Which parts fail
Components named in complaints (battery, alternator, wiring, ignition, instrument cluster, infotainment).
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).
Tl* the contact owns a 2004 Ford Explorer. The contact stated that the service engine and the battery warning lights illuminated. The contact also stated that the vehicle jerked and made a loud noise. The vehicle was taken to a dealer who replaced the front driver side hub and wheel bearing, the rear springs, the three passenger gear calipers, four rear driver side calipers, the battery, five rear brake pads, and six rear rotors plus an oil change. Three weeks after the repairs, the vehicle stalled without warning. In addition, the brake pedal hesitated to respond. The vehicle was towed back to the dealer, who diagnosed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 140,817.
While driving at approximately 20 MPH other vehicles were pointing at consumer's vehicle, indicating that the vehicle was on fire. Smoke was coming from the hood, the base of the chassis, the vents, and from the tire hub. The hub caps melted. The fire also disinterested the brakes. Vehicle had to be stopped by the use of the emergency brake. Consumer took the vehicle to a Ford dealership, who advised the consumer to take it to the dealership where it was purchased. This dealership provided no assistance. Consumer refused to drive the vehicle to the other dealership because of the condition of the vehicle, which was currently under warranty. Dealer stated that the cause of the fire was undetermined.
While driving down the street I activated the cruise control feature, but when I deexcellerated using the the steering wheel cruise control buttons down to a speed below 40, the engine shut off and power steering off, while I was still in motion on the street. I had to put the vehicle into park and crank up again (which almost didn't crank back up), to get back running. This is the first time using my cruise control feature and have read other horror stories of their Ford Explorer shutting off mid drive due to using the decel button during cruise control. Must be recalled for highway and interstate safety hazard immediately.
The throttle would not respond after starting. Electronic throttle control and engine service warning lights lit on dash. Engine would not rev over 1000 RPM. Had to get electronic throttle body replaced at a cost of $875 plus $65 towing. Electronic throttle control failure has been common fords going back to 2002. Ford has replaced over 1.6 million units under their consumer satisfaction program. However, there was no recall. Called Ford, and was assigned a case #, however, Ford would not assist with payment. Vehicle out of warranty. 31,155 actual mileage
Good morning, my car was parked in the driveway, not running, 11:15 pm, when horn started to continuously and would not stop. Smelt wires burning. I started the car and was attempting to move it out of my neighborhood and upon driving, I tapped the horn and it stopped. Smell of wires burning. It happened again, yesterday am and today am, on the way to go, and I hit the horn and it stopped. Can this be airbag related??? I am scared to drive my car, fearing the airbag will open or a fire is going to start.
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
My SUV shuts off, at full speed!!! I've been in contact with Ford's corporate office, dealerships and other mechanics..... It is an issue that tens of thousands of Ford Explorer owners have had. There are thousands of complaints online! It is so common that mechanics know what you're talking about, before you finish a description of the problem. It's alsoi common for individuals to replace motors and continue to have their vehicles shut off on them, at full speed!!!. I am afraid for my child's safety, as well as my own.
Brake lights came on by themselves, both while driving and at a standstill. I could pull the on the brake peddle but when I shut the door the brake lights would come on. When driving it must have been confusing to people behind me thinking I kept applying the brakes. I took it to a shop to have the brake light switch replace and found that there wasn't a replacement switch available and a different one hd to be wired in at the cost of over $180.00.
Tl* the contact owns a 2004 Ford Explorer. The contact was driving 2 MPH in reverse when the back up sensor failed and the contact crashed into another vehicle. The crash caused no injuries and the police were contacted. The vehicle was not taken to the dealer for inspection of the failure or repairs. The manufacturer was not contacted. The failure and the current mileage was 131,000.
Driving down the road at 10:52 pm and with no warning the entire truck shut down/off. All lights inside and out shut off, engine shut off, no power to the entire vehicle. Coasted to a stop, put it in park and turned the key off and then back on - the truck started right up with out a problem.
Electrical complaints in other Explorer years
Frequently asked questions
How common are electrical problems on the 2004 Ford Explorer?
NHTSA has 55 complaints about the electrical system of the 2004 Ford Explorer, 4% of the model year's 1,304 complaints. The component named most often is starter assembly (3 mentions).
Is there a recall for 2004 Ford Explorer electrical problems?
No. NHTSA lists no electrical system 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 electrical problems start?
Half of the complaints with a recorded mileage happened before about 52,000 miles, and 30% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 1 fire and 0 injuries to electrical system 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.