Which parts fail
Components named in complaints (front, side and curtain air bags, sensors and inflators).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Ford Expedition owners, lightly cleaned up (personal details are redacted by NHTSA).
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.
Tl* the contact owned a 2004 Ford Expedition. While driving approximately 40 MPH and attempting to make a left turn, the driver lost control and the vehicle crashed into a tree in a neighbor's yard. None of the air bags deployed and there were no warning indicators. A police report was filed. The contact sustained injuries that required medical attention. The vehicle was totalled and was towed away by the insurance company. The dealer was contacted (lafayette Ford in fayetteville, nc) where it was diagnosed that the air bags were not impacted directly. The manufacturer was not made aware of the failure. The failure mileage was approximately 178,000.
The vehicle was involved in a major front-end accident which the driver suffered a significant injury and was ejected from the vehicle. The airbags failed to deploy, and the seatbelt latch neglected to keep the driver from being ejected from the vehicle. The driver lost control of the vehicle on a city street and collided with a power pole and then a signal pole. Upon head-on collision with the signal pole, the vehicle came to a stop but the airbags never deployed and the seat belt latch failed to keep the driver in the vehicle. The driver was ejected from the vehicle and suffered major injury.
Tl* the contact owns a 2004 Ford Expedition. While driving 30 MPH, the driver was not focused and crashed into a tree. The air bags failed to deploy. A police report was filed and there were no injuries reported. The vehicle was towed to a dealer where it was not diagnosed or repaired. The manufacturer was made aware of the failure. The failure mileage was 180,000. Updated 11/25/15 updated 12/10/15.
Was driving down interstate highway and a car next to me swerve sideways into my lane right into my path had nowhere to go. My car left front side of my vehicle and center struck the other vehicles right side. My passengers side airbag went off but my drivers side did not. There was no passenger in my front seat.
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.
I was driving at aproximately 30-40 MPH when a deer croosed the road and I swerved to miss it and lost control of my vehicle. I then crashed in to a thick tele pole and broke it in two, the vehicle proceeded several feet into a barrier head on. The front of my vehicle was damaged by hitting the pole on the pasenge side in line with the seat, totaling the vehicle and ripping off the front passenger tire and conecting parts, further damage to the center of the vehicle when it struck the afore mentioned barrier. I don't know if this is a legitimate complaint or even a complaint. But I was told that my air bags should have deployed as I crashed going faster than 14 MPH, they did not deploy. I wish they did because I was hurt and am still feeling some of the injuries since July 6, 2004 ( over 3 weeks ago ). I felt like evil kenevil after missing a jump. …
I was in a accident on 11-19-04. A lady ran the light and I brodsided her.I was going about 35 when we hit and she the same.the womens car rolled over.all the damage was to the front and side panals of my car.my insurance is having to replace my frame becuase it was damaged.my air bags never deployed.I contacted Ford with my problem.the customer assistance assured me they took this mater serouslyand someone will call me.the next day the legal department called me.when I told her the problem she kept saying"what do you want me to do about it".I told her I wanted to know if my airbags were supposed to deploy.she siad she would have the codes run and she would call me right back.that was the last I heard from them.I found out a couple days later the airbags were supposed to deploy and my insurance will call Ford.I was hurt in this accident and Ford did not seem to care.I have four Ford …
While traveling about 55 MPH on i85 in charlotte during a thunderstorm, we were in the center lane and an 18 wheeler was in the right lane. Suddenly, the front of the vehicle lifted up and we went left -head on with the concrete median. Then bounced off the wall and came back across two lanes of traffic and hit the 18 wheeler head on. Bounced off the truck heading straight ahead in the center lane where we started and coasted off the road. Not one of our air bags deployed! 55mph -2 head on collisions - and they didn't even attempt to come out! We had to have a tow truck come and pick up our 2004 Ford Expedition (1 owner) and they took it to a Ford dealership for the insurance adjuster to come and investigage. We had to rent a car to get off the highway with our family. The vehicle was totalled immediately by my insurance company.
Airbag complaints in other Expedition years
Frequently asked questions
How common are airbag problems on the 2004 Ford Expedition?
NHTSA has 46 complaints about the air bags of the 2004 Ford Expedition, 15% of the model year's 297 complaints. The component named most often is frontal (10 mentions).
Is there a recall for 2004 Ford Expedition airbag problems?
No. NHTSA lists no air bags recall for the 2004 Ford Expedition. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Ford Expedition airbag problems start?
Half of the complaints with a recorded mileage happened before about 87,000 miles, and 22% before 25,000 miles.
Is it dangerous?
Owners linked 29 crashes, 1 fire and 46 injuries and 1 death to air bags problems on this model year. If you notice symptoms, have the car checked before driving further.
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.