2004 Ford Expedition Body and structure Problems
- Complaints
- 24about this part
- Share
- 8%of 297 total for the year
- Median mileage
- 87,500miles
- Trend
- FallingComplaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.
NHTSA recorded 24 complaints about the body and structure of the 2004 Ford Expedition, 8% of the 297 complaints for this model year. Where a mileage was given, the median is 87,500 miles.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“Rusted out rocker panels, brake lines, front end radiator mounts, fender mounts. The entire under carriage is rusting away. We have had to replace all the brake lines as they have rusted away, redid the rocker panels rust away. Now we have to replace the entire front end because of rust. Will not pass pa state inspection due to rust. Is the Expedition in the recall for rust?”
NHTSA complaint #11130883, filed 2018-09, 125,000 miles“My letter to paoli Ford to: paoli Ford 3/18/06 attn. General manager re: 2004 e.b. Expedition purchased 3/04 problems: door rattles, brake failure no Ford product to date has required as many service calls as this 2004 Expedition. The door rattles have never been totally fixed after7 attempts. I believe that there is a design flaw in the advance trac system that has caused a brake failure on two occasions. I do not intent to wait around for a third time. Last summer, I was traveling at approximately 50 m.p.h. When approaching a light in heavy traffic. The brakes failed. …”
NHTSA complaint #10154000, filed 2006-03, 4,000 miles“The frame is rusting. See photos. The body is rusting away also the brake lines. The entire vehicle is rusting away. Why has this 2004 Ford not included in a recall for rust.”
NHTSA complaint #11343564, filed 2020-08, 85,000 miles“Roof canel rust, had repaired it 4 times since 2007. Ford is unwilling to take ownership of the defect and with each repair, the roof is weaker. Spoke to two dealerships and this defect keeps them in business since this is all they do.”
NHTSA complaint #10476942, filed 2012-09, 38,938 miles“1 own a 2004 Ford Expedition and the original paint is bubbling up on the tailgate around the license plate holder and door handle there have been hundreds of complaints and Ford does not want to except responsibility.”
NHTSA complaint #10263675, filed 2009-03, 65,000 milesRelated service bulletins
- 10235153Apr 4, 2023For 2000-2024 Ford and Lincoln vehicles, swapping a module from a vehicle for diagnosis purposes is likely to cause errors and is not recommended. It is also not recommended to…
- 10177863Jul 13, 2020This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/Mercury vehicles equipped with aluminum body panels may exhibit…
- 10156863Feb 7, 2019Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without…
- 10155551Feb 7, 2019Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without…
- 10014165Dec 27, 2004Aluminum corrosion - service tip.
Body and structure: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2025 | 2 | 5% |
| 2024 | 5 | 6% |
| 2023 | 4 | 6% |
| 2022 | 13 | 11% |
| 2021 | 11 | 5% |
| 2020 | 22 | 5% |
| 2019 | 16 | 3% |
| 2018 | 13 | 3% |
| 2017 | 6 | 2% |
| 2016 | 3 | 1% |
| 2015 | 8 | 5% |
| 2014 | 6 | 8% |
| 2012 | 15 | 13% |
| 2011 | 10 | 14% |
| 2010 | 10 | 17% |
| 2009 | 7 | 25% |
| 2008 | 34 | 23% |
| 2007 | 9 | 4% |
| 2006 | 19 | 6% |
| 2005 | 15 | 5% |
| 2004 | 24 | 8% |
| 2003 | 32 | 5% |
| 2002 | 14 | 4% |
| 2001 | 25 | 4% |
| 2000 | 47 | 5% |
| 1999 | 20 | 2% |
| 1998 | 25 | 3% |
| 1997 | 38 | 4% |
Other parts of the 2004 Ford Expedition
46 complaintsBrakes
43 complaintsElectrical system
36 complaintsEngine
29 complaintsTransmission and drivetrain
27 complaintsEngine cooling
26 complaintsTires
26 complaintsFuel system
23 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 27, 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