2004 Ford Expedition: problems, recalls and reliability
4 recalls and 296 owner complaints on record; the weakest area is air bags (13% of complaints).
Data updated weekly · latest recall Apr 2009
All counts are reports filed with NHTSA in the United States - US market only, not worldwide totals.
Common problems
Computed from 296 owner complaints filed with NHTSA for this exact model year.
“The contact owns a 2004 Ford Expedition. The contact stated that the turn signals, the hazard lights, and the cigarette lighter had become inoperable. The TPMS warning light was illuminated. The dealer and the manufacturer were not notified of the failure. The vehicle was not diagnosed or repaired. The failure mileage was unknown.”Owner report · Electrical System · Feb 2025
“The contact owns a 2004 Ford Expedition. The contact stated while driving approximately 10 MPH, the vehicle lunged forward while depressing the accelerator pedal. The contact was unable to drive above 15 MPH because the vehicle became difficult to control. The contact stated that the check engine warning light was illuminated. The contact had taken the vehicle to an independent mechanic who diagnosed and determined that the rear axle was fractured, the rear subframe was severely corroded, and the rear driver's side sway bar and rear differential were corroded. The vehicle had not been repaired. The manufacturer had not been informed of the failure. The failure mileage was 110,665.”Owner report · Structure · Nov 2022
“The contact owns a 2004 Ford Expedition. The contact stated while driving at 40 MPH, the vehicle shut down completely, and the warning messages indicated check gage and check service engine. The contact was able to pull over on the side of the road. The dealer was not contacted. The manufacturer was not made aware of the failure. The failure mileage was 127,708.”Owner report · Engine · Oct 2022
Show 7 more owner reports
“The contact owns a 2004 Ford Expedition. The contact stated that while her daughter was driving at an undisclosed speed, the vehicle was jerking. The contact stated that one spark plug exploded and then another spark plug exploded and went through the cylinder head. The contact called the local dealer but the vehicle was not diagnosed or repaired. The vehicle was taken to an independent mechanic where the spark plug was replaced. The manufacturer was notified and referred the contact to the NHTSA for assistance. The failure mileage was approximately 87,000.”Owner report · Engine · May 2022
“Electrical fire today. Vehicle was parked outside garage. A clicking noise was heard and noticed the mirror was trying to move/click and car was filled with smoke. Mirror switches didn't work when tried. Knocked mirror off and fire stopped. Wiring Harness around the emergency brake area melted. Fire melted a hole in the dash corner by windshield. Vehicle was last driven about 25 hrs. earlier with no issues. Approx. 128K miles. Glad it wasn't in garage and the clicking was heard or garage/house would have burned. We haven't done anything to it yet.”Owner report · Electrical System · Jan 2022
“The contact owns a 2004 Ford Expedition. The contact stated while driving at various speeds, the vehicle lost motive power without warning and the steering wheel became difficult to steer on several occasions. The vehicle was taken to an independent mechanic, but the failure could not be replicated. The throttle was replaced however, the failure recurred. The manufacturer was not made aware of the failure. The failure mileage was 216,000. The Vin was not available.”Owner report · Engine · Jul 2021
“Tl* the contact owns a 2004 ford expedition. While driving various speeds, the vehicle suddenly stalled and shut off. Later, after restarting the engine, the vehicle operated normally. The vehicle was taken to an independent mechanic who diagnosed that the fuel pump relay circuit board had malfunctioned and burnt out. The circuit board was replaced and the failure was remedied. An unknown local dealer was contacted. The manufacturer was not contacted. The failure mileage was 180,000.”Owner report · Fuel/Propulsion System · Sep 2019
“My dash vents are not sending any a/c out the front vents, and I also feel heat from the floor board of my car along with exhaust emissions. I know that the san diego police had the same problem with their expeditions and they were recalled and repaired,now they changed to ford explorers . Is there anything still on the books for the expeditions? The vehicle can be in any function,it is just not working, and also I hear a tumpping noise in my right rear panel. I am unable to send any pictures because everything is covered.”Owner report · Unknown Or Other · Jun 2019
“Tl* the contact owns a 2004 ford expedition. While driving 60 mph, the vehicle stalled without warning. The contact was able to restart the vehicle after waiting several minutes. The vehicle was taken to cowles parkway ford (located at 13779 noblewood plaza, woodbridge, va 22193, (703) 986-5500) where it was diagnosed that the fuel pump needed to be replaced. The vehicle was repaired, but the failure recurred a day later. After further research, the contact became aware that the fuel pump relay needed to be replaced. The vehicle was not repaired. The manufacturer was contacted. The approximate failure mileage was 188,000.”Owner report · Fuel/Propulsion System · Nov 2018
“Rusted out rocker panels, brake lines, front end radiator mounts, fender mounts. The entire under carriage is rusting away. We have had to replace all the brake lines as they have rusted away, redid the rocker panels rust away. Now we have to replace the entire front end because of rust. Will not pass pa state inspection due to rust. Is the expedition in the recall for rust?”Owner report · Structure · Aug 2018
When filing, owners marked a crash in 48 of these complaints and injuries in 58 - self-reported to NHTSA, not verified accident statistics.
Recalls - 4 campaigns
CERTAIN ANZO COMBINATION HEADLAMP ASSEMBLIES SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES. SOME COMBINATION LAMPS ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS WHICH FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT."
Remedy: ANZO WILL NOTIFY OWNERS AND REPLACE THE HEADLAMPS FREE OF CHARGE. THE RECALL BEGAN MAY 9, 2006. OWNERS MAY CONTACT ANZO USA AT 909-468-3688.
CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
Remedy: PRO-A MOTORS WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE LAMPS. THE RECALL BEGAN ON APRIL 3, 2006. OWNERS MAY CONTACT PRO-A MOTORS AT 323-838-2988.
CERTAIN TRADESONIC COMBINATION LAMPS SOLD AS REPLACEMENT LAMPS FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. COMBINATION LAMPS NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
Remedy: TRADESONIC WILL NOTIFY OWNERS AND REPLACE THE LAMPS FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING JULY 2006. OWNERS MAY CONTACT TRADESONIC AT 626-934-8884.
SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
Remedy: SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON MAY 11, 2009. OWNERS MAY CONTACT SABERSPORT AT 1-909-598-7589.
Specifications
Factory options offered for the 2004 model year, decoded from the NHTSA vPIC database. Individual vehicles have one of each.
How other years compare
Check your exact Expedition by VIN
Recalls and equipment differ between individual vehicles. Decode your VIN to see what applies to yours.
Open VIN decoderFrequently asked questions
Is the 2004 Ford Expedition reliable?
NHTSA has 296 owner complaints and 4 recall campaigns on record for the 2004 Ford Expedition. The most complained-about area is air bags (13% of complaints).
At what mileage do 2004 Ford Expedition problems usually appear?
Half of the complaints that mention mileage were filed at 80,000 miles or less.
Does the 2004 Ford Expedition have open recalls?
4 recall campaigns have been issued, the latest concerning exterior lighting:headlights. Check your specific vehicle by VIN - recall repairs are free at franchised dealers.
Source: NHTSA recall campaigns and owner complaints (public domain). Counts reflect reports on file and are not a defect rate.