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#BS-2004-FOREXP-33C9

2004 Ford ExplorerProblems, Recalls & Reliability

Based on reports from 1,647 owners and 4 recalls for this exact model.

Data updated ·checked October 21, 2026 · NHTSA complaints through October 19, 2026

Complaints
1,647
Crashes
69
Fires
21
Recalls
4
TSBs
109
🛑

Preliminary Verdict

Red Flag

Based on 1,647 complaints, 69 crashes, 21 fires, and 4 recalls. Complaint rate is 4.5x the class average.

See full verdict with buy/skip conditions

Top reported problems

1

cracked panel below the rear window

769 complaints • Severity 6.4/10

$X,XXX
2

transmission slipping shifts hard

392 complaints • Severity 7.9/10

$X,XXX
3

transmission failure

172 complaints • Severity 9.1/10

$X,XXX
4

o d light is flashing

84 complaints • Severity 8.3/10

$X,XXX
5

supports for sun visors cracked

67 complaints • Severity 7.6/10

$X,XXX

Preview: What's in your full report

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Mechanic Inspection Checklist

!Check the Power Train:automatic TransmissionHIGH

308 owners reported power train:automatic transmission issues — failures commonly reported around 67K miles.

!Inspect the Structure:bodyMED
Look for symptoms of wear and premature failure
+ 6 more items in full checklistUnlock

Failure Timeline by Mileage

271
0–30K
331
30–60K
361
60–90K
192
90–120K
108
120–150K
111
150K+

Peak failure range: 60–90K miles (361 reports) • Median: 67K miles

Full report: which components fail at each mileageUnlock

30,000-Mile Cost Projection

Best Case

$X,XXX

Most Likely

$X,XXX

Worst Case

$X,XXX

Top cost driver: Power Train:automatic Transmission (308 reports).

Includes fuel costs, common repairs, and recall riskUnlock

Also in your report

Owner Intelligence

AI-synthesized themes from real complaints

Buyer Lot Checklist

Questions, test drive checks, walk-away triggers

Negotiation Talking Points

Data-backed dollar deductions

Buy / Skip Verdict

Final recommendation with conditions

10 sections total in the full reportUnlock all

Where the complaints fall

Power Train:automatic Transmission308 (19%)
Structure:body209 (13%)
Drivetrain108 (7%)
Engine91 (6%)
Structure80 (5%)
Visibility71 (4%)
Structure:body:hatchback/liftgate:hinge And Attachments58 (4%)
Speed Control55 (3%)

2004 Ford Explorer: Known Issues & Problem Areas

Power Train:automatic Transmission Issues

Power Train:automatic Transmission complaints account for 19% of all reports filed for the 2004 Ford Explorer, with 308 owners filing complaints with NHTSA. The median mileage at time of complaint is 66,783 miles, suggesting issues tend to surface around the 67K-mile mark.

Structure:body Issues

Structure:body complaints account for 13% of all reports filed for the 2004 Ford Explorer, with 209 owners filing complaints with NHTSA. Owners should pay attention to structure:body-related symptoms during test drives and pre-purchase inspections.

Drivetrain Issues

Drivetrain complaints account for 7% of all reports filed for the 2004 Ford Explorer, with 108 owners filing complaints with NHTSA. Owners should pay attention to drivetrain-related symptoms during test drives and pre-purchase inspections.

Engine Issues

Engine complaints account for 6% of all reports filed for the 2004 Ford Explorer, with 91 owners filing complaints with NHTSA. Owners should pay attention to engine-related symptoms during test drives and pre-purchase inspections.

Data sourced from NHTSA owner complaints and community reports. The full report analyzes severity, repair costs, and failure patterns for each category.

Complaint trend by year

115
04
129
05
74
06
124
07
166
08
219
09
204
10
153
11
120
12
70
13
94
14
66
15
36
16
31
17
15
18
15
19
1
20
8
21
1
22
4
23
2
24

Complaints filed with NHTSA by year for the 2004 Ford Explorer. Recent trend: decreasing.

Don't negotiate blind — know what this car costs to own

Repair costs • Negotiation scripts • Mechanic checklist • Buy/skip verdict

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Recall History (4 recalls)

06E026000Apr 2006

EXTERIOR LIGHTING

CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.

06E049000Jul 2006

EXTERIOR LIGHTING

CERTAIN CK MOTORSPORTS COMBINATION HEADLIGHTS, CLEAR CORNER, BUMPER, AND SIDE MARKER LIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON THE PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.

07E104000Jan 2008

VISIBILITY:GLASS, SIDE/REAR

CERTAIN CURVED TEMPERED REPLACEMENT GLASS MANUFACTURED BY HANGZHOU SAFETY GLASS LTD AND SUPPLIED TO SAFELITE BY AUTO TEMP INC., IDENTIFIED AS DOT-430, AND SOLD FOR USE ON CERTAIN DOMESTIC AND FOREIGN VEHICLES MAY NOT BREAK INTO SMALL PIECES AS EXPECTED OF TEMPERED GLASS AND FAILS TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 205, "GLAZING MATERIALS."

09E025000Jul 2009

EXTERIOR LIGHTING:HEADLIGHTS

DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.

Recall severity analysis & seller scripts

The full report rates each recall's severity and gives you scripts for asking the seller about recall completion.

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NHTSA Defect Investigations (4)

All closed. Investigations are how NHTSA decides whether a defect needs a recall.

DP05005ClosedOpened Sep 2005 · closed Jan 2006

SPARK PLUG EJECTION FROM CYLINDER HEAD

ENGINE AND ENGINE COOLING:ENGINE

EA09013ClosedOpened Aug 2009 · closed Feb 2013

Vehicle Rollaway Allegations

POWER TRAIN:AUTOMATIC TRANSMISSION:GEAR POSITION INDICATION (PRNDL)

PE09020ClosedOpened Apr 2009 · closed Aug 2009

VEHICLE ROLLAWAY ALLEGATIONS

STEERING:COLUMN

RQ08003ClosedOpened Jun 2008 · closed Oct 2008

REAR LIFTGATE GLASS HATCH FAILURE

STRUCTURE:BODY:HATCHBACK/LIFTGATE

The worst model year for the Ford Explorer is the 2006 — worth knowing if you're cross-shopping years. The biggest problem area is transmission.

2004 Ford Explorer vs. Class Average (Sport Utility Vehicle - 2WD)

This vehicle

1,647

Class avg

368

4.5x the class average — significantly more complaints than typical sport utility vehicle - 2wd vehicles.

Complaint counts correlate with sales volume — popular vehicles naturally generate more reports. The full report normalizes for this.

About this data

NHTSA Complaints

Federal database of owner-filed safety complaints. 1,647 records for this vehicle.

NHTSA Recalls

Manufacturer-issued safety recalls. 4 recalls found for this vehicle.

Repair Cost Data

Real-world repair costs from owner reports and independent databases.

Last updated (checked October 21, 2026). NHTSA complaints received through October 19, 2026.

Other Ford Explorer Model Years

20272026202520242023202220212020201920182017201620152014201320122011201020092008200720062005200420032002200120001999199819971996199519941993199219911990198819871986
View all Ford Explorer years →

2004 Ford Explorer: Frequently Asked Questions

What is the most common problem with the 2004 Ford Explorer?
The most commonly reported issue with the 2004 Ford Explorer is related to the power train:automatic transmission, with 308 complaints filed with NHTSA.
Is the 2004 Ford Explorer reliable?
The 2004 Ford Explorer has 1,647 complaints, 69 crash reports, and 21 fire reports filed with NHTSA. This is 4.5x the class average — higher than typical for its segment.
How much does it cost to fix 2004 Ford Explorer problems?
Repair costs vary by issue. The full BumperScan report includes detailed repair cost estimates (low/median/high) for every major issue, plus a 30,000-mile total cost of ownership projection.
Does the 2004 Ford Explorer have any recalls?
Yes, the 2004 Ford Explorer has 4 recalls on record. The full report includes recall severity analysis and scripts for asking the seller about recall completion.
What mileage do Ford Explorer problems start?
Based on 1374 complaints with mileage data, the median mileage at time of complaint is 66,783 miles. The highest concentration of reported issues occurs in the 60–90K mile range. The full report breaks down exactly which components fail at each mileage bracket.
When was the 2004 Ford Explorer data last updated?
BumperScan last checked this vehicle against NHTSA on October 21, 2026, covering owner complaints received through October 19, 2026 plus the latest recalls, investigations and technical service bulletins. Its numbers last changed on October 4, 2026.
What’s in the full report?
10 sections of AI analysis: severity-ranked issues, component scores (0-100), 30K-mile cost projection, failure timeline by mileage, recall details with seller scripts, owner sentiment analysis, mechanic checklist, buyer lot checklist, negotiation ammo with dollar figures, and a buy/skip verdict.
How is this different from free NHTSA data?
NHTSA gives you raw complaint text. BumperScan cross-references 2.1M+ complaints with community repair cost data, EPA fuel data, and recall records — then uses AI to synthesize it into actionable advice with dollar figures.
How is this different from Carfax?
Carfax is VIN-specific history ($45/report). BumperScan is model-level reliability intelligence — what problems this car is known for, what they cost, and whether you should buy it. Complementary, not competing.
What if the report isn’t useful?
100% money-back guarantee. If the report doesn’t help you make a more informed decision, we’ll refund you — no questions asked.
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10 sections of AI analysis based on 1,647 owner reports. Know before you buy.

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