2004 Ford Explorer Fuel system Problems
- Complaints
- 33about this part
- Share
- 3%of 1,304 total for the year
- Median mileage
- 42,000miles
- Trend
- RisingComplaints filed in the last 3 full calendar years are at least 25% higher than in the 3 years before.
NHTSA recorded 33 complaints about the fuel system of the 2004 Ford Explorer, 3% of the 1,304 complaints for this model year. Where a mileage was given, the median is 42,000 miles. 1 a fire, according to the filers.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“I am having electronica issues with my 2004 Ford Explorer, that control lighting and speed of my vehicle. Also the left signal arm that controls high beams, and lighting snapped off while I was on the freeway on august 5th, 2018. The electrical problem started in june 2018.”
NHTSA complaint #11118597, filed 2018-08, 203,011 miles“2004 Ford explore dies on the road while driving. Going 70 MPH down the interstate and the vehicle died luckily I was driving on the side lane and got off to the shoulder so we weren't stuck in the middle of interstate traffic. Called a tow truck and had the vehicle diagnosed at an auto repair shop. Fuel pump had to be replaced. The auto shop replaced the pump.”
NHTSA complaint #10348467, filed 2010-08, 85,555 miles“On april 6th of this year I purchased a 2004 Ford Explorer. The next day I took the car for city inspection...it passed. The very next day (sunday) the check engine light came on. The ABS light would also illuminate. I took the car to autozone to have it diagnosed (EGR valve). Only the check engine light could be diagnosed because the ABS light came on at random while I was driving. The car was still under the 1000 mile warranty so the EGR valve was replaced and a speed sensor believed to be the problem with the ABS light. …”
NHTSA complaint #10485460, filed 2012-11, 114,000 miles“My gas gauge on my 2004 Ford Explorer has failed me many times. I took it to my dealership & they told me to add some fuel additive to my gas tank & this would cure the problem. Well it has not & my warranty is out!!! I'm very concerned for my wife's safety if she runs out of gas, so we have to keep a written log as to the mileage before fill-up's. I'm told the sensor is bad & would cost close to $1,000.00 to repair. I have complained to Ford & they refuse to repair since the warranty is out. …”
NHTSA complaint #10226585, filed 2008-05, 58,000 miles“2004 Ford Explorer xls, 41,000 miles on multiple occasions my car has shut off, loosing power for the brakes and steering. It usually happens when decelerating at a stoplight, or even decelerating off the highway onto an exit ramp. It has occurred at least four of five times and I've been very lucky each time to be able to pull over, put my car in neutral, and restart it. The car has no trouble starting back up. I've researched on the internet about this problem and have found that my experience is not unique. …”
NHTSA complaint #10266188, filed 2009-04, 40,000 milesRelated service bulletins
- 10021052Feb 27, 2007Mil on with dtc p0463 or erratic fuel gauge operation.
- 10019379Jan 1, 2006Malfunction indicator lamp on with pcm diagnostic trouble code p0463 and/or ic diagnostic trouble code b1201 - fuel gauge drops to empty or slow to update after refueling.
- 10013388Oct 31, 2005Fuel gauge slow to update after refueling.
- 10017860Jul 1, 2005Malfunction indicator lamp coming on with diagnostic trouble codes (dtcs) p0171, p0172, p0174 and/or p0175 (fuel system too rich or lean).
- 10011332Sep 1, 2004Fuel gauge slow to update.
Fuel system: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2026 | 3 | 7% |
| 2025 | 3 | 3% |
| 2023 | 3 | 3% |
| 2022 | 37 | 14% |
| 2021 | 28 | 6% |
| 2020 | 42 | 3% |
| 2019 | 17 | 6% |
| 2018 | 23 | 3% |
| 2017 | 49 | 3% |
| 2016 | 112 | 5% |
| 2015 | 94 | 5% |
| 2014 | 72 | 4% |
| 2013 | 153 | 7% |
| 2012 | 34 | 4% |
| 2011 | 40 | 3% |
| 2010 | 9 | 8% |
| 2009 | 2 | 6% |
| 2008 | 2 | 1% |
| 2007 | 4 | 2% |
| 2006 | 27 | 4% |
| 2005 | 66 | 13% |
| 2004 | 33 | 3% |
| 2003 | 11 | 1% |
| 2002 | 72 | 2% |
| 2001 | 11 | 3% |
| 2000 | 19 | 2% |
| 1999 | 34 | 3% |
| 1998 | 63 | 3% |
| 1997 | 56 | 3% |
| 1996 | 23 | 2% |
| 1995 | 16 | 2% |
| 1994 | 33 | 3% |
| 1993 | 12 | 1% |
| 1992 | 18 | 3% |
| 1991 | 26 | 4% |
| 1990 | 2 | 17% |
Other parts of the 2004 Ford Explorer
460 complaintsBody and structure
426 complaintsVisibility (wipers, defrost, mirrors)
112 complaintsVehicle speed control
76 complaintsEngine cooling
71 complaintsElectrical system
55 complaintsBrakes
53 complaintsEngine
44 complaintsSteering
41 complaintsWheels
41 complaintsAir bags
39 complaintsOther or unknown
37 complaints
← All problems reported for the 2004 Ford Explorer
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 29, 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