Most common 2004 Ford Expedition problems
Share of the 297 complaints; one complaint can involve more than one system. "~" is the median mileage when the problem started.
Ford Expedition complaints by model year
Best Expedition years: 2014, 2013, 2012. Years to avoid: 2019, 2020, 2024, 2017, 2018. Compare all years →
NHTSA defect investigations
Federal safety investigators have looked into 2 possible defects involving the 2004 Ford Expedition:
Steel wheel fracture
Ford special service vehicle (ssv) expeditions use a steel full face wheel design similar to that investigated in pe03009, rq04007, ea04034 (crown victoria police interceptor) and pe03026 (GM pickups and suvs).a total of 8,251 ssvs (2.2% of total production) were produced within model years 2004-2006 and sold primarily for use by state, federal, and municipal law enforcement (le) agencies.Ford stipulates that the…
Spark plug ejection from cylinder head
On September 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 Ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or…
What 2004 Ford Expedition owners say
Engine & cooling all 55 →
The contact owns a 2004 Ford Expedition. The contact stated that while her daughter was driving at an undisclosed speed, the vehicle was jerking. The contact stated that one spark plug exploded and then another spark plug exploded and went through the cylinder head. The contact called the local dealer but the vehicle was not diagnosed or repaired. The vehicle was taken to an independent mechanic where the spark plug was replaced. The manufacturer was notified and referred the contact to the NHTSA for assistance. The failure mileage was approximately 87,000.
The contact owns a 2004 Ford Expedition. The contact stated while driving at various speeds, the vehicle lost motive power without warning and the steering wheel became difficult to steer on several occasions. The vehicle was taken to an independent mechanic, but the failure could not be replicated. The throttle was replaced however, the failure recurred. The manufacturer was not made aware of the failure. The failure mileage was 216,000. The Vin was not available.
Air bags all 46 →
Tl* the contact owned a 2004 Ford Expedition. While driving approximately 35 MPH and turning to avoid a crash, the contact lost control of the vehicle. The vehicle went over the median, crashed into a concrete pillar, slid sideways down the pillar, and the passenger side crashed into a pole. The air bags failed to deploy. The contact received injuries to the right arm as well as teeth and facial injuries. One rear seat passenger received teeth and facial injuries. Another rear seat passenger received rib injuries. The driver received injuries to the front of the body. All passengers required medical attention. A police report was filed. The vehicle was destroyed, towed, and salvaged. The manufacturer was not made aware of the failure. The approximate failure mileage was 127,000.
Tl* the contact owned a 2004 Ford Expedition. While driving 55 MPH, the driver lost control of the vehicle and it spun out of control. As a result, the vehicle rolled over multiple times and crashed into a mountain. The air bags failed to deploy. A police report was filed. The front seat passenger sustained a hand injury that resulted in a finger being amputated. The rear driver side passenger on the second row sustained a forehead laceration, and the rear driver side passenger on the third row sustained a fractured shoulder, hip, and three fractured ribs. Medical attention was required. The vehicle was destroyed. The manufacturer was not notified of the failure. The failure mileage was 160,000.
Brakes all 43 →
Tl* the contact owns a 2004 Ford Expedition. While the vehicle was parked, it rolled down an incline and struck a boulder at the end of the driveway. A police report was not filed and there were no injuries. The dealer was not contacted. The manufacturer was notified of the failure and informed the contact that the vehicle was not included in a recall. No further assistance was offered. The failure mileage was 208,000.
I was in a collision with another car. The brakes failed.\n Going over 3540 miles per hour, airbag and passenger side and drivers side neither one deployed.
2004 Ford Expedition engines & fuel economy
| Engine | Transmission | Drive | MPG city / hwy / combined |
|---|---|---|---|
| 4.6L 8-cyl | 4-speed automatic | RWD | 14 / 18 / 15 |
| 5.4L 8-cyl | 4-speed automatic | RWD | 12 / 16 / 14 |
| 4.6L 8-cyl | 4-speed automatic | 4WD/AWD | 12 / 17 / 14 |
| 5.4L 8-cyl | 4-speed automatic | 4WD/AWD | 12 / 16 / 13 |
EPA ratings. Class: SUV.
Frequently asked questions
Is the 2004 Ford Expedition a good car?
Based on 297 owner complaints filed with NHTSA, the 2004 Expedition rates average: about as many complaints as a typical year of the Expedition at the same age. Complaint counts don't account for sales volume or individual maintenance, so have any used car inspected before buying.
What is the most common problem with the 2004 Ford Expedition?
The engine & cooling — 55 complaints, 19% of all complaints for this model year, most often about engine. Next are the air bags (46) and brakes (43).
How many recalls does the 2004 Ford Expedition have?
NHTSA lists no recalls for the 2004 Ford Expedition. You can still confirm with your VIN using our VIN recall check.
What are the best and worst years of the Ford Expedition?
The best years by complaints, compared at the same age, are 2014, 2013 and 2012. Years to avoid or approach with caution: 2019, 2020, 2024, 2017 and 2018. See the full Ford Expedition years comparison.
At what mileage do 2004 Ford Expedition problems happen?
The median mileage reported in complaints is about 76,000 miles; 39% of problems with a recorded mileage started before 50,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.