2004 Ford Expedition Fuel system Problems
- Complaints
- 23about this part
- Share
- 8%of 297 total for the year
- Median mileage
- 126,000miles
- Trend
- FallingComplaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.
NHTSA recorded 23 complaints about the fuel system of the 2004 Ford Expedition, 8% of the 297 complaints for this model year. Where a mileage was given, the median is 126,000 miles.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“While driving in the city on local streets, the engine just stops with no ability to drive. I am an instant safety problem on the road. This happened 3 times in one day. Fortunately, no one was injured. After a few minutes, the car starts up again. My mechanic can't duplicate the problem. Anyone help before there is a major life-threatening accident!! Thanks!”
NHTSA complaint #10884825, filed 2016-07, 115,000 miles“Our 2004 Ford Expedition eddie bauer suddenly turns off while we are driving at any speed. In a year's time, it has turned off four or more times. Most of those times, we were traveling at speeds of about 60mph. All of the power shuts off, steering and brakes included. We turn the key off and it does restart. Luckily we have not been in any terrible accidents!”
NHTSA complaint #10875319, filed 2016-06, 200,000 miles“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“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“Was driving my SUV and was coming close to my turn off let off the gas and my vehicle cut off had to steer to side of the road. Had fuel pump replaced was driving the next day after pump was replaced stopped still and the vehicle started shaking and cut off. It started up about ten minutes later. …”
NHTSA complaint #10579301, filed 2014-04, 150,000 milesFuel system: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2025 | 1 | 3% |
| 2024 | 2 | 3% |
| 2023 | 4 | 6% |
| 2022 | 14 | 12% |
| 2021 | 14 | 6% |
| 2020 | 5 | 1% |
| 2019 | 10 | 2% |
| 2018 | 9 | 2% |
| 2017 | 20 | 6% |
| 2016 | 17 | 8% |
| 2015 | 22 | 13% |
| 2013 | 2 | 2% |
| 2012 | 4 | 3% |
| 2011 | 4 | 6% |
| 2009 | 2 | 7% |
| 2008 | 9 | 6% |
| 2007 | 37 | 17% |
| 2006 | 24 | 8% |
| 2005 | 65 | 21% |
| 2004 | 23 | 8% |
| 2003 | 38 | 6% |
| 2002 | 21 | 6% |
| 2001 | 22 | 4% |
| 2000 | 19 | 2% |
| 1999 | 27 | 3% |
| 1998 | 28 | 3% |
| 1997 | 19 | 2% |
Other parts of the 2004 Ford Expedition
46 complaintsBrakes
43 complaintsElectrical system
36 complaintsEngine
29 complaintsTransmission and drivetrain
27 complaintsEngine cooling
26 complaintsTires
26 complaintsBody and structure
24 complaintsVehicle speed control
21 complaintsVisibility (wipers, defrost, mirrors)
15 complaintsSteering
14 complaintsOther 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 30, 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