated that there was corrosion on the rear liftgate. The vehicle was taken to the dealer who stated there were no recalls for the failure. The manufacturer was also contacted who confirmed that there were no recalls and offered no further assistance. The vehicle was not repaired. The failure mileage was 97,000.

- Clive, IA, USA

problem #2

Jun 142008

Expedition 8-cyl

  • 90,000 miles
The contact owns a 2004 Ford Expedition. The paint near the front hood, the rear lift gate, the door latch and the wind-shield wiper has corroded. The vehicle has not been inspected or repaired for the failure. The failure mileage was 90,000. The current mileage was 93,000. Updated 11/12/09 the consumer stated the vehicle has never been in an accident. The vehicle is stored in a garage overnight. Updated 11/17/09.

- Northville, MI, USA

problem #1

Jan 012009


  • 65,000 miles
1 own a 2004 Ford Expedition and the original paint is bubbling up on the tailgate around the license plate holder and door handle there have been hundreds of complaints and Ford does not want to except responsibility.

- San Juan, PR, USA

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