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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 3 of 11)

« Read the previous 20 complaints

problem #168

Feb 052014

Explorer

  • 89,846 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 rear liftgate was cracked. The vehicle was not taken to a dealer or an independent mechanic for repairs. The manufacturer was notified of the issue. The approximate failure mileage was 89,846.

- Florissant, MO, USA

problem #167

Jan 202014

Explorer 6-cyl

  • Automatic transmission
  • 8,620 miles
The contact owns a 2004 Ford Ford Explorer. The contact stated there was a crack underneath the window of the tailgate. The vehicle was not taken to a dealer or an independent mechanic for diagnostic testing or to be repaired. The manufacturer was made aware of the problem. The approximate failure mileage was 8,627...updated 03/25/14

- Lawton, OK, USA

problem #166

Nov 132013

Explorer

  • 147,000 miles
The contact owns a 2004 Ford Explorer. The contact noticed a crack on the lift gate near the manufacturer's emblem. The vehicle was not repaired. The manufacturer was notified of the problem. The approximate failure mileage was 147,000.

- Bear , DE, USA

problem #165

Oct 232013

Explorer 8-cyl

  • 125,300 miles

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

The rear liftgate panel cracked for no apparent reason.

- Lafayette, IN, USA

problem #164

Nov 052013

Explorer

  • 25,000 miles
The contact owns a 2004 Ford Explorer XLT. The contact stated that upon inspection, the left hinge that held the trunk window snapped unexpectedly. The window was held by the contact while another person latched the window back into place. The vehicle was not diagnosed or repaired. The manufacturer was notified. The failure mileage was 25,000.

- Cardington, OH, USA

problem #163

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 #162

Jun 092013

Explorer 6-cyl

  • 139,000 miles

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

I opened the lift gate window to load groceries when the right side of the window suddenly let go up near the hinge. This caused the right side of the window to drop and then the left hinge broke, causing the entire rear window to drop. I was able to catch it so it didn't break and eventually release the support struts so I could get it into the back of the vehicle. It appears that the fastener near the hinge was corroded through and when I tried to open the window the weight was finally too much for it so it snapped, releasing the window on that side. Fortunately this fastener failed in a parking lot and not on a freeway or the whole rear window may have come off and posed a danger to the cars behind. Ford has already issued a recall for 2002 and 2003 models which used the same hinge assembly, don't know why 2004 was not included.

- Broadview Heights, OH, USA

problem #161

May 132013

Explorer

  • 35,000 miles
The contact owns a 2004 Ford Explorer. The contact stated that the rear hatch was defective and the plastic that covered the license plate area on the hatch became fractured. As a result, when the hatch was opened, the contact and two children sustained lacerations to the hands. The vehicle was not taken to the dealer. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was 35,000 and the current mileage was 114,000.

- Liberty Township , OH, USA

problem #160

Mar 282013

Explorer 8-cyl

  • 85,000 miles
The contact owns a 2004 Ford Explorer. The contact stated that the horizontal panel under the rear lift gate was fractured. The vehicle was not taken to a dealer. The manufacturer was made aware of the failure. The vehicle was not repaired. The approximate failure and current mileage was 85,000.

- South Daytona, FL, USA

problem #159

Apr 262013

Explorer

  • 80,000 miles
My daughter weighs 99 lbs she opened hatch at gas station and the window portion of the entire hatchback fell off also there is a crack in the plastic down the hatch which I see on every old Explorer.

- Lewiston, NY, USA

problem #158

Apr 012008

Explorer

  • 40,000 miles

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

Rear body panel around back window split

- Washington, DC, USA

problem #157

Nov 192007

Explorer 6-cyl

  • 21,652 miles
The contact owns a 2004 Ford Explorer. The contact stated that as she approached the vehicle, she noticed that the horizontal panel under the rear lift gate was fractured. The vehicle was taken to the dealer where they advised her that the panel needed to be replaced. The vehicle was replaced for the horizontal panel and emblem. The manufacturer was contacted and offered no assistance. The failure mileage was approximately 21,652. The current mileage was approximately 36,000.

- Safety Harbor, FL, USA

problem #156

Feb 152013

Explorer

  • 50,000 miles
The contact owns a 2004 Ford Explorer. The contact stated that there was an excessively long fracture in the rear liftgate near the manufacturing emblem below the rearview window. The vehicle was not inspected or repaired. The manufacturer was made aware of the problem. The approximate failure mileage was 50,000.

- Baltimore, MD, USA

problem #155

Oct 312012

Explorer

  • 57,000 miles
The rear panel cracked for no apparent reason.

- Columbia, SC, USA

problem #154

Jan 022013

Explorer

  • 63,000 miles
While the vehicle was parked for 2 or 3 days under the carport in the driveway, the back panel under the window cracked for absolutely no reason.

- Houston, TX, USA

problem #153

Dec 202012

Explorer 6-cyl

  • 83,658 miles
The rear window hinge pin (passenger side) has corroded and broken allowing the window to fall off of the rear tail gate. I noticed the broken hinge before using the lift gate which has prevented it from falling off thus far. I have read that this is a very common problem on this vehicle and Ford will not own up to the problem.

- Massillon, OH, USA

problem #152

Nov 302012

Explorer 6-cyl

  • 92,850 miles
There is a crack to the left of the Ford isignia on the rear lift tail gate. The crack runs from the bottom of the rear panel just below the rear window to the bottom of that panel. The panel is the top half of the lift gate where the gate opens to enter items without opening the entire tail gate. I understand from other Ford Explorer owners that this can cause the rear window to blow out because the panel is no longer secure due to the crack. Obi# 10487645

- Clear Spring, MD, USA

problem #151

Nov 302012

Explorer

  • 92,000 miles
The contact owns a 2004 Ford Explorer. The contact stated that after exiting the vehicle, she noticed that the rear hatchback window panel was fractured. The vehicle was not taken to a mechanic. The vehicle was not repaired. The manufacturer was contacted about the failure and advised the contact that they were unaware of the issue. The failure and current mileages were approximately 92,000.

- Clear Spring, MD, USA

problem #150

Nov 192012

Explorer

  • 160,000 miles
The contact owns a 2004 Ford Explorer. The contact stated that the panel on the exterior of the rear lift gate was fractured. The vehicle was not taken to the dealer for diagnostic testing. The vehicle was not repaired. The approximate failure mileage was 160,000.

- Brandon, FL, USA

problem #149

Nov 202012

Explorer 6-cyl

  • 84,238 miles
Vehicle was parked. Operator opened rear hatch glass, at which time the right hinge separated. This caused the glass to slam down. Fortunately, the operator was able to jump out of the way to avoid injury. The glass did not break, but the struts are bent. Both the right and left hinges appear to be defective and in need of replacement. The rear hatch is not usable until the hinges and struts are replaced.

- Woburn, MA, USA

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