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Lincoln AviatorModel year report

2004 Lincoln Aviator Problems

Complaints
81filed with NHTSA
Median mileage
70,500miles, 68 complaints with mileage
Recalls
0campaigns on record
Trend
StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
NHTSA crash rating
—overall rating starts with 2011 models
EPA fuel economy
14 mpgcombined, 4.6L 8-cyl RWD · 12 city / 17 hwy

Sources: NHTSA records for the 2004 Lincoln Aviator (complaints, recalls, investigations), EPA fuel economy. Report an error

What owners report

Owners of the 2004 Lincoln Aviator most often describe transmission and shifter problems — gears slipping, harsh or delayed reverse engagement, and shifters that bind or come apart — along with cracked liftgate panels around the rear emblem and engine misfires traced to coil packs and cylinder head work. Many reports arrive between roughly 50,000 and 100,000 miles, and several owners describe the problems as developing gradually before a loss of drive or a check-engine light.

  1. Transmission and drivetrain

    Shift cable and gear shifter failure

    • 22 complaints (27%)
    • median 79,000 mi at 7.2 yrs old (21 state mileage)
    • 1 mention a crash, fire or injury
    • owner-quoted repair $2,250 (median of 6 quotes)
    • filed 2004–2019

    Complaints describe the console shifter sticking, refusing to leave Park, or coming apart, and in some cases the shift cable dislodging from its bracket on the transmission so the vehicle will not move or the indicated gear no longer matches the actual gear. Several owners report the key could not be removed from the ignition or the vehicle would not go into Neutral after the shifter failed. According to complaints, dealers typically replaced the shift assembly or cable, and several owners said no recall covered the repair. Mostly reported between about 30,000 and 90,000 miles, with a few at higher mileage.

    3 related service bulletins

    What to check: Work the shifter slowly through every position, including Park and Reverse, and check that the indicated gear matches; ask whether the shift cable or lever assembly has been replaced.

    2 excerpts from owner complaints in NHTSA records

    “The switch, attached to the brake pedal, which releases the shift lock, and activates brake lights, has failed twice. The first time, we were able to remove the switch and clean the internal contacts, and the problem was fixed for approx. Six months. The second time, I was stopped in traffic by another driver to inform me that my brake lights were not working and he almost rear-ended me. …”

    NHTSA complaint #10198461, filed 2007-08, 62,000 miles

    “I recently purchased a 2004 Lincoln Aviator. About a month after I purchased this vehicle it started to develop problems. The rear bearing seal failed and oil is leaking out. The gear shifter on the console is starting to stick and not go into gear. I understand the Aviator is having a lot of problems in these areas. The vehicle only had 79000 miles on it when I purchased it. Ford must have used inferior materials to make the Aviator. …”

    NHTSA complaint #10356799, filed 2010-09, 79,000 miles
  2. Engine

    Engine misfire and cylinder head trouble

    Mentioned in 12 of 60 sampled complaints

    Owners report rough idling, stalling or shuddering under acceleration, and a check-engine light, with diagnosis pointing to ignition coils and later to a burned valve or cracked cylinder head on the number 7 or 8 cylinder. Complaints describe repeated coil replacements on the same cylinder before a head or valve job was recommended, with quoted repair costs in the thousands. Some owners said the work was declined or only partly covered once mileage exceeded the extended coverage. Most often reported between about 20,000 and 130,000 miles, with head and valve work typically at higher mileage.

    4 related service bulletins

    What to check: Ask whether coils, plugs or cylinder head work have been done and on which cylinders, and have a pre-purchase scan check for misfire codes and pending codes.

    2 excerpts from owner complaints in NHTSA records

    “I tried to pull off at a very busy intersection and nothing. I came very close to getting into a crash. I am now told from the dealership that I need a new transmission and transfer case. I've taken very good care of my vehicle since I purchase my 2004 Lincoln Aviator lux with 80,000 miles on it and always had it serviced at the dealership. I thought I was making a good decision when purchasing a Lincoln. I'm a single parent and wanted a reliable vehicle. Worst decision I ever made!!! …”

    NHTSA complaint #10641636, filed 2014-10, 126,000 miles

    “I purchased this vehicle as a certified used vehicle. It had an extended warranty. Once it expired I've experienced every single complaint people have stated online about this vehicle. As of today (12/02/13) it still has only 74,000 miles on it and the latest problem is the transmission needs to be replaced but they don't know why. I am a stay at home mom and wear-and-tear on it is very minimal (grocery shopping, to and from school, etc.). I have never had so many problems on a so called luxury vehicle before! …”

    NHTSA complaint #10554425, filed 2013-12, 72,614 miles
  3. Body and structure

    Cracked liftgate panel around rear emblem

    • 16 complaints (20%)
    • median 64,500 mi at 6.0 yrs old (14 state mileage)
    • filed 2007–2015

    Owners describe a crack in the plastic liftgate panel beside the Lincoln emblem, often appearing without an impact and sometimes noticed as a black line after the vehicle was parked. Complaints say dealers and body shops attributed it to a weak spot and cold weather, and that repairs were generally at the owner's expense, with the crack returning after repair. Some owners say the rear glass could eventually come loose if the crack spreads. Reported from roughly 30,000 to 100,000 miles, several owners noting cold weather or winter trips.

    What to check: Inspect both sides of the rear emblem on the liftgate for hairline cracks and look along the base of the rear glass; ask whether the panel has been repaired or replaced.

    2 excerpts from owner complaints in NHTSA records

    “As I was exiting a store and walking toward my vehicle, I noticed what looked like a black streak on the back of my liftgate. When I was closer, I saw that it was a crack in the back of the lift gate on the right side of the emblem of the vehicle from the bottom of the back window to the bottom of the lift gate. …”

    NHTSA complaint #10568568, filed 2014-03, 71,000 miles

    “Without impact the tailgate applique of my 2004 Lincoln Aviator cracked. I understand this is common among ford explorers merc. Mountaineers and aviators as reported by my local ford dealer and various bodyshops and thousands on the internet with similar defects. Ford wont fix if its out of warranty . The broken tailgate section can dislodge and cause damage to pedestrians or motorists. Please advise as this is a widespread manufactures defect. Thank you”

    NHTSA complaint #10363862, filed 2010-11, 30,292 miles
  4. Transmission and drivetrain

    Transmission slipping and harsh reverse engagement

    • 18 complaints (22%)
    • median 72,807 mi at 7.3 yrs old (18 state mileage)
    • 1 mention a crash, fire or injury
    • owner-quoted repair $3,000 (median of 5 quotes)
    • filed 2004–2019

    Complaints describe gears slipping, delayed or harsh engagement into Reverse, and intermittent loss of drive while accelerating from a stop, sometimes escalating to the vehicle being stuck in Neutral and needing a transmission replacement. Some owners mention a fluid-related program and that the transmission fluid was found to be incorrect from the factory. According to complaints, dealers sometimes replaced the solenoid pack or the whole transmission, and some owners said no fault could be reproduced on a test drive. Reported from under 30,000 miles up to about 130,000, with many in the 60,000 to 85,000 range.

    4 related service bulletins

    What to check: Test drive from cold, checking for delayed or harsh Reverse engagement and slipping under acceleration, and ask whether the transmission fluid service program and solenoid pack updates were done.

    2 excerpts from owner complaints in NHTSA records

    “My main problem is that the car has an intermittent transmission problem. The car slips out of gear and the engine races. I have mentioned the problem to the service department on several occasions and they tell me it?s my problem till it does it for them. The other day I got a letter from Lincoln saying that the factory had put the wrong transmission fluid in the car. The service department still does not think this is my problem. The car has been in for the AC being broken; the brake rotors have been replaced. …”

    NHTSA complaint #10106495, filed 2005-01, 5,000 miles

    “2004 Lincoln Aviator gears were slipping and would not shift; had it checked and was told the transmission was failing. 2 days later we had to have it towed to the shop because it was stuck in neutral . Had to replace the transmission at only 63,000 miles. Never had a transmission fail with only 63k miles, all preventative maintenance is kept up on our vehicle. Loud noise at startup and A/C does not work, I believe it is the clutch. No help from ford even though there are multiple complaints of transmission/power train problems. …”

    NHTSA complaint #10419511, filed 2011-08, 63,000 miles
  5. Electrical system

    Electrical shutdowns and brake light switch faults

    • 6 complaints (7%)
    • median 40,000 mi at 4.5 yrs old (6 state mileage, few)
    • filed 2005–2017

    Complaints describe the brake lights failing to illuminate because of a faulty switch at the pedal, in one case repeatedly, and separate reports of the electrical system and headlights cutting out while driving. Some owners also describe the engine shutting off with warning lights on, requiring a restart. Dealer responses described in the complaints include replacing the brake light switch and being unable to reproduce the shutdown. Reported across a wide range, from about 20,000 to over 160,000 miles.

    3 related service bulletins

    What to check: Have someone watch the brake lights while you press the pedal, check that the shifter unlocks properly, and ask whether the brake light switch or battery drain issues have been addressed.

    2 excerpts from owner complaints in NHTSA records

    “I purchased brand new car worth $60,000 and from day 1 the first time I put the key it showed an error on the dashboard. I been to service center 5 times, and as of today 04/20/05 the care is with the dealer for the same problem. I been calling ford motors for the same problem, but have not received any calls from ford motors. I am paying $905 + insurance for the car which is 6 months old and sitting in the repair shop.”

    NHTSA complaint #10118192, filed 2005-04, 11 miles

    “Early this morning was driving on the freeway in our 2004 Lincoln Aviator. There was a moderate rain fall and zero natural light was available. Without warning, the electrical system, including the headlights, in the vehicle shut off. I was traveling at approx. 70 MPH and was carrying a total of seven people. Unable to see, I drove off the road and was horrified to discover that I almost ran into the guard rail. While this situation did not result in any damage or fatalities, this could have easily been a disaster resulting in multiple deaths. …”

    NHTSA complaint #10283886, filed 2009-09, 105,400 miles

Buying note. The 2004 Aviator's reports concentrate on transmission and shifter repairs, cracked liftgate panels and engine misfire or cylinder head work, so a pre-purchase inspection focused on those areas and a scan for stored codes is worth the cost. Ask for service records showing transmission fluid service, coil or head repairs, and brake light switch replacement.

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.

NHTSA recorded 81 consumer complaints for the 2004 Lincoln Aviator. 68 of the complaints include a mileage, and 31% of those were filed for vehicles with under 50,000 miles; the median is 70,500 miles. Of all complaints, 2 involved a crash, 1 a fire, 3 an injury, according to the filers. NHTSA lists 0 recall campaigns and 31 technical service bulletins for this model year.

Not compared (before 2008). Model years 2008–2023 of the same vehicle that have at least 25 complaints are compared, and a model needs at least 3 of them.

Which parts are reported most

Complaints can name more than one part, so the counts add up to more than the total. Select a part to see its complaints, recalls and bulletins.

Also reported: Brakes (3), Exterior lighting (3), Equipment (2), Fuel system (2), Seats (2), Tires (2), Wheels (2), Latches, locks and linkages (1).

Example complaints

Transmission and drivetrain: “My Lincoln Aviator started making a horrible noise in the rear of the vehicle on the morning of september 4, 2011. My wife took the Aviator to the aaa car care center to find and repair the issue. The aaa certified technician placed the Aviator on the lift and discovered the entire differential unit was hanging freely and literally swinging under the vehicle. After further inspection, the welding that holds the mount to which the differential until is bolted, broke from the frame. …”

NHTSA complaint #10507210, filed 2013-04, 118,000 miles

Engine cooling: “My 2004 Lincoln Aviator engine has a burnt valve with less than 90k miles on it. Rich morton Lincoln dealership in glen burnie, md says my repair will be $5,400 if I want to fix it, which they do not recommend. I see online that many others have the very same problem with this vehicle. I have also had to tow in my car as several times the gearshift stuck in park and could not be shifted to drive. I spoke with other owners who had the same problem. Also, my tailgate window randomly flies up while driving, just like other owners have reported. …”

NHTSA complaint #10375188, filed 2011-01, 89,500 miles

Body and structure: “I was driving east on the 202 fwy in phoenix at a speed between 65-68 MPH when I heard a loud bang and both side air curtains deployed. Time: 9:30 p.m. Feb. 20, 2015.”

NHTSA complaint #10689877, filed 2015-02, 129,802 miles

Electrical system: “The vehicle down shift when turning into the first as it goes into second makes in awful noise. When I parked it and tried to start it and it was dead.the mechanic figure it had something to do with the starter he got under the vehicle to applied starter told me to start it and it did and it pinned him under the vehicle.they later said the belt had popped. The vehicle had ben leaking a lite fluid they believed it to be the differential oil. Its a four wheel drive. I had it towed to bohn ford 6/5/17they are charging 350.00 to replace the belt.city st. …”

NHTSA complaint #10993329, filed 2017-06, 167,786 miles

Mileage when problems were reported

31% of the 68 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 35,000 and 94,000 miles.

9%0–107%10–2515%25–5028%50–7518%75–10021%100–1503%150+
Share of complaints by mileage when the problem was reported, in thousands of miles (68 complaints with mileage). Red bars: under 50,000 miles. Bucket widths differ. Median: 70,500 miles.

Complaints by year filed

Trend: stable. Complaints filed in the last 3 full calendar years are within 25% of the 3 years before.

’04’06’08’1017’12’14’16’19
Complaints by year the complaint was filed with NHTSA. Red bars: the last 3 full calendar years used for the trend. The current year (2026) is partial.

Fuel economy and running cost

EPA ratings for each 2004 Lincoln Aviator version. Annual fuel cost is the EPA's estimate at its current fuel prices for 15,000 miles a year (55% city driving).

VersionEngineTransmissionCityHwyComb.Fuel / yr
Aviator 2WD4.6L 8-cyl5-speed automatic121714$5,850
Aviator 4WD4.6L 8-cyl5-speed automatic121613$6,300

Source: U.S. EPA and Department of Energy, fueleconomy.gov. Ratings are for comparing vehicles; real-world mileage varies with driving and conditions.

Recalls and investigations

NHTSA lists no recall campaigns for the 2004 Lincoln Aviator in the data used here. A recall can apply to some vehicles of a model year and not others, so check a specific vehicle by VIN at nhtsa.gov/recalls.

Technical service bulletins

TSBs are manufacturer notes to dealers about known repair procedures. They are not recalls and do not by themselves mean a vehicle has a fault. 31 on record; the latest 10 are shown.

See all 31 bulletins →

Other model years of the Lincoln Aviator

YearComplaintsMedian miRecallsCrash ★MPGScore (50 = typical)Trend
2025189,00015521—Too new
2024762,0008521—Too new
20232420,99016521—Too new
20224934,0002152150 · TypicalRising
20214060,0002852135 · FewerRising
202011011,0003052187 · MoreRising
20055170,9760—13Not compared (before 2008)Falling
20048170,5000—14Not compared (before 2008)Stable
200311164,0001—14Not compared (before 2008)Falling

All Lincoln Aviator model years · Best and worst years by complaints

Frequently asked questions

What are the most common problems with the 2004 Lincoln Aviator?

Owners of the 2004 Lincoln Aviator most often describe transmission and shifter problems — gears slipping, harsh or delayed reverse engagement, and shifters that bind or come apart — along with cracked liftgate panels around the rear emblem and engine misfires traced to coil packs and cylinder head work. The issues reported most often: Shift cable and gear shifter failure; Engine misfire and cylinder head trouble; Cracked liftgate panel around rear emblem.

How many NHTSA complaints does the 2004 Lincoln Aviator have?

NHTSA recorded 81 consumer complaints for the 2004 Lincoln Aviator as of Oct 28, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.

What part of the 2004 Lincoln Aviator is reported most often?

Transmission and drivetrain is named most often, in 21 complaints (26% of the total), followed by engine cooling with 15.

Has the 2004 Lincoln Aviator been recalled?

NHTSA lists no recall campaigns for this model year in the data used here. To check a specific vehicle, enter its VIN at nhtsa.gov/recalls.

What gas mileage does the 2004 Lincoln Aviator get?

The EPA rates the 2004 Lincoln Aviator (Aviator 2WD, 4.6L 8-cyl) at 14 mpg combined, 12 city and 17 highway, with an estimated annual fuel cost of $5,850 at 15,000 miles a year. Other engine and drive versions are rated differently.

At what mileage are problems with the 2004 Lincoln Aviator reported?

Among the 68 complaints that include a mileage, the median is 70,500 miles and the middle half falls between 35,000 and 94,000 miles; 31% were filed for vehicles with under 50,000 miles.

About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 28, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate. Fuel economy is from the EPA and DOE (fueleconomy.gov).

Complaint counts come from NHTSA’s public complaint database; we count each complaint once. The source records for this vehicle are on nhtsa.gov. Scores and trends are our own summaries of that data, described in the methodology. This page is not legal, safety or repair advice: for a specific vehicle, check its VIN at nhtsa.gov/recalls and ask a qualified mechanic. See an error? Tell us.