2004 Nissan Frontier Problems

What owners report

Owners of this model year most often report transmission trouble (slipping, hard shifts, leaks, housing cracks) and fuel-system problems where the steel fuel tank rusts and leaks vapors. Steering complaints also recur, several of them tied to a lower steering-column recall, and a cluster of airbag complaints describes bags that did not deploy in collisions. Many reports involve trucks with well over 100,000 miles and rust in the frame, oil pan and fuel tank.

1. 1
   Transmission and drivetrain

   Automatic transmission slipping, hard shifting or fluid leak

   • 13 complaints (20%)
   • median 47,347 mi at 8.1 yrs old (10 state mileage)
   • 1 mention a crash, fire or injury
   • filed 2004–2022

   Complaints describe the automatic transmission slipping when accelerating uphill or downhill, sometimes needing a shift to neutral and back to Drive before the truck responds, and often only once the engine is hot. Others report slow transmission fluid leaks, a cracked transmission housing found by a mechanic, a failed transmission switch, and knocking noises with hesitant gear engagement when shifting. In several cases the dealer could not duplicate the problem, and one owner was quoted a large repair estimate for the transmission and radiator. Reported from very low mileage up to about 123,000 miles, with most complaints in the 55,000-105,000 mile range.

   3 related service bulletins

   What to check: Check the transmission fluid level and colour, look for fluid weeping or staining on the bottom pan and around the bellhousing, and drive the truck both cold and after it is fully warm, testing uphill acceleration.

   2 excerpts from owner complaints in NHTSA records

   “My truck suddenly had issues shifting. I went online and saw there was a lawsuit and common issues with the radiator and transmission. I was not notified about the lawsuit or the issue from Nissan. I also called a mechanic and they said it is a common issues and it would be about $6,000 to replace the transmission and radiator. This is unacceptable as Nissan should have notified customers so that we could have had it fixed before it turned into a major issue.”

   NHTSA complaint #11053478, filed 2017-12, 102,000 miles

   “When driving from 50- 70 MPH vehicle vibrated under the floor board. The dealer replaced the drive shaft, however problem recurred. The dealer moved the shaft 1/4 turn and the same problem recurred. The Nissan manufacturer suggested that this particular make/model does in fact experience this type of problem.”

   NHTSA complaint #10075451, filed 2004-07, 164 miles
2. 2
   Fuel system

   Rusted fuel tank leaking vapors

   • 8 complaints (12%)
   • median 70,000 mi at 5.0 yrs old (7 state mileage, few)
   • filed 2008–2020

   Owners describe a strong fuel smell inside and around the truck, a check engine light, and inspection or diagnostic results pointing to rust on the top of the fuel tank or at the tank/hose connection causing an evaporation leak. Several report long waits because replacement tanks were on back order, and the repair was not covered since the trucks were out of warranty. Related complaints cover a failed fuel sending unit showing empty on a full tank and a fuel gauge that reads incorrectly. Mostly reported between roughly 32,000 and 90,000 miles on trucks several years old, in some cases with visible rust underneath.

   What to check: Inspect the top and seams of the fuel tank for rust from underneath, and ask whether the tank or sending unit has been replaced; a fuel smell when parked is a reason to look closer.

   2 excerpts from owner complaints in NHTSA records

   “The check engine light turned on in may vehicle. I had it checked and it turns out the gas tank/ hose connection to the tank is rusted causing a fume leak. This leak can be smelled inside the vehicle and is very strong outside the vehicle and is a potential fire hazard. This occurred in august 2006. I had to order a replacement tank which is on backorder until sometime in september.”

   NHTSA complaint #10239435, filed 2008-08, 70,000 miles

   “This truck has been worked on multiple times for rust, corrosion, gas tank leaks, bearings and rear differential. It continues to rust and corrode. The motor runs well but the vehicle has rusted even with excellent care. I am so disappointed. The gas tank has been fixed multiple times and continues to corrode and leak. I think that all of these issues need to be checked on. The rear differential has corroded and all of these issues are very expensive every time that it has to be fixed. I would appreciate your help with these problems.”

   NHTSA complaint #11320150, filed 2020-04, 90,000 miles
3. 3
   Steering

   Stiff or wandering steering (steering box / column)

   • 5 complaints (8%)
   • median 57,000 mi at 8.6 yrs old (4 state mileage, few)
   • filed 2010–2023

   Complaints describe the steering wheel becoming very stiff at highway speed or taking two hands to turn, with mechanics pointing to the power steering box. Other owners report the wheel jerking violently and the truck wandering out of its lane, traced to fractured front wheel bearings and related parts, or front-end parts that were incorrect for the truck. Several describe learning about a steering column recall only after buying the truck, and difficulty getting the repair scheduled. Reported from about 46,000 to 105,000 miles; several complaints explicitly reference the steering column recall.

   Recall 10V5540003 related service bulletins

   What to check: Confirm with a dealer whether recall 10V554000 (lower steering column joint) was performed for the VIN, and test the steering at low and highway speed for stiffness, play or wandering.

   2 excerpts from owner complaints in NHTSA records

   “This vehicle has a steering column recall that I was not notified about until I purchased it in 2012. I contacted Nissan to schedule the repair but they informed me that I would have to take the vehicle 250 miles to the nearest dealership. I explained that would not be able to do that since I live on an island in a remote part of alaska. I asked if a local certified mechanic would be able to make the repairs and they told me no, it only can be done by a certified Nissan dealership. …”

   NHTSA complaint #10551397, filed 2013-11, 105,000 miles

   “Powering steering box failure on a 2004 Nissan Frontier. My vehicle has only 49,000 miles on it and was purchased new. Two mechanics, one Nissan and one an independent mechanic, identified the steering box as the culprit for the difficult steering in the vehicle. Both said it should not fail. The Nissan mechanic went on to say that he had only seen one fail in his ten years as a mechanic, and that involved a vehicle that was in a severe accident. The failure prevents me from steering and at times takes two hands to steer. …”

   NHTSA complaint #10302372, filed 2010-01, 49,000 miles
4. 4
   Air bags

   Airbags not deploying in collisions

   • 6 complaints (9%)
   • median 115,000 mi at 10.2 yrs old (4 state mileage, few)
   • 5 mention a crash, fire or injury
   • filed 2009–2018

   Several owners describe front-end or side impacts, some with the truck declared a total loss, where the airbags did not deploy; in one case the passenger bag deployed but the driver bag did not. Another complaint covers an airbag warning light that blinks constantly with the ignition on and while driving. These are reported as observations after a crash, and the trucks were generally not diagnosed for the cause. Reported at mileages from roughly 85,000 to 120,000 miles, after collisions in mixed conditions.

   3 related service bulletins

   What to check: Watch the airbag warning light through the ignition self-test on a test drive, and ask whether any airbag or seat-related repairs or SRS work have been done.

   2 excerpts from owner complaints in NHTSA records

   “I have a 2004 Nissan Frontier crew cab, long bed (6') and the air bags (both driver & passenger) did not deploy. The entire front end of the truck suffered damage. The damage is significant enough that the hood folded upwards. My daughter hit an impala without side impact air bags on the driver's side door hard enough to snap the impala's front axle. This severe of an accident should have caused the air bags to deploy but, they didn't. …”

   NHTSA complaint #10392568, filed 2011-03, 84,650 miles

   “I have a 2004 Nissan Frontier 4x2, crew cab xe 4 door long. My truck was in an accident and it is considered a total loss. The truck was hit on the left side and the air bag did not deploy. The only air bag that deployed was the passengers side.”

   NHTSA complaint #10265371, filed 2009-04
5. 5
   Body and structure

   Corrosion of frame, oil pan and underbody

   • 12 complaints (18%)
   • median 79,875 mi at 5.3 yrs old (10 state mileage)
   • 1 mention a crash, fire or injury
   • filed 2004–2020

   Owners report rust and corrosion on the frame, particularly in heat-affected zones, and rust-through on the engine oil pan that left oil stains where the truck was parked. Some describe repeated corrosion-related repairs to the fuel tank and rear differential and say the truck keeps rusting despite careful maintenance. A related complaint notes the truck was sold without a rear bumper, which the owner questioned. Typically reported on trucks past 90,000 miles, often over a decade old, in some cases tied to long-term exposure to road salt or coastal conditions.

   2 related service bulletins

   What to check: Get underneath and check the frame rails, oil pan, fuel tank straps and rear axle for flaking or perforation, and ask where the truck has been kept and driven.

   2 excerpts from owner complaints in NHTSA records

   “For the second time in less then three years my rear axel and wheel have come loose and very close to falling off. Both times the mechanics told me it was because of a broken washer. After doing some research I have found that other Frontier owners have had similar axel problems. Mechanics have told me that they are aware of Frontier rear axel problems. This is a major safety concern for myself and for other Frontier owners. This problem could cause serious and dangerous accidents that could injure or kill people. …”

   NHTSA complaint #10473248, filed 2012-09, 164,387 miles

   “I noticed small oil stains under the Nissan while parked in my driveway, at work, and anywhere I would stop. Upon further investigation, I noticed the oil pan is rusting through. I have done research and noticed I am not the only person experiencing this problem. This could be a major problem if the motor would lock up at a high rate of speed due to lack of lubrication. Got a quote of $1500 to replace the oil pan. Seems kind of steep considering I am not the one who put the, in my opinion, sub par oil pan on these vehicles. …”

   NHTSA complaint #10616626, filed 2014-07, 123,000 miles

Buying note. This model year is old enough that condition matters more than reputation, so have an independent mechanic inspect the frame, fuel tank and oil pan for rust, and verify whether the steering column recall was completed. Check the transmission warm and under load, and confirm the airbag warning light behaves normally.

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.