2004 Nissan Xterra Problems

What owners report

Owners of the 2004 Nissan Xterra most often write about steering trouble — heavy or binding steering, fluid leaks, and problems that persisted or appeared after the steering column recall repair. A second recurring theme is a rusted fuel tank or sending-unit flange that leaks fuel or vapor, mostly on higher-mileage trucks. Rear leaf springs breaking and assorted electrical faults (batteries, starters, brake-light wiring) also come up repeatedly, often at moderate mileage.

1. 1
   Steering

   Heavy, binding or leaking power steering

   • 14 complaints (17%)
   • median 83,000 mi at 8.0 yrs old (13 state mileage)
   • filed 2008–2021

   Owners describe the steering becoming stiff or hard to turn, sometimes binding at low speed or failing to return after a turn, and at times losing power assist after power steering fluid drained away. Several say the fluid escaped from a rusted bracket, cooler line or steering gear, and some report the gear box cracked or the steering wheel sat loose after the recall repair on the lower steering column joint was performed. Dealers and shops variously replaced the steering gear, hoses and fluid, and in some cases declined to link later problems to the recall. Mostly reported between roughly 20,000 and 95,000 miles, with a number of cases above 140,000 miles; several owners mention the trouble in wet or cold climates where corrosion is common.

   Recall 10V5540002 related service bulletins

   What to check: Ask whether recall 10V554000 (lower steering column joint) was performed and whether the steering gear, hoses or lines have been replaced since. Turn the wheel lock to lock with the engine running and look for stiff spots, noise or fluid weeping at the front of the vehicle.

   2 excerpts from owner complaints in NHTSA records

   “After repairing steering column problem (recall id# 10v554000) less than one year, the gear box cracked and power steering fluid drained causing power steering lost function. I think gear box cracked problem is related to the steering column problem. I have contacted Nissan dealer and regional office but they denied the relationship of the problem.”

   NHTSA complaint #10491671, filed 2013-01, 83,000 miles

   “I took my vechicle to ace auto and he claim he fixed it gave me a list the second time but not the first time it sat there for a year than I got it out for 2 months back in again its goes real slow back fires now and sterring wheel locked one day now its acting like it dont have power to it.everytime you go sppeed limit the steering locks it shakes and not enough power to go barely go up the hill too.”

   NHTSA complaint #10947220, filed 2017-01, 125,450 miles
2. 2
   Fuel system

   Rusted fuel tank and sending-unit flange leaks

   • 10 complaints (12%)
   • median 140,000 mi at 9.9 yrs old (7 state mileage, few)
   • filed 2010–2019

   Complaints describe a fuel smell inside or around the vehicle and fuel or vapor escaping at fill-ups, traced to rust on top of the tank or around the fuel pump mounting flange. Owners say the area holds water and corrodes, and some report a check-engine light with an evaporative-emissions leak code and being told the tank must be replaced. According to complaints, dealers and the manufacturer often characterized it as wear rather than a warrantable problem. Reported mostly between about 58,000 and 160,000 miles, typically on trucks several years old in areas where road salt and moisture are common.

   What to check: Look at the top of the tank and the flange around the fuel sending unit for rust, and check for a fuel smell after filling the tank. Ask whether the tank has been replaced and whether any evaporative-emissions codes are stored.

   2 excerpts from owner complaints in NHTSA records

   “June 12 2016 at the tri-par in slinger, wi I was filling up the gas tank, when gas began spilling out of the vehicle's wheel well. I immediately stopped it after I noticed it. The station along with the slinger fire department estimated a gallon was spilt. It appears the gas tank neck has rusted out, causing the spill. They deemed the vehicle not safe to drive and recommend we have it towed home, which we did.”

   NHTSA complaint #10874269, filed 2016-06, 131,000 miles

   “I smell gas inside the car, I took it to a shop and they told me the gas tank is all rusted on top, causing the gas to spill out. Speaking with Nissan they said this is part of wear and tear of the vehicle, which I do not agree with.”

   NHTSA complaint #10806577, filed 2015-11, 128,000 miles
3. 3
   Electrical system

   Electrical faults: no-start, battery and brake-light wiring

   • 8 complaints (10%)
   • median 10,000 mi at 2.1 yrs old (7 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2005–2020

   Complaints cover a range of electrical symptoms: the engine quitting and then not cranking, repeated starter replacement, batteries not holding charge, a short that melted a dome light, and brake lights staying on so cruise control would not engage. Some owners report instrument cluster and four-wheel-drive indicator problems that persisted after repeated repairs. Dealers replaced starters, batteries, clusters and control modules with mixed results. Reported across a wide mileage span, from a few hundred miles on nearly new trucks to over 150,000 miles.

   4 related service bulletins

   What to check: Start the truck several times cold and warm, confirm all dash gauges and warning lights work, and check that the brake lights go off with the pedal released. Ask about starter and battery replacement history.

   2 excerpts from owner complaints in NHTSA records

   “When driving my Xterra, it loses power and cuts out on me. This is very dangerous and cuts completely off when I'm accelerating. There is a declaration and then the vehicle won't crank or start leaving me stranded. This is not the first time over years that the Xterra has cut off on me. All dashboard systems stop completely when it happens. I have no control over the car when it happens.”

   NHTSA complaint #11343229, filed 2020-08, 220,715 miles

   “There was a break-in of my car and the dome light was left on. The dome light apparently short-circuited and burned off. The hot light fell on my driver's side seat and burned a hole in the seat. The truck is now totaled by my insurance.”

   NHTSA complaint #10142216, filed 2005-11, 10,000 miles
4. 4
   Suspension

   Rear leaf springs breaking

   • 5 complaints (6%)
   • median 57,000 mi at 4.6 yrs old (5 state mileage, few)
   • filed 2008–2015

   Owners report a rear leaf spring cracking or breaking, sometimes on one side and later the other, with some saying it happened while driving and that the broken spring came close to the fuel tank. Complaints describe the trucks as never taken off-road, and mechanics quoted in the reports called the breakage premature for the mileage. Most cases appear to have been repaired at the owner's expense. Reported from around 40,000 to 170,000 miles, with several cases in the 40,000-70,000 mile range.

   3 related service bulletins

   What to check: Inspect both rear leaf spring packs for cracks, missing leaves or sagging, and listen for clunks from the rear over bumps. A suspension shop can check the packs and the front ball joints at the same time.

   2 excerpts from owner complaints in NHTSA records

   “Rear leaf springs broke on vehicle. Vehicle never driven off road. First one cracked at 57,000 and 2nd one broke at 64,000 miles. Mechanic thought that failure of these was premature and a safety hazard to drive.”

   NHTSA complaint #10222220, filed 2008-03, 57,000 miles

   “The contact owns a 2004 Nissan Xterra. The contact stated that the vehicle was taken to an independent mechanic for routine service when the mechanic diagnosed that the leaf spring was fractured. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 170,319.”

   NHTSA complaint #10676126, filed 2015-01, 170,319 miles
5. 5
   Engine cooling

   Radiator, hose and cooling-system leaks

   • 6 complaints (7%)
   • median 80,000 mi at 11.4 yrs old (5 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2008–2018

   Owners describe losing coolant weekly or daily, overheating in traffic or on the highway, and finding a split hose or a cracked radiator tank. One complaint notes the lower radiator support rusted out so the radiator dropped into the fan. Repairs described are hose and radiator replacement, with overheating recurring in at least one case until further work was done. Reported mostly between about 60,000 and 134,000 miles.

   1 related service bulletin

   What to check: Check coolant level and look for crusty residue at hose ends, the radiator seams and the lower support bar. Let the truck idle until warm to confirm the fan engages and the temperature gauge stays steady.

   2 excerpts from owner complaints in NHTSA records

   “Nissan uses faulty equipment in their vehicles and ashly at their consumer affairs dept actually told me that Nissan only expects their vehicles to last the 3 yrs or 36k miles!! Since I purchased this vehicle I have had the A/C compressor replaces, all heater hosses replaced, oil leaks, coolant leaks, drive belts replaced and the alternator replaced. My car literally broke down in my driveway. I was returning from vacation with my son, my dog and my cat-if my trip would have 15 mins. Longer I would have broke down on the side of the road. …”

   NHTSA complaint #10272677, filed 2009-06, 62,640 miles

   “The lower radiator support bar for my Nissan Xterra has rusted out. This causes the main radiator to sink which has since hit the main fan. Only replacement is to replace the entire radiator brace. As a main structure component of the vehicle this should not be rusting out.”

   NHTSA complaint #10806572, filed 2015-11, 80,000 miles

Buying note. On a 2004 Xterra, budget time to check steering and fuel-tank condition, since those are the areas owners write about most, and confirm whether the steering column recall work was done. A pre-purchase inspection that includes the rear leaf springs, cooling system and electrical grounds is worthwhile on a truck of this age.

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.