347 complaints reported

2004 Ford Explorer Structure

Owner-reported problems and safety issues filed with NHTSA. Review common failures, severity levels, and complaint trends over time.

Reports
347
Crashes
1
Fires
0
Injuries
19

Complaint Timeline

Chronological view of owner reports

Mar 2008

2004 FORD EXPLORER EDDIE BAUER EDITION. REAR LIFT GATE CRACKS WITHOUT CAUSE. RESEARCH HAS INDICATED THIS IS A KNOWN PROBLEM SINCE EARLY 2000 WITH NO CORRECTIVE RESOLUTION BY FORD. WHAT HAPPENS IF THESE PIECES FALL OFF DURING INITIAL CRACKS WITHOUT DRIVE AWARENESS AND INJUIRES SOMEONE OR PROPERTY? I BELIEVE FORD SHOULD BE MADE TO FIX THIS KNOWN ERROR BEFORE ACCIDENTS OCCUR AND NOTIFY CUSTOMERS THE CHANCES OF THIS OCCURRING IS HIGH. *TR

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: Mar 2008
Mar 2008

PAINT PEELING FROM VEHICLE. *TR

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: Jan 2007
Feb 2008 Injury

NOTICED THAT THE BACK PANEL OF TAILGATE IS CRACKED ON FRIDAY, FEBRUARY 22, 2008. THE CRACK RUNS FROM UNDERNEATH THE REAR WINDSHIELD TO THE FORD EMBLEM AND THE CONTINUES TO THE HANDLE OF THE TAILGATE. THE CRACK IS OPEN, AND I HAVE CUT MY FINGER ON IT WHEN CLOSING THE TAILGATE. I'M TRYING TO CLOSE IT ANOTHER WAY, BUT THERE'S NO OTHER PLACE TO PUT YOUR HAND TO CLOSE THE TAILGATE BECAUSE THE CRACK COMES DOWN TO THE MIDDLE OF THE HANDLE. I AM AFRAID THAT THE PANEL WILL FALL COMPLETELY OFF OR THE REAR GLASS WILL DISLODGE AND FALL OUT. I AM TAKING THE VEHICLE TO THE DEALERSHIP THIS WEEK TO DETERMINE HOW TO GET IT FIXED. *TR

Type: Vehicle, Vehicle: 2004 FORD EXPLORER SPORT, Manufacturer: Ford Motor Company
Incident: Feb 2008
Feb 2008

TL*THE CONTACT OWNS A 2004 FORD EXPLORER. IN AN ATTEMPT TO LOAD THE REAR OF THE VEHICLE, THE CONTACT NOTICED AN 1/8 INCH WIDE AND 6 INCH LONG CRACK IN THE CENTER BELOW THE REAR WINDOW. THE REAR WINDOW WOULD NOT CLOSE DUE TO THE CRACK. THE DEALER WAS NOTIFIED OF THE FAILURE. THE CURRENT MILEAGE WAS 52,000 AND FAILURE MILEAGE WAS 49,551. UPDATED 05/06/08. *LJ THE TOP PORTION OF THE HATCH HAS SHIFTED. UPDATED 05/06/08

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: Nov 2007
Feb 2008

THE BACK PANEL OF THE CAR UNDERNEATH THE WINDOW HAS DEVELOPED A 4 INCH VERTICAL CRACK OVERNIGHT. THE HATCH HAS NOT BEEN OPEN OR CLOSED FOR SEVERAL WEEKS AND HAS NOT BEEN BUMPED OR HIT TO MY KNOWLEDGE. *TR

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: Feb 2008
Feb 2008

MY WIFE AND I NOTICED A CRACK UNDER THE REAR WINDOW, (1/8 BY 6") TO THE LEFT OF THE FORD EMBLEM IN THE CENTER OF THE REAR HATCH.. THERE WAS NO IMPACT INVOLVED, IT JUST APPEARED OVERNIGHT. LATER THE REAR WINDOW WAS RAISED AND THE HINGE ON THE LEFT SIDE IS LOOSE, AND CANNOT BE TIGHTENED. NOW WE CAN'T CLOSE THE THE REAR WINDOW ALL THE WAY. WHEN IS SOMETHING GOING TO BE DONE ABOUT THIS ONGOING PROBLEM WITH THE 2004 EXPLORERS? FORD IS VERY AWARE OF THIS PROBLEM AND AND THEY COULD CARE LESS. I COULD HAVE TAKEN OUR EXPLORER TO A KIA DEALER INSTEAD OF A FORD DEALER AND RECEIVED THE SAME TYPE OF SERVICE..NO HELP AT ALL. IT SEEMS THAT FORD DOESN'T CARE ABOUT QUALITY ANYMORE AND ONLY ABOUT THE MIGHTY DOLLAR, NO MATTER HOW THEY GET IT! *TR

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: Nov 2007
Feb 2008

THE PAINT ON MY HOOD IS PEELING AWAY. I DID NOT NOTICE SOME PAINT "BUBBLING" ON THE HOOD OF MY 2004 FORD EXPLORER WHEN I BOUGHT IT BRAND NEW. AFTER WASHING IT I SAW THE PAINT WAS CLEARLY DEFECTED. IT DID NOT BOTHER ME AT FIRST, BUT NOW AFTER 3 YEARS AND 52,000 MILES THE PAINT IS CHIPPING AWAY WHERE IT WAS "BUBBLED". THE AREA IN QUESTION IS THE FRONT LEFT CORNER OF THE HOOD, IN TWO SMALL PLACES. WHEN I NOTICED IT WAS CHIPPING AWAY THERE WAS ALREADY 4" SQUARE INCHES OF SHEET METAL SHOWING. I TOOK IT TO THE DEALER WHERE I BOUGHT IT AND THEY SAID IT WAS A KNOWN ISSUE (FORD TSB 04-25-1) BUT THEY COULD NOT DO ANYTHING ABOUT IT SINCE MY TRUCK IS OUT OF THE WARRANTY PERIOD. THEY EXPLAINED THE ALUMINUM HOOD IS THE PROBLEM AND AN ENTIRE NEW HOOD WOULD COST $1300. THEY EXPLAINED THAT FORD KNOWS ABOUT THE PROBLEM BUT HAS DECIDED NOT TO ISSUE A RECALL. *TR

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: Dec 2008
Feb 2008

THE BACK GLASS HINGES ON 2004 EXPLORER BROKE CAUSING THE GLASS TO COME OFF MY VEHICLE. LUCKILY I CAUGHT IT AND HAD MY HUSBAND COME UNDO ALL THE PIECES SO NOTHING ELSE WAS BROKEN. *TR

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: Jan 2008
Jan 2008

TL*THE CONTACT OWNS A 2004 FORD EXPLORER SPORT. SHE STATED THAT THE TAILGATE ABOVE THE GLASS CRACKED. THE MANUFACTURER CONFIRMED THAT THERE WAS NO RECALL FOR HER VIN. THE VEHICLE WILL NOT BE REPAIRED SINCE THE CONTACT DOESN'T HAVE A WARRANTY. THE FAILURE AND CURRENT MILEAGE WAS 35,133.

Type: Vehicle, Vehicle: 2004 FORD EXPLORER SPORT, Manufacturer: Ford Motor Company
Incident: Nov 2008
Jan 2008

2004 FORD EXPLORER REAR BACK PANEL HAS A SIGNIFICANT CRACK WHICH CAME ON SUDDENLY. I DID NOT REALIZE THAT THIS PROBLEM HAS HAPPENED TO OTHERS UNTIL I STARTED CHECKING ON HOW TO FIX IT VIA THE NET. *TR

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: May 2008
Dec 2007

2004 FORD EXPLORER'S REAR HATCH/TAILGATE HINGES BROKE. *TR

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: Dec 2007
Dec 2007

TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE GLASS ON THE REAR HATCH DOOR HAS CRACKED AND THE CONTACT FEELS THAT IT MAY SHATTER AT ANY MOMENT WHILE DRIVING. THE DEALER STATED THAT IT IS NOT A DEFECT AND THE CONTACT WOULD HAVE TO PAY FOR THE REPAIR. THE VIN, ENGINE SIZE, AND NUMBER OF CYLINDERS WERE UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 49,000.

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: Jul 2007
Dec 2007

A LARGE CRACK HAS FORMED ON THE REAR LIFT GATE PANEL RIGHT NEXT TO THE FORD EMBLEM. THE CRACK RUNS VERTICALLY AND RUNS THE LENGTH OF THE PANEL WHICH IS SEVERAL INCHES. THIS CRACK IS NOT DUE TO ANY PHYSICAL DAMAGE AND APPEARS TO EXPAND/CONTRACT IN DIFFERENT OUTDOOR TEMPERATURES. THIS PANEL SUPPORTS THE GLASS IN THE REAR LIFT GATE. *TR

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: Jan 2006
Dec 2007

CRACKED PANEL BELOW THE REAR WINDOW. *TR

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: Nov 2007
Nov 2007

TL*THE CONTACT OWNS A 2004 FORD EXPLORER. AFTER DRIVING 55 MPH, THE CONTACT NOTICED PAINT CHIPPING ON THE HOOD OF THE VEHICLE. SHE TOOK THE VEHICLE TO THE DEALER AND THEY STATED THAT THE FAILURE WAS NOT COVERED BY THE WARRANTY AND ADVISED HER TO REPAIR IT HERSELF. SHE TOOK THE VEHICLE TO A MECHANIC AND HE STATED THAT THE FAILURE WAS A MANUFACTURER DEFECT AND SHE SHOULD NOT HAVE TO PAY FOR THE PAINT JOB. THE CURRENT AND FAILURE MILEAGES WERE 46,500.

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: Aug 2007
Oct 2007

BUBBLING AND BLISTERING OF THE PAINT FROM THE HOOD OF 2004 FORD EXPLORER. *TR

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: Sep 2006
Oct 2007

THE REAR WINDOW LIFTGATE HINGE ON MY 2004 FORD EXPLORER FRACTURED. THIS WAS OBVIOUSLY A DEFECTIVE HINGE IN THAT IT SHOULDN'T HAVE WORN OUT LIKE IT DID. I HAD TO BRING IT TO THE DEALER WHO REPLACED BOTH HINGES FOR APPROX $165. THEY TOLD ME THERE WAS A RECALL FOR THIS SAME PROBLEM FOR THE YEARS PRIOR TO MY MODEL YEAR. THEY ALSO SAID THAT THE HINGE WAS THE SAME TYPE THAT WAS FAILING IN THE PRIOR MODEL YEARS. I AM FILING THIS COMPLAINT IN ORDER TO HAVE ANY OF THIS TYPE OF HINGE THAT WAS USED TO BE INCLUDED IN THE RECALL. THE RECALL WAS # 04V442000. *TR

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: Oct 2007
Oct 2007

TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE LIFT GATE FELL OFF THE HINGES WHEN IT WAS BEING CLOSED. THE CONTACT WAS FORCED TO DRIVE THE VEHICLE WITH THE LIFT GATE DISCONNECTED. A MECHANIC STATED THAT IT NEEDED TWO GLASS BRACKETS AND THE HINGES NEEDED TO BE REPLACED. THE REPAIR COST WOULD BE MORE THAN $600 AT THE OWNER'S EXPENSE. THERE WERE NO WARNING SIGNS THAT THE LIFT GATE WAS LOOSE. THE DEALER STATED THAT THERE WAS NO WARRANTY AVAILABLE. THE FUEL SYSTEM WAS UNKNOWN. THE FAILURE AND CURRENT MILEAGES WERE 45,000. UPDATED 11/14/07

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: Oct 2007
Oct 2007

FOUND A CRACK IN THE LIFTGATE PANEL. NO IMPACT WAS SUFFERED TO THE PANEL. CRACK GOES FROM TOP TO BOTTOM RIGHT THOUGH THE FORD EMBLEM. *TR

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: Dec 2007
Oct 2007

2004 FORD EXPLORER EDDIE BAUER. PANEL UNDER TAILGATE CRACKED. CLEAR CRACK FROM TOP TO BOTTOM WHERE FORD EMBLEM IS, APPEARED OVERNIGHT. WAS NOT INVOLVED IN ANY ACCIDENT. 53,385 MILES *JB

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: Oct 2007
Oct 2007

FORD EXPLORER 2004, BACK TAILGATE WINDOW FELL OFF VEHICLE. THERE WAS A RECALL FOR THE 2003, FORD REFUSES TO PAY FOR REPAIR, CLAIMING THAT THEY HAVEN'T HAD ENOUGH COMPLAINTS TO WARRANT AN ADDITIONAL RECALL. THIS BACK WINDSHIELD FELL OFF THE VEHICLE INTO MY HUSBANDS HANDS. THANK GOD MY CHILDREN WEREN'T THE IN THE WAY OR INJURED. THIS RECALL OF THE 2003, TO PLACE ON SEPTEMBER 13,2004, WELL AFTER MY VEHICLE WAS MADE AND PURCHASED. I FEAR FOR THE OWNERS OF THIS $35,000.00 VEHICLE, AND WHAT MAY HAPPEN WHILE FORD DRAGS THEIR FEET WITH THIS RECALL. I IS SOMEWHAT APPARENT THAT THE SAME HINGES WERE USED ON THIS VEHICLE AS THE 2003. PLEASE LET THE PUBLIC KNOW. THANKS. *JB

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: Jul 2007
Sep 2007

2004 FORD EXPLORER 33,663. MILES PANEL UNDER WINDOW OF HATCHBACK HAS CRACKED DOWN THE MIDDLE. AFTER VIEWING THE SAME COMPLAINT FROM OWNERS OF THIS SAME VEHICLE, I DO NOT UNDERSTAND WHY THEIR HAS NOT BEEN A RECALL. *TR

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: Sep 2007
Sep 2007

DEVELOPED CRACK IN BACK PANEL UNDER REAR WINDOW ON LIFTGATE. NOTHING TOUCHED IT. CAME OUT ONE MORNING AND FOUND IT THERE. FORD WILL NOT FIX IT WITHOUT ME PAYING $150. I'VE SEEN 200+ COMPLAINTS ON THE INTERNET WITH THE SAME PROBLEM. I BET OVER 50% OF THE EXPLORERS SOLD DO THIS. THIS IS NOT NORMAL.

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: Aug 2007
Jul 2007

I HAVE A CRACK ON THE REAR LIFT GATE OF MY 2004 FORD EXPLORER. IT RUNS VERTICALLY FROM UNDER THE WINDOW, AROUND THE LEFT SIDE OF EMBLEM, TO THE BOTTOM OF PANEL. I UNDERSTAND THAT THIS IS A COMMON DESIGN FLAW. I HAD THIS REPAIRED ONCE ALREADY IN SEPTEMBER 2006. THIS IS THE 2ND OCCURRENCE AND FORD IS NOT REPAIRING IT UNDER WARRANTY, BECAUSE MY 12 MONTH PERIOD ENDED 6 WEEKS AGO. I FEEL THIS NEEDS TO BE RECTIFIED, AS IT IS A 2ND OCCURRENCE AND OBVIOUSLY A MANUFACTURER FLAW. *TR

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: Jul 2007
Jul 2007

TL* THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE OPENING THE REAR GLASS HATCH THE CONTACT HEARD THE GLASS CRACK ,AND NOTICED THAT THE HINGE CAME LOOSE ON THE RIGHT HAND SIDE OF THE HATCH. THE CONTACT CAN PROVIDE PICTURES. THE CURRENT AND FAILURE MILEAGE WAS 51,283. *AK

Type: Vehicle, Vehicle: 2004 FORD EXPLORER, Manufacturer: Ford Motor Company
Incident: Jan 2007

Trend Over Time

Complaints by year

Quick Summary

The 2004 Ford Explorer has 347 Structure complaints on file. 1 crashes have been reported. Review the timeline above for detailed owner experiences.