Which parts fail
Components named in complaints (wheels, lug nuts, original-equipment tires, TPMS).
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).
on 5/6/21 at Ramp Ford 4869 Nesconset Hwy.,Pt. Jeff.Sts.,NY at 10:00am dealer sevice Mgr. met with NYSDMV Auto Facilities Inspector on a claim against Mavis Discount Tire,556 Route 25A, Mt Sinai,NY case 1Pi-01937 on a right rear wheel. Ramp removed R/R wheel to inspect with state inspector, appears like axle nut on r/r has not been removed r/0361772. On 7/12/21 Mt. Sina Tire r/0 7828-18 when fixing a tire flat, found r/r one broken stud,one addition lug nut missing from r/r wheel. Immediately Ramo service manager denied his tech improperly reassembled r/r wheel nuts on all five wheel assembly studs. With three studs the Ford vehicle was in inimanent highway danger. Such lost of 40% of wheel nuts may have caused lost of life. Mt. Sinai tire replaced fourth missing nut, fixed flat and scheduled fifth wheel assembly stud. …
The right rear passenger wheel came off my 2004 Ford Explorer when I was driving westbound on interstate 70 near kingdom city, mo. All five (5) bolts and lug nuts securing the wheel/tire were broken off. My wife and I were traveling at 70 MPH in the right hand lane of interstate when there was a sudden loud noise from the rear and the vehicle swerved violently to the right and then left. The vehicle spun and entered into the grass median in the middle of the interstate and the cable stopping system. The vehicle became entwined with the cable system causing it to flip on its side and come to rest. The left and right side air bags deployed, but the front air bags did not. My wife and I had difficulty releasing the seat belts since the vehicle was laying on its right side. I was finally able to release both seat belts and open the sun roof for both of us to exit the vehicle. …
While driving home from work last week I noticed a slight 'bumping' feel like an unbalanced tire, so I took a look when I got to my driveway but found nothing. The next day on my way to work the "bumping' was much worse so I stopped to check and found a large bulge on the tread of the right front tire. After slowly returning home I removed it and set it aside. A few hours later the threads were separating badly so I let the air out before it blew apart. I ordered a replacement tire (different brand) but I've still got three more of these on the vehicle .they have 36K miles on them and a 60K warranty with only modest thread wear but I still check them every day. I don't feel safe. Consumer stated he still has a defective tire.
Tl* the contact owns a 2004 Ford Explorer equipped with capitol precision trac ii tires, size: 245/65r17. While driving approximately 55 MPH, the contact was alerted by another driver that there was a bulge in the rear passenger side tire. The contact discovered that the tire had a bulge on the outside wall. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The VIN was not included in NHTSA campaign number: 14t013000 (tires). The VIN was unavailable. The approximate vehicle failure mileage was 147,000 and approximate tire failure mileage was 3,500. The dot number and VIN were not available.
Daughter driving vehicle, right wheel bearing ceased, causing rear end of vehicle to fish tail, had to drive home on back road (not highway) as the vehicle would have flipped. Car was smoking so bad, could not be placed into garage as it would have burned down the house. Had to be towed, damaged from bearing to rear axel and emergency brake/cables. If she were on the highway she would have been killed. There are multiple complaints about this problem, what will it take? Anyone heard of any class actions to make Ford step up to bat and recall these unsafe vehicles?
While driving north on us23 at brighton mi the right front wheel and tire separated from the vehicle because of the fracture of the 5 wheel lugs. According to the msp this is a common occurance because of metal fatigue caused by the improper use of impact and not torque wrenches when the vehicle is serviced. The problem is being ignored by the auto manufacturers, and I have found publications on this subject matter. There are likely millions of affected vehicles in service, and the wheel loss would produce results similar to the previous Ford/Firestone tire problem.
Tl* the contact owns a 2004 Ford Explorer. The contact stated that the wheel studs detached on multiple tires while driving. The failure recurred three times on multiple wheels on different occasions. The contact stated that the vehicle was taken once to an independent mechanic where the studs were replaced; however, the failure continued. The contact also stated that she replaced multiple studs herself. The manufacturer and dealer were not made aware of the failure. The failure mileage was approximately 120,000.
Car starts but will go forward when shifted in reverse. Turned the car off then back on, but when I would put the car back in reverse or drive, it stalled out. Had it towed and then it was fine after that. Now its about 6 months later, now my orange wrench light pops up and cruise control shuts off at 65mph. Then it jerks a couple times. Have had it checked and came back with 14 codes mainly for transmission.
I took my car for a new set of tires at America's tire (discount tire). After changing the tire, one the technical noticed I have a "loose hub assembly" on my left rear wheel and he suggested that I should get that fixed immediately because it's a safety issue. There is a possibility the wheel May come off at freeway speed. I took my cars in to my mechanic the next day, and he jacked up my car. The mechanic put one of his hand at 12 and the other at 6 o'clock on the tire, and rocks it. The tire was wobbling back and forth when he did that, which suggested a bad wheel bearing, or possible bad hub assembly. At the end, it was determined that I had a bad wheel bearing, which was replaced for $400. Usually a hub assembly/wheel bearing should still be in good condition at 52,000 miles. I guess because it's a Ford. …
While driving home at 25 MPH, I heard and felt a vibration from the front of the car. Since I was only a few hundred yards from my parking lot I continued directly into the parking lot (only minor turns were necessary). Upon entering the parking lot, I turned the car left to park in my spot. Immediately after turning the wheel left, the right front of the car collapsed. I got out of the car and noticed the right front wheel had fallen off and the entire hub (and car front end) actually landed inside the wheel (thus minimizing secondary damage). Upon closer inspection, I found 2 lug nuts still attached to the studs on the ground next to the wheel. Inspection of the hub showed that 4 of the 5 studs had sheared off flush with the hub (there was one stud remaining on the hub). Next day, I replaced the entire hub assembly and checked the torques on the other 3 wheels. …
Wheel & Tire complaints in other Explorer years
Frequently asked questions
How common are wheel & tire problems on the 2004 Ford Explorer?
NHTSA has 60 complaints about the wheels & tires of the 2004 Ford Explorer, 5% of the model year's 1,304 complaints. The component named most often is lugs/nuts/bolts/studs (7 mentions).
Is there a recall for 2004 Ford Explorer wheel & tire problems?
No. NHTSA lists no wheels & tires 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 wheel & tire problems start?
Half of the complaints with a recorded mileage happened before about 72,000 miles, and 13% before 25,000 miles.
Is it dangerous?
Owners linked 3 crashes, 2 fires and 2 injuries to wheels & tires 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.