2004 Ford Explorer Problems

What owners report

Owners of the 2004 Explorer most often describe transmission trouble — delayed or harsh engagement into reverse, slipping, and eventual transmission replacement — frequently at relatively low mileage. A second large group concerns the rear liftgate: cracked plastic around the Ford emblem and broken glass hinges. Remaining reports involve intermittent engine stalls, rear-wheel lug stud failures, and wind noise or water entry.

1. 1
   Transmission and drivetrain

   Harsh or delayed reverse engagement and transmission

   • 366 complaints (28%)
   • median 49,000 mi at 4.3 yrs old (303 state mileage)
   • 18 mention a crash, fire or injury
   • owner-quoted repair $1,700 (median of 40 quotes)
   • filed 2004–2019

   Complaints describe a thud, bang, or several-second delay when shifting into reverse, and occasional slipping or revving as if in neutral before the gear engages. Some owners report shop visits where a solenoid pack or fluid additive was replaced, and others were told the problem could not be reproduced or that a new transmission was needed. A few describe the vehicle surging or rolling unexpectedly after being placed in park. Reported from very low mileage up to about 100,000 miles, with many appearing between roughly 20,000 and 70,000 miles.

   6 related service bulletins

   What to check: Drive the vehicle from cold and shift slowly through reverse and drive, feeling for a delay or clunk. Ask whether the transmission fluid service or additive program was performed and whether the unit has been replaced.

   2 excerpts from owner complaints in NHTSA records

   “Well we just bought this Explorer and just as I have read from others on this website our Explorer is doing similar things. Such as shifting in reverse takes 3-7 seconds to take hold, going up the mountains the SUV had major kickbacks and jerks. I have not taken to dealership as of now. Will make an apt. And put results later.”

   NHTSA complaint #11057243, filed 2017-12, 197,000 miles

   “As I put the transmission into reverse, when backing out of my garage, there is a hesitation in the shift into reverse between 4 and 8 seconds, then the transmission goes into reverse with a bang. This just started happening to me, lately, on a number of occaisions. The Explorer was bought in july of 2004 and as of this date has 9,500 miles on it, and the latest incident was 12-15-04.”

   NHTSA complaint #10103080, filed 2004-12, 9,501 miles
2. 2
   Body and structure

   Cracked rear liftgate panel above the emblem

   • 298 complaints (23%)
   • median 68,000 mi at 6.3 yrs old (253 state mileage)
   • 6 mention a crash, fire or injury
   • owner-quoted repair $500 (median of 19 quotes)
   • filed 2006–2019

   Owners describe a vertical crack in the plastic panel below the rear glass, usually beside or near the Ford emblem, discovered without any prior incident. Several note the dealer recognized it as a common pattern on this body style but said no recall applied and the repair would be at the owner's cost. Complaints also mention concern about whether the panel still supports the glass. Mostly reported between roughly 40,000 and 120,000 miles, often noticed on parked vehicles.

   3 related service bulletins

   What to check: Inspect the plastic panel under the rear window on both sides of the emblem for hairline cracks, and ask whether any panel or hinge work has been done.

   2 excerpts from owner complaints in NHTSA records

   “The hatch below my rear window has cracked on both sides of the Ford logo on my Explorer. It seemed to have happened over night. I am concerned that it may not be strong enough to hold the window in while driving. Ford has had three years of models with this some problem and hasn't made it right by it's owners.”

   NHTSA complaint #10369160, filed 2010-12, 106,090 miles

   “I noticed my 2004 Ford Explorer has developed a vertical crack in the plastic tailgate attached to the rear window left of the Ford emblem. I took it to the dealership and they recognized it as a common problem with the 2004 Explorer and also warned me the hinges on the rear glass fail often as was the case on my vehicle. Service tech stated there was no recall as yet and I got to pay for the new hinges and holding off on the crack thinking Ford made do the right thing and repair the fault.”

   NHTSA complaint #10279401, filed 2009-08, 145,000 miles
3. 3
   Body and structure

   Rear glass hinges break and liftgate falls

   • 279 complaints (21%)
   • median 79,500 mi at 6.9 yrs old (240 state mileage)
   • 27 mention a crash, fire or injury
   • owner-quoted repair $675 (median of 16 quotes)
   • filed 2004–2023

   Complaints describe a loud snap from the rear, then the glass window sagging or dropping when opened or closed; in some cases a hinge pin pulled through the hinge structure. Owners report being hit or nearly hit by the falling glass and describe difficulty closing the window afterward. Some were told by the dealer that hinge failures are common on this model and that no recall covered it. Reported from around 57,000 miles into the 150,000-mile range, typically during opening or closing of the rear glass.

   1 related service bulletin

   What to check: Open and close the rear glass slowly and watch the hinges for cracking, looseness, or a sagging window; check that both support struts hold the glass up.

   2 excerpts from owner complaints in NHTSA records

   “1. The events leading to the failure were normal use of the vehicle. 2. Rear lift-gate hinges on 2004 Ford Explorer xlt began failing with a loud bang from the rear of the vehicle. The rear window began to sag and over the course of several months cracks appeared in the hinge structure. I have purchased new hinges, but at this time I still need to install them.”

   NHTSA complaint #10291664, filed 2009-11, 80,000 miles

   “On 19 apr 2012 while opening the back hatch window, the passenger side hinge of the window failed. When this occurred the driver side hinge was bent and the hydrulic lifts popped open the window rather rapidly which could have severely injured me if it hit me. I was unable to close the window myself so I could drive again. A bystander helped me out to close it. After reading other reports and complaints online, this is not an isolated incident for 2004 Ford explorers.”

   NHTSA complaint #10456026, filed 2012-04, 116,000 miles
4. 4
   Engine

   Engine stalls or dies while driving

   • 148 complaints (11%)
   • median 67,450 mi at 5.5 yrs old (134 state mileage)
   • 5 mention a crash, fire or injury
   • owner-quoted repair $3,277 (median of 6 quotes)
   • filed 2004–2021

   Owners describe the engine shutting off without warning at low speeds, while braking or turning, or while descending a hill with cruise control set; several mention losing power steering and power brakes at the same moment. Complaints note the engine restarts normally afterward, sometimes with no warning light, and that dealers had difficulty reproducing the stall or replaced components such as a fuse, throttle body, or computer part. Reported across a wide mileage range, from around 18,000 miles to over 150,000 miles, often at speeds under 50 mph.

   3 related service bulletins

   What to check: Test drive at low speed with the air conditioning on and, where safe, with cruise control set on a downhill grade; ask whether the throttle body or any stall-related diagnostics were addressed.

   2 excerpts from owner complaints in NHTSA records

   “While driving, the vehicle just shut off. I had no control of the vehicle once it shut off, except to utilize the emergency brake to get me stopped. Once stopped, I put it in park and it started up first try. No check engine light came on. Same thing happens on a regular bases. Usually happens while braking or turning at speeds lower than 30mph, then engine just stalls and everything turns off. …”

   NHTSA complaint #10505180, filed 2013-04, 82,500 miles

   “This is in response to the investigation of Ford for limp mode . Every time that I use my cars cruse control under 50 MPH the car goes in to limp mode. After I pull over and restart the car it run normaly,”

   NHTSA complaint #10508099, filed 2013-04, 120,000 miles
5. 5
   Body and structure

   Rear wheel studs or lug nuts break

   Mentioned in 4 of 60 sampled complaints

   Complaints describe a wheel wobble or noise followed by finding several broken lug studs on one wheel, and in two cases the wheel separating at highway speed. Owners report paying for replacement of studs themselves and, in one case, front studs replaced on both sides by an independent shop. Reported between roughly 18,000 and 155,000 miles, sometimes shortly after a tire rotation.

   What to check: Have the lug studs and nuts on all four wheels inspected for stretch, rust, or missing hardware, and confirm correct torque after any tire rotation.

   2 excerpts from owner complaints in NHTSA records

   “Without warning the rear wheel of my 2004 Ford, Explorer broke off going 65 on the interstate. All five lugs snapped off. No one took responsibility. I had to pay for repairs. It was either a defect or negligence on the part of the dealer where I had it serviced.”

   NHTSA complaint #10183514, filed 2007-02, 37,000 miles

   “The right rear passenger wheel came off my 2004 Ford Explorer when I was driving westbound on interstate 70 near kingdom city, mo. All five (5) bolts and lug nuts securing the wheel/tire were broken off. My wife and I were traveling at 70 MPH in the right hand lane of interstate when there was a sudden loud noise from the rear and the vehicle swerved violently to the right and then left. The vehicle spun and entered into the grass median in the middle of the interstate and the cable stopping system. …”

   NHTSA complaint #10807523, filed 2015-11, 154,871 miles

Buying note. Because transmission complaints dominate the record for this year, a thorough test drive with attention to reverse engagement and a check of transmission service history matter most. Also inspect the rear liftgate panel and glass hinges, since cracking and hinge failures are among the most frequently described body issues.

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.