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 Explorer owners, lightly cleaned up (personal details are redacted by NHTSA).
Back windows fell off track and windows fell down, cannot roll them up. AC and Heater broke and won't work at all. Fuel system is too lean. Transmission is going out Timing Chain and tensioners making loud knocking noise. Burning oil.
Tl contact owns a 2004 Ford Explorer. The contact stated that the vehicle would not start. She depressed the accelerator pedal and the vehicle started and began to vibrate. She then placed the vehicle in reverse and heard a loud clunking noise. She smelled a strong gas odor inside the passenger compartment. The contact looked in her rearview mirror and noticed a large amount of smoke coming from the exhaust system. She parked the vehicle and had it towed. She then noticed that all of the radiator fluid leaked out. The mechanic stated that the valve failed and damaged the entire engine. The mechanic also stated that the engine needed to be replaced and appeared to be a manufacturer defect. The current and failure mileages were 63,000. …
Cracks on rear panel happened a few years ago. I was told it's a common known problem with Ford, but they won't repair it and it's not needed. Now the hatch won't fully close or lock shut due to the parts behind the Ford emblem rusting out due td the cracks. Water has gotten behind it, also the rear wiper will not work due to the water getting through from the cracks. I can now not drive my only truck that fits my family. We were leaving to go out to a family advent, and I noticed the back hatch was open, that is when I found out how damaged it was due to the panel being cracked. I called Ford, they told me I would have to repair it out of my own pocket at a Ford dealership. This could cause a huge issue if I drove and the back widow fully came off while driving, it could have severally hurt someone or damaged another vehicle and or person, or persons. …
I have replaced the panel under the rear lift gate window 3 times at a cost of over $ 400 per time. This panel cracks near the Ford emblem on either the right or left side. I called Ford and filed a complaint and was told that they have no information on this being an issue. I am an auto insurance claims adjuster and I see this problem daily on my insured's vehicle. My panel has cracked for the 4th time and Ford is refusing to do anything about it. I have had the vehicle since 2006. I can submit the invoices for my repairs and photos if needed to support this matter. The panel appears to crack due to the lift gate flexing when it is opened and closed. The local Ford dealership said they try to put something behind the panel when they replace it to help reinforce it.
The panel under the rear lift gate window has cracked 3 times now. This panel cracks near the Ford emblem on either the right or left side. I called Ford and filed a complaint and was told that they have no information on this being an issue. My panel has cracked for the 4th time and Ford is refusing to do anything about it. I have had the vehicle since 2005. I can submit photos if needed to support this matter. The panel appears to crack due to the lift gate flexing when it is opened and closed. In the past 3 years, I have observed "all" the fords around that year have busted panels and they're telling me there is no problem.....another cover-up in the making!
Went to open rear window hatch and right hinge snapped off causing whole rear window panel to fall on me. The left hinge managed to stay in place and was able to get center latch reattached to keep the window panel from completely falling off. Only a matter of time until left hinge snaps. Taking it in for repair but both hinges could have easily snapped and potentially fallen into the roadway. This is a heavy load bearing hinge and if broken when a child opened it could have caused serious injury. I notice this is not uncommon with this particular vehicle and is a danger not only to the owner but potentially to those on the road behind this model.
Plastice parts are deteriorating, desolving in front inside drive sun visor-lighted visor broke off; centerl rear A/C and heat moon roof light console falls off-plastice clips desolved and will not fasten into roof assembly, causing blocked eyesight and at time on right turn hitting head or eyes . This is unsafe and Ford motor knows of complainst. Part are not availble. This is a highway safety issue. The model was the eddie bauer top of the line $40,,835 car fmv $5000 only 54000 miles pri level code 450240u74 ship wgt 4357
Bought a 2004 Ford Explorer in March 22, 2017 from lbsi automotive. Seen a crack in rear panel, didn't think much of it. On July 9 2017 went to open lift gate at walmart and hinge busted and window shattered on me and my husband hit my face glass all over me, cut my husband in few places, . Looking online to replace it and seen that the crack in rear panel was causing problems. I had a 3 month old son in back seat and thank god it didn't get on him. My opinion the dealer should have been aware of this and told us.
I have cracks in the plastic on the outside of my lift gate . Each time I use the handle to lift the cracks become worse. There are several posts online asking about the same problem. Every one I see in a parking lot or on the road has the same problem. Ford reports that it affects 1997-2007 explorers. I don't understand why this hasn't been addressed. I called Ford and they referred me to your organization. Some of these cracks I have seen reach to the back window which I believe would be a safety hazard.
I noticed one day that the rear panel of my 2004 Ford Explorer xlt was cracked. There was no crash nor indication of damage from outside source. I believe the cracked formed because of the expansion of water which seeped in throughout the year. There is no recall for this problem and I see the crack on every Explorer on the road within a few years of mine. I need to get a recall in order to fix this problem not caused by me and which everyone else I know who has this model have the same problem.
NHTSA investigations
Rear liftgate glass hatch failure
This investigation was opened on June 23, 2008, based on 34 complaints involving eight injuries in which the rear liftgate glass hatch on model year 2004 Ford explorers or Mercury mountaineers broke off and fell, usually while individuals were operating the glass hatch or loading or unloading items from the rear of the vehicle.Ford conducted recall 04v-442 in 2004 to address similar problems on model year 2002 and…
Body complaints in other Explorer years
Frequently asked questions
How common are body problems on the 2004 Ford Explorer?
NHTSA has 426 complaints about the body & structure of the 2004 Ford Explorer, 33% of the model year's 1,304 complaints. The component named most often is body (209 mentions).
Is there a recall for 2004 Ford Explorer body problems?
No. NHTSA lists no body & structure recall for the 2004 Ford Explorer. 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 Explorer body problems start?
Half of the complaints with a recorded mileage happened before about 72,000 miles, and 5% before 25,000 miles.
Is it dangerous?
Owners linked 2 crashes, 1 fire and 24 injuries to body & structure 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.