Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
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).
Multiple and intermittent engine stoppage. The engine stalls suddenly while driving in traffic causing hazard to self and others. Sudden loss of power steering makes control of vehicle difficult as power steering is non functional as you attempt to pull to the side of a busy road. Braking systems also are mostly non functional without the vacuum created by the running engine making it very difficult to stop quickly. This presents a dire emergency condition for the surprised driver, and a hazard to other occupants as well as other drivers nearby. A driver who is small in stature May be unable to man-handle the stiff steering condition. Once stopped, the engine May restart right away or not, stranding occupants in unsafe conditions and cause an accident chain involving life and death. …
The vehicle shuts off while driving (at any speed) and often without warning. In addition, the vehicle May also not start at all then start without explanation. The most common recommendation is to replace the fuel relay. To do so, you must replace the Smart junction box/fuel relay panel. This appears to be a common problem with numerous mentions and is often difficult to diagnose and commonly becomes a process of elimination. The biggest concern is the safety issue and odds of accident or fatality. Diagnoses typically requires complete failure because the symptoms can rarely be duplicated. This has happened frequently with complete failure happening. Hardwiring the fuel pump rules that out. Fuel relay is found to be hot to the touch.
Vehicle lost power for 3-5 seconds at highway speeds approximately 65 MPH on three separate events. Vehicle slowed down due to power loss while in heavy traffic. Three other times at idle speed in drive and in park engine stalled and immediately restarted. Loss of power steering due to engine not running when stall event happened. I performed inspection of fuel pump relay which is internal to passenger side fuse block. Found inadequate solder joint on integrated relay printed circuit and burn marks on outside of fuel pump relay. Located salvage fuse block same make and model and inspected. Same damage on salvage fuse block assembly. Replaced with aftermarket fuse block with revised solder joint and updated relay.
Also like many other complaints I have seen, the 2004 Ford Expedition I have has shut off on me several times while driving and I was told to switch out the entire fuse box. I called the dealer and they said to replace it, it would be about $500 for it. It's ridiculous Ford hasn't issued a recall because this seems like a problem many people are having as well. We have almost gotten into a couple of accidents because of this issue! We can't keep having to rely on one less vehicle, but what other alternative do we have if it's going to cost us, the consumer, a lot of money to replace for something the manufacturer should be responsible for.
Tl* the contact owns a 2004 Ford Expedition. While driving 60 MPH, the vehicle stalled without warning. The contact was able to restart the vehicle after waiting several minutes. The vehicle was taken to cowles parkway Ford (located at 13779 noblewood plaza, woodbridge, va 22193, [phone]) where it was diagnosed that the fuel pump needed to be replaced. The vehicle was repaired, but the failure recurred a day later. After further research, the contact became aware that the fuel pump relay needed to be replaced. The vehicle was not repaired. The manufacturer was contacted. The approximate failure mileage was 188,000.
The vehicle has been shutting down randomly (highway, streets, stops, etc) and it is very much a safety situation at high speed on the freeway since the steering wheel locks up and brakes do not work. I've taken it to two different places for diagnosis including the local Ford dealership and they have not been able to diagnose the problem. It is understood the vehicle is 10-11 years old but the inability for the dealership to diagnose the problem is really frustrating. From reading complaints, there are others that sound similar and appears to be associated with the vehicle's fuse relay box.
Tl* the contact owns a 2004 Ford Expedition. While driving various speeds, the vehicle suddenly stalled and shut off. Later, after restarting the engine, the vehicle operated normally. The vehicle was taken to an independent mechanic who diagnosed that the fuel pump relay circuit board had malfunctioned and burnt out. The circuit board was replaced and the failure was remedied. An unknown local dealer was contacted. The manufacturer was not contacted. The failure mileage was 180,000.
Tl* the contact owns a 2004 Ford Expedition. While driving approximately 75 MPH, the vehicle lost power without warning. The vehicle was pulled over to the side of the road and towed to an independent mechanic who diagnosed that the engine did not get fuel from the fuel pump. The technician recommended that the fuse panel be replaced. The manufacturer was made aware of the failure and stated that there was no recall. The vehicle was not repaired. The failure mileage was 169,900.
Tl* the contact owns a 2004 Ford Expedition. While driving at various speeds, the vehicle stalled without warning. The vehicle was restarted and taken to a dealer and an independent mechanic; however, the cause of the failure was unable to be determined. The contact mentioned that the alternator, battery, transmission, fuel pump, and fuel bypass switch were replaced; however, the failure recurred. The manufacturer was notified of the failure. The failure mileage was 126,000.
When driving home from seattle wa. To walla walla wa. At a speed of 70 MPH the vehicle died and I had to get off the road, it then restarted and did it to me 3 more times. When I took it to the shop the mechanic stated that it was in the fuse box. He had just did a replacement on the same type vehicle that had caught fire. It is the fuel relay in the fuse box that malfunctions and catches fire. I feel this is a safety issue.
Fuel System complaints in other Expedition years
Frequently asked questions
How common are fuel system problems on the 2004 Ford Expedition?
NHTSA has 23 complaints about the fuel & propulsion system of the 2004 Ford Expedition, 8% of the model year's 297 complaints. The component named most often is storage › tank assembly (1 mentions).
Is there a recall for 2004 Ford Expedition fuel system problems?
No. NHTSA lists no fuel & propulsion system 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 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 126,000 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.