Which parts fail
Components named in complaints (doors, hood, frame, rust, paint and trim).
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).
The contact owns a 2004 Ford Expedition. The contact stated while driving approximately 10 MPH, the vehicle lunged forward while depressing the accelerator pedal. The contact was unable to drive above 15 MPH because the vehicle became difficult to control. The contact stated that the check engine warning light was illuminated. The contact had taken the vehicle to an independent mechanic who diagnosed and determined that the rear axle was fractured, the rear subframe was severely corroded, and the rear driver's side sway bar and rear differential were corroded. The vehicle had not been repaired. The manufacturer had not been informed of the failure. The failure mileage was 110,665.
Tl* 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.
Rusted out rocker panels, brake lines, front end radiator mounts, fender mounts. The entire under carriage is rusting away. We have had to replace all the brake lines as they have rusted away, redid the rocker panels rust away. Now we have to replace the entire front end because of rust. Will not pass pa state inspection due to rust. Is the Expedition in the recall for rust?
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. …
Tl contact owns a 2004 Ford Expedition. The contact stated that there was inadequate sealant on the front windshield. In rainy conditions, water would leak into the vehicle. In addition, when the windshield wiper unit was activated, the windshield cleaner would also leak into the vehicle. The contact could hear a crackling sound coming from the dashboard. All the digital components on the instrument panel became inoperable due to the leak in the front windshield. The dealer stated that the windshield could be resealed at the cost of less than $100. If the windshield needed to be replaced, it would cost over $200. There were no recalls for the failure. On a separate occasion, the engine started on its own. The VIN was unable to be accepted by the system. The current and failure mileages were less than 97,000. Updated 04-20-09 updated 04/24/09.
Tl contact owns a 2004 Ford Expedition. The contact stated that the radio light has been illuminating intermittently for the past year. Currently, it has turned completely off and the odometer light illuminates intermittently every other day. The contact stated that during the entire winter season, when she would close the two passenger doors, they would pop back open. Since the weather has warmed up, the doors are closing and staying closed more often. She also stated that the check engine light illuminates and was told that this was due to the fuel injection. The VIN and engine size were unknown. The current mileage is 113,000 and failure mileage was 70,000.
Tl* 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.
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.
Tl* 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.
Tl* 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.
Body complaints in other Expedition years
Frequently asked questions
How common are body problems on the 2004 Ford Expedition?
NHTSA has 24 complaints about the body & structure of the 2004 Ford Expedition, 8% of the model year's 297 complaints. The component named most often is body (14 mentions).
Is there a recall for 2004 Ford Expedition body problems?
No. NHTSA lists no body & structure 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 body problems start?
Half of the complaints with a recorded mileage happened before about 90,000 miles, and 6% before 25,000 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.