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Body and structurePart report

2004 Ford Explorer Body and structure Problems

Complaints
426about this part
Share
33%of 1,304 total for the year
Median mileage
72,000miles
Trend
RisingComplaints filed in the last 3 full calendar years are at least 25% higher than in the 3 years before.

NHTSA recorded 426 complaints about the body and structure of the 2004 Ford Explorer, 33% of the 1,304 complaints for this model year. Where a mileage was given, the median is 72,000 miles. 2 of these say a crash was involved and 1 a fire, according to the filers.

Example complaints

Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.

“My car was parked in front of my residence on the street, it had not been driven that day. The back window in the tailgate exploded, causing damage to the tailgate. No one was driving it, it had not been touched that day. There was a prior crack in the tailgate which I have seen on other Explorer's, and since learned that it is a defect in the care.”

NHTSA complaint #10781412, filed 2015-10, 163,225 miles

“Sun visor bracket cracked and disintegrated leaving sun visor blocking my view. Had to pull over and disconnect the wire and remove visor. 2nd incident, pressed button to open rear glass and the hinges snapped ejecting the heavy glass panel at me. Had a child been opening it, they could have been killed. As it was, I caught the glass panel.”

NHTSA complaint #10758636, filed 2015-08, 130,000 miles

“Car was parked. I opened rear hatch (just the window part) and the passenger side hinge broke causing hatch to fall down on my head (quite painful!). About a year ago this same thing happened with the drivers side hinge (though I was able to catch it before it hit my head). I had that side repaired, but now it looks corroded so I worry it will happen again.”

NHTSA complaint #10715046, filed 2015-05, 231,173 miles

“Cracked rear hatch. I had heard about this problem and my hatch didn't crack till after this cold winter. But, this is the first winter that this Explorer has been kept outside, not garaged. My garaged is under my house and insulated. It never gets below freezing in the garage. I called Ford and asked them if they can help financially with the repairs. They said no.”

NHTSA complaint #10700921, filed 2015-03, 91,000 miles

“The back hatch has split next to the Ford sign. It got cold and when I got up to crank my truck I saw it.it was not hit and was in the shed when this happen. I was told it had a recall from someone that has the same thing happen to her. We also have had the transmission replaced.Ford really need to fix this .I can say I will never buy another Ford!!!!!!!!!!!!!!!!!!!!!!!”

NHTSA complaint #10669404, filed 2014-12, 182,000 miles

Related service bulletins

Body and structure: other model years

YearComplaintsShare of year
202625%
202577%
2023109%
2022114%
2021256%
2020454%
201915050%
201828839%
201765939%
201659124%
201541123%
201427616%
201343920%
201214417%
20111109%
201011%
200926%
200811%
2007115%
2006112%
200515130%
200442633%
200335431%
200248615%
2001298%
2000293%
1999473%
1998482%
1997503%
1996634%
1995395%
199415813%
1993869%
19926210%
1991315%

Other parts of the 2004 Ford Explorer

Transmission and drivetrain
460 complaints
Visibility (wipers, defrost, mirrors)
112 complaints
Vehicle speed control
76 complaints
Engine cooling
71 complaints
Electrical system
55 complaints
Brakes
53 complaints
Engine
44 complaints
Steering
41 complaints
Wheels
41 complaints
Air bags
39 complaints
Other or unknown
37 complaints
Suspension
37 complaints

← All problems reported for the 2004 Ford Explorer

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