Skip to content
Electrical systemPart report

2004 Ford Expedition Electrical system Problems

Complaints
36about this part
Share
12%of 297 total for the year
Median mileage
102,500miles
Trend
FallingComplaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.

NHTSA recorded 36 complaints about the electrical system of the 2004 Ford Expedition, 12% of the 297 complaints for this model year. Where a mileage was given, the median is 102,500 miles. 1 of these say a crash was involved and 2 a fire, according to the filers.

Example complaints

Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.

“When driving home from seattle wa. To walla walla wa. At a speed of 70 MPH the vehicle died and I had to get off the road, it then restarted and did it to me 3 more times. When I took it to the shop the mechanic stated that it was in the fuse box. He had just did a replacement on the same type vehicle that had caught fire. It is the fuel relay in the fuse box that malfunctions and catches fire. I feel this is a safety issue.”

NHTSA complaint #11006585, filed 2017-07, 124,000 miles

“Battery drains, took fuse to radio out and fixed the problem for a while but then the locks started to act on there own no way to fix dealers keep saying they never heard of the problem or they want to try things but all they end up dong is costing me more money. But I have found hundreds of people on the internet with the same problems.”

NHTSA complaint #10557228, filed 2013-12, 98,000 miles

“Also like many other complaints I have seen, the 2004 Ford Expedition I have has shut off on me several times while driving and I was told to switch out the entire fuse box. I called the dealer and they said to replace it, it would be about $500 for it. It's ridiculous Ford hasn't issued a recall because this seems like a problem many people are having as well. We have almost gotten into a couple of accidents because of this issue! …”

NHTSA complaint #11000740, filed 2017-06, 82,000 miles

“This has occurred a three times in last month...first being in july. I park my vehicle, turn ignition off and pull out key and the air conditioner is still blowing and radio is still going for a couple seconds after key is pulled out...only a couple seconds and immediately shuts itself off. This is definitely an electrical or ignition issue.I do know radio will stay on until door opened, thats a feature of the vehicle, but this is different, air stays blowing?? …”

NHTSA complaint #10762386, filed 2015-09, 231,000 miles

“My vehicle, without any warning at any speed, including highway speeds, shuts off completely,without any warning or indication that it is about to do this. Always on a straight road with almost a full tank of gas. The cause a relay switch which is soldiered into the memory board that controls the vehicle's brain box that shorts out. After doing research on the internet, I am both shocked and disgusted that the nhsta has not investigated this faulty design by Ford and made them recall all of the 2003- 2008 expeditions. …”

NHTSA complaint #11002736, filed 2017-07, 190,000 miles

Related service bulletins

Electrical system: other model years

YearComplaintsShare of year
2026110%
2025616%
20241519%
20231726%
20222017%
20212410%
2020358%
2019173%
2018349%
20179326%
20163315%
20154527%
20141318%
20131011%
20122017%
2011710%
20101017%
2009518%
200896%
2007188%
20063211%
20057624%
20043612%
200310417%
20024614%
200111820%
200021424%
199911712%
199811514%
19979511%

Other parts of the 2004 Ford Expedition

Air bags
46 complaints
Brakes
43 complaints
Engine
29 complaints
Transmission and drivetrain
27 complaints
Engine cooling
26 complaints
Tires
26 complaints
Body and structure
24 complaints
Fuel system
23 complaints
Vehicle speed control
21 complaints
Visibility (wipers, defrost, mirrors)
15 complaints
Steering
14 complaints
Other or unknown
11 complaints

← All problems reported for the 2004 Ford Expedition

About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 28, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.

To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology