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 Explorer owners, lightly cleaned up (personal details are redacted by NHTSA).
I need a new gas tank for my vehicle and Ford stopped making the gas tank for my vehicle. That is a very big safety issue. I called Ford and they were helping to find one from junkyard's I don't want one from a junkyard that I have to repair. I asked for Ford to make a gas tank or pay for them to have mine fixed right at a Ford dealership, no help. That's a big safety problem. Ford provided the contacts phone number to the junkyards but the contact doesn't want the gas tank from a junkyard who probably put holes in them to drain the gasoline out of the tank.
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.
I am having electronica issues with my 2004 Ford Explorer, that control lighting and speed of my vehicle. Also the left signal arm that controls high beams, and lighting snapped off while I was on the freeway on August 5th, 2018. The electrical problem started in June 2018.
This is a on going problem, our Ford Explorer has trouble with the linkage to the carburetor, the first time we had problem with the Explorer was oct of 04. Bickford Ford in snohomish wa. Tried to repair it. Then there was two times bickford tried to fix it, the last time we talked to bickford they said that they did not know how to fix the problem and that Ford motor co. Did not know how to fix it either. We also tuck it to another auto repair shop and they said that they could not fix it either. We have no chose but to continue to drive it , but we are also afraid it could cause a bad accident. The problem is , when you are stopped or just starting out and give gas it dose not start to go so you give it a little bit more gas and then it will jump forward or backward( if you are backing up) to appoint that it will some times squeal the tires. …
My 2004 Ford Explorer has been killing when coming to a stop, slowing down and when I am driving at speeds up to 40mph. My power steering then goes. There are no warnings when this is going to happen. It is occurring daily and I then have to put the truck in park, remove the key and then restart. When I do that, it runs like it never happened. No check engine light ect... I have been calling the dealership about this from day one. At first I was told that if it does not fail when I bring it in it will be hard to say what it is. Then I called back because it was happening more frequently. I brought my truck in thurs. The dealership had it all day and said it was ready to go. I drove 1/2 mile down the road and the truck killed. I immediately called them back to let them know. I will be bringing it back next week. …
I have a 2004 Ford Explorer with 57,000 that started stalling while driving about 3 month ago. It shuts off like someone turned the key. The occurrence is very random and there is never anything common between occurrences except it typically happens when I am braking. It's as if it's running out of gas. It took about 10 minutes each time before it would restart. All 4 times, even though it died like the key was turned off, it acted like it was out of gas when I was trying to restart it and then all of the sudden it would start like normal. Since then the following has been done: fuel filter replaced, maf sensor cleaned and the iac valve inspected. The service shop where it is taken says there is never an error code in the system when I bring it in. The vehicle is currently unsafe to drive with this condition.
My gas gauge on my 2004 Ford Explorer has failed me many times. I took it to my dealership & they told me to add some fuel additive to my gas tank & this would cure the problem. Well it has not & my warranty is out!!! I'm very concerned for my wife's safety if she runs out of gas, so we have to keep a written log as to the mileage before fill-up's. I'm told the sensor is bad & would cost close to $1,000.00 to repair. I have complained to Ford & they refuse to repair since the warranty is out. I have also complained to Ford about a back hatch panel that has cracked for no apparent reason directly under the exterior Ford emblem & they will not repair this since it is out of warranty. These are both for sure manufacturer defects, that Ford should be made to repair at their cost.
1-"miles to e" have always registered as dashes after a fill up since 2004. Dealer says nothing is wrong and to add gas additive (which doesn't work) or I can have it fixed at my expense. Dealer has been sold and new dealer now has "no record" of my previous complaints-- whenever I had the car in for service I asked them to check it. I see plenty of other complaints for this same problem but Ford refuses to fix this as well. 2-back hatch below window has cracked recently. Husband had same vehicle different year and his cracked as well. Dealer acknowledges many vehicles with same problem but says there is no recall and Ford will not fix it. I see there is now a class action suit for this defect. Just wanted to go "on record" as another unhappy Ford owner (of over 40 yrs).
Dt: while driving on September 16, 2005 the ABS failed. When this occurred it caused the consumer's vehicle to almost hit another vehicle. The ABS, maintenance, and four wheel lights came on and blinked when he lost the brakes. A diagnosis test was performed, and it showed that there was a problem with the speed sensor. The dealership replaced the speed sensor in the rear which was called asy-t. The fuel gauge broke. It showed the fuel tank level was higher than what it really was. The driver's rear window motor had to be replaced. The cover over the hatchback handle had to be replaced. Also, had to replace the weather stripping. There has been a repair done to the four by four unit. There were multiple problems with the vehicle.
We lease a 2004 Ford Explorer [redacted]. The vehicle stalls. We have had duthler Ford in grand rapids michigan try and repair the problem. They have had it in the shop off and on for well over 3-weeks. We thought it was repaired the last time because we have had no problems over the last 3,000 miles...until yesterday. They vehicle stalled 2-times and lost acceleration 3-times. All the drivers in my family (4) have experienced this problem, and foturnately no one has been injured (yet). Ford and the dealer say they don't know what to do. This is not acceptable. It's only a matter of time before someone gets hurt. Updated 07/19/2012
Fuel System complaints in other Explorer years
Frequently asked questions
How common are fuel system problems on the 2004 Ford Explorer?
NHTSA has 33 complaints about the fuel & propulsion system of the 2004 Ford Explorer, 3% of the model year's 1,304 complaints. The component named most often is storage › fuel gauge system (5 mentions).
Is there a recall for 2004 Ford Explorer fuel system problems?
No. NHTSA lists no fuel & propulsion 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 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 42,000 miles, and 32% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 0 injuries to fuel & propulsion 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.