2004 Ford Explorer Sport Trac Problems

What owners report

Complaints on this model year cluster around two themes: transmission slipping and harsh or delayed shifting, often reported between roughly 30,000 and 90,000 miles, and body-mount bushings behind the cab that crumble and let the body move on the frame. Owners also frequently describe airbags that failed to deploy in a crash or deployed without an impact, and front-end or suspension noises tied to tire wear and loose front-end parts.

1. 1
   Air bags

   Airbags that do not deploy, or deploy unprompted

   • 17 complaints (20%)
   • median 56,000 mi at 4.6 yrs old (14 state mileage)
   • 10 mention a crash, fire or injury
   • filed 2004–2024

   Several owners describe airbags that did not deploy in a collision, including rollover and side-impact crashes, while others report side curtain or side airbags deploying with no impact, sometimes while the vehicle was parked or a door was shut normally. In the unintended-deployment cases the dealer inspected but did not identify a cause, and one owner was quoted a substantial repair cost after warranty coverage was declined. Complaints also mention seat belts that no longer retract or lock. Reported from about 10,000 to 110,000 miles, with unintended deployments noted at low mileage and no-deployment reports spread across the range.

   What to check: Check that the airbag warning lamp behaves normally on start-up and ask whether any airbag or seat belt work has been done. Test that both front seat belts pull out, retract and lock, since owners report both restraint problems together.

   2 excerpts from owner complaints in NHTSA records

   “The side air bags (both) deployed for no apparent reason while I was driving down the road at approximately 30 MPH. My vehicle is a 2004 Ford Explorer Sport Trac. (4 door pickup). The vehicle was returned to a Ford dealer for repair and initially they said it would be a warranty repair but called back a week later indicating that Ford would not warrant the repairs and the cost to me would be $2300 to $2500. …”

   NHTSA complaint #10159911, filed 2006-06, 32,000 miles

   “On august 8th 2008 I was involved in a car wreck while driving my 2004 Ford Explorer Sport Trac. When the vehicle wrecked it flipped over onto the drivers side of the vehicle, and slid down the highway on its side. The airbags did not deploy, and the point of contact with the other vehicle was on the front driver's side corner panel of the truck. I feel that the impact of the wreck should have deployed the airbags.”

   NHTSA complaint #10261466, filed 2009-03, 52,000 miles
2. 2
   Transmission and drivetrain

   Transmission slipping and harsh 2-3 shifts

   • 11 complaints (13%)
   • median 37,000 mi at 3.5 yrs old (11 state mileage)
   • 1 mention a crash, fire or injury
   • owner-quoted repair $1,800 (median of 5 quotes)
   • filed 2004–2017

   Owners describe the automatic transmission slipping between gears, most often on the 2-3 upshift, sometimes with the overdrive-off light flashing and a sudden loss of acceleration. Several mention Ford's customer satisfaction program for improperly formulated transmission fluid and say the fluid service or additive did not resolve the slipping; some were quoted transmission control or rebuild work. A few report driveline vibration, whining and a thumping noise from the transmission or driveshaft area at low miles. Mostly reported between about 20,000 and 92,000 miles, with several cases first noticed in the 30,000-40,000 mile range and some as early as the first few thousand miles.

   4 related service bulletins

   What to check: Ask whether the 04B22 transmission fluid service was performed and whether the transmission has been serviced or rebuilt since. On a test drive, watch for delayed or harsh engagement into reverse and for slipping or flaring on the 2-3 shift.

   2 excerpts from owner complaints in NHTSA records

   “The truck's transmission slips going from first to second gear. This was a noticeable problem around 35k miles, and has continued to happen infrequently. Ford sent a letter, january 2005, stating that the transmission fluid used at the assembly plant needed to be replaced because, that over time, it could cause delayed/harsh engagements. When I took the vehicle in for the fluid replacement (42k miles approx), I mentioned this problem to the service employee. …”

   NHTSA complaint #10138943, filed 2005-10, 38,000 miles

   “I purchased a 2004 Ford explorer sport tracker 11 monthes ago. The first incident was the shocks towers. So, I thought. When I brought it into the dealership, they said it wasn't the shock towers but the sway bar. This occurred around september 2004.. Than I brought it into the dealership again because the transmission was slipping. I was told the transmission was brought into the shop. I only have 23,000 miles on the truck. When I bought this truck it had 23 miles on it when it brought it. I have put alot of highway miles on it. …”

   NHTSA complaint #10105921, filed 2005-01, 19,000 miles
3. 3
   Suspension

   Front-end noise, tire wear and suspension looseness

   • 12 complaints (14%)
   • median 35,203 mi at 3.5 yrs old (7 state mileage, few)
   • filed 2005–2015

   Owners report uneven or accelerated inside-edge tire wear, humming or whining from the front end at highway speed, and vibration that persisted after balancing and alignment checks. Some were told ball joints or front-end parts were loose or out of specification, while others describe hard, uncontrolled rear bouncing over bumps at highway speeds and a squeak from the rear sway bar link. One owner reported the vehicle pulling sideways after hitting a bump. Mostly reported between about 16,000 and 45,000 miles, with tire wear and vibration first noticed in the mid-20,000s.

   1 related service bulletin

   What to check: Inspect the inside edges of the front tires for cupping or uneven wear and check ball joints and sway bar links for play. Ask whether the rear sway bar link squeak has been addressed.

   2 excerpts from owner complaints in NHTSA records

   “I had uneven wear on my tires that were the original tires from the factory. I bought the car new from the Ford dealer. I was told that the tire specs and brand were not the ideal type for this kind of vehicle. No warranty coverage given. I did buy michelin at owl and they have held up to present 2014 at 106250 miles.”

   NHTSA complaint #10627092, filed 2014-08, 45,000 miles

   “My truck began making loud whinning noises june 2007, the steering was very tight when using the A/C and check engine light came on, A/C did not cool or get a tight seal for air flow, front tire wear has accelerated causing shaky steering, power steering got worse, although all fluids were new and belts look worn out and with all this I only had 52,120 miles. I had wreck in 07 because of the steering and reported it to my insurance for payment. …”

   NHTSA complaint #10237236, filed 2008-08, 35,203 miles
4. 4
   Body and structure

   Rear hatch glass shattering and trim/seal problems

   • 5 complaints (6%)
   • median 70,000 mi at 6.0 yrs old (5 state mileage, few)
   • filed 2008–2015

   Complaints describe the rear hatch glass shattering spontaneously, in some cases while the vehicle was stopped, with owners pointing to the hatch struts or springs letting go and bending the hatch. Others report cracks developing in the liftgate plastic panel, water leaking into the bed past the tonneau cover in rain, and a spare tire and carrier separating from under the vehicle. One owner also described being unable to release the tonneau cover from inside. Reported from under 14,000 miles up to very high mileage, with most cases in the 65,000-100,000 mile range.

   What to check: Open and close the rear hatch and check the glass, struts and liftgate panel for cracks or looseness, and inspect the spare tire carrier and cable underneath the vehicle.

   2 excerpts from owner complaints in NHTSA records

   “I own a 2004 Ford Explorer Sport Trac. The rear hard cover that covers the bed of the truck does not seal tightly. During heavy or steady rain, water will trickle into the bed of the truck. Dampening anything stored in that area. I have contacted Ford corporate headquarters to lodge a complaint. Ford claims the cover was never advertised as being weather sealed. Has anyone else encountered this problem? Is there a cure for it ? I have tried adjusting the cover. This only helped slightly.”

   NHTSA complaint #10245507, filed 2008-10, 13,900 miles

   “While operating 2004 Ford explorer, stopped at stop sign and the rear hatch glass literally exploded. Upon looking, it was realized the hatch arms/ springs let go, bending the hatch causing the glass to completely shatter.”

   NHTSA complaint #10285014, filed 2009-09, 70,000 miles
5. 5
   Body and structure

   Body mount bushings crumbling

   • 5 complaints (6%)
   • median 81,200 mi at 9.5 yrs old (5 state mileage, few)
   • filed 2011–2015

   Owners describe the body-to-frame mounting bushings as crumbling when touched and breaking down on trucks that never saw road salt. The result is a cab that feels loose on the frame, with shaking, rattling and excess body roll; one owner reported that replacing shocks and sway bars did not help. Owners who contacted Ford say they were told there was no warranty coverage, customer satisfaction program or recall for the mounts. Mostly reported between about 27,000 and 100,000 miles, including trucks kept in warm, salt-free climates.

   What to check: Look at the body mounts along the frame rails for cracking or missing material, and drive over uneven pavement to feel for excess body shake or roll.

   2 excerpts from owner complaints in NHTSA records

   “I went to install a pair of step bars on my truck, and noticed that my body bushings looked odd. I touched one of them and it crumbled, and upon further investigation I noticed at least 3 sets on each side were in the same shape. I called Ford customer service and was told to take it to the dealer to have it checked, and that there was no warranty, customer satisfaction plan, or recall. I told them I was a mechanic and did not need to go to the dealer, but they did register my complaint. …”

   NHTSA complaint #10429517, filed 2011-10, 96,000 miles

   “Body/chassis mounts are deteriorating and crumbling. Body is now loose on the frame and has slight movement. These mounts are not rubber like most; they are some sort of urethane composite. Internet research and truck owner sites confirm this to be a common problem. Ford does not see this as a safety/recall issue and has directed owners of suspect vehicles to your department. This particular vehicle has never been in salt or snow . …”

   NHTSA complaint #10508536, filed 2013-04, 81,200 miles

Buying note. Budget for a transmission inspection and a fluid/service history check on any example, and look closely at the body mounts, rear hatch glass and front tire wear. Many of these complaints involve repairs owners paid for themselves, so receipts for prior transmission and suspension work are worth asking about.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.