2004 Ford Explorer recalls & complaints
Source: NHTSA, updated daily. Last checked 2026-10-18. Recalls apply to specific VINs — run your VIN to confirm.
4 safety recalls, most serious first
1. Lights
What's wrong, in plain English: Headlights, tail lights or turn signals may not work, making the car hard to see. CERTAIN CK MOTORSPORTS COMBINATION HEADLIGHTS, CLEAR CORNER, BUMPER, AND SIDE MARKER LIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON THE 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.
What could happen: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
The fix: CK MOTORSPORT WILL NOTIFY OWNERS AND REPLACE THE NONCOMPLIANT LAMPS FREE OF CHARGE. THE RECALL BEGAN ON JULY 1, 2006. OWNERS MAY CONTACT CK MOTORSPORT AT 1-909-610-7211.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 2004 EXPLORER.
- Book a repair at any authorized Ford dealer. Quote NHTSA campaign 06E049000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Manufacturer hotline: 1-909-610-7211.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: EXTERIOR LIGHTING
Summary: CERTAIN CK MOTORSPORTS COMBINATION HEADLIGHTS, CLEAR CORNER, BUMPER, AND SIDE MARKER LIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON THE 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.
Consequence: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
Remedy: CK MOTORSPORT WILL NOTIFY OWNERS AND REPLACE THE NONCOMPLIANT LAMPS FREE OF CHARGE. THE RECALL BEGAN ON JULY 1, 2006. OWNERS MAY CONTACT CK MOTORSPORT AT 1-909-610-7211.
Notes: THIS RECALL ONLY PERTAINS TO AFTERMARKET REPLACEMENT EQUIPMENT AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON VEHICLES MANUFACTURED BY THE VEHICLE MANUFACTURERS. FOR MORE INFORMATION ON THE LAMP MODEL NUMBERS, CLICK ON DOCUMENT SEARCH AND VIEW DOCUMENT TITLED "LAMP MODEL NUMBERS." CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.
2. Visibility (wipers / glass)
What's wrong, in plain English: You may not be able to see the road clearly. CERTAIN CURVED TEMPERED REPLACEMENT GLASS MANUFACTURED BY HANGZHOU SAFETY GLASS LTD AND SUPPLIED TO SAFELITE BY AUTO TEMP INC., IDENTIFIED AS DOT-430, AND SOLD FOR USE ON CERTAIN DOMESTIC AND FOREIGN VEHICLES MAY NOT BREAK INTO SMALL PIECES AS EXPECTED OF TEMPERED GLASS AND FAILS TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 205, "GLAZING MATERIALS."
What could happen: IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT(S) MAY BE SERIOUSLY INJURED BY SHATTERED GLASS.
The fix: SAFELITE WILL NOTIFY ITS RETAIL CUSTOMERS AND REPLACE THE GLASS FREE OF CHARGE. RETAIL CUSTOMERS CAN CONTACT SAFELITE TOLL FREE AT 1-888-843-2906. SAFELITE WILL NOTIFY ITS WHOLESALE CUSTOMERS AND REIMBURSE WHOLESALE CUSTOMERS FOR CURRENT INVENTORY AND AT A SPECIFIED RATE FOR REPLACING THEIR CUSTOMER'S GLASS. WHOLESALE…
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 2004 EXPLORER.
- Book a repair at any authorized Ford dealer. Quote NHTSA campaign 07E104000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Manufacturer hotline: 1-888-843-2906.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: VISIBILITY:GLASS, SIDE/REAR
Summary: CERTAIN CURVED TEMPERED REPLACEMENT GLASS MANUFACTURED BY HANGZHOU SAFETY GLASS LTD AND SUPPLIED TO SAFELITE BY AUTO TEMP INC., IDENTIFIED AS DOT-430, AND SOLD FOR USE ON CERTAIN DOMESTIC AND FOREIGN VEHICLES MAY NOT BREAK INTO SMALL PIECES AS EXPECTED OF TEMPERED GLASS AND FAILS TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 205, "GLAZING MATERIALS."
Consequence: IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT(S) MAY BE SERIOUSLY INJURED BY SHATTERED GLASS.
Remedy: SAFELITE WILL NOTIFY ITS RETAIL CUSTOMERS AND REPLACE THE GLASS FREE OF CHARGE. RETAIL CUSTOMERS CAN CONTACT SAFELITE TOLL FREE AT 1-888-843-2906. SAFELITE WILL NOTIFY ITS WHOLESALE CUSTOMERS AND REIMBURSE WHOLESALE CUSTOMERS FOR CURRENT INVENTORY AND AT A SPECIFIED RATE FOR REPLACING THEIR CUSTOMER'S GLASS. WHOLESALE CUSTOMERS CAN CONTACT SAFELITE'S WHOLESALE DIVISION, SERVICE AUTOGLASS TOLL FREE AT 1-888-246-6298. THE RECALL BEGAN ON JANUARY 15, 2008.
Notes: THIS RECALL ONLY PERTAINS TO CERTAIN CURVED TEMPERED REPLACEMENT GLASS MANUFACTURED BY HANGZHOU SAFETY GLASS, LTD. (DOT-430) AND SUPPLIED TO SAFELITE BY AUTO TEMP INC., AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON THE VEHICLES LISTED ABOVE. CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.
3. Lights
What's wrong, in plain English: Headlights, tail lights or turn signals may not work, making the car hard to see. 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.
What could happen: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
The fix: DOPE, INC. WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON JULY 28, 2009. OWNERS MAY CONTACT DOPE, INC. AT 1-626-272-1798.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 2004 EXPLORER.
- Book a repair at any authorized Ford dealer. Quote NHTSA campaign 09E025000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Manufacturer hotline: 1-626-272-1798.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: EXTERIOR LIGHTING:HEADLIGHTS
Summary: DOPE, INC. IS RECALLING 42,540 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.
Consequence: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Remedy: DOPE, INC. WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON JULY 28, 2009. OWNERS MAY CONTACT DOPE, INC. AT 1-626-272-1798.
Notes: THIS RECALL ONLY PERTAINS TO AFTERMARKET REPLACEMENT EQUIPMENT AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON VEHICLES PRODUCED BY THE VEHICLE MANUFACTURER. IN ORDER TO DETERMINE IF YOUR AFTERMARKET LAMP ASSEMBLY IS AFFECTED BY THIS NONCOMPLIANCE, PLEASE REVIEW THE LIST OF MODEL NUMBERS PROVIDED TO US BY DOPE, INC. THE LIST CAN BE FOUND UNDER "DOCUMENT SEARCH" LOCATED AT THE BOTTOM OF YOUR SCREEN.
OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO <A HREF=HTTP://WWW.SAFERCAR.GOV>HTTP://WWW.SAFERCAR.GOV</A> .
4. Lights
What's wrong, in plain English: Headlights, tail lights or turn signals may not work, making the car hard to see. 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.
What could happen: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
The fix: 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.
What to do
- Check whether your car is affected: enter your 17-digit VIN at nhtsa.gov/recalls. A recall covers specific VINs, not every 2004 EXPLORER.
- Book a repair at any authorized Ford dealer. Quote NHTSA campaign 06E026000.
- The repair is free. By US law, safety recall repairs cost the owner nothing, no matter the car's age or mileage.
- Buying this car used? Ask the seller for proof the recall was completed, or run the VIN yourself before paying.
Official wording from NHTSA
Component: EXTERIOR LIGHTING
Summary: 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.
Consequence: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
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.
Notes: THIS RECALL ONLY PERTAINS TO PRO-A MOTORS AFTERMARKET LAMPS AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON THE LISTED PASSENGER VEHICLES. FOR MORE INFORMATION ON THE LAMP MODEL NUMBERS, CLICK ON DOCUMENT SEARCH AND VIEW DOCUMENT TITLED "LAMP MODEL NUMBERS." CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.
Useful for owners
- OBD2 code reader — see what the car's computer is reporting
- Compact car fire extinguisher
- 2004 Ford Explorer owner's manual
Owner complaints filed with NHTSA
Most complained-about parts: Transmission / drivetrain (477), Body / structure (446), Engine (123), Visibility (wipers / glass) (115), Vehicle Speed Control (84).
Complaints are unverified reports from owners. A pattern (many complaints about the same part) matters more than any single one.
Read recent complaints (8)
06/05/2024 · Airbags
All four side curtain airbags deployed while I was driving my car in a parking lot. There was no collision and no reason whatsoever for the airbags to deploy. The airbags in the dash did not deploy. The airbag hit me in the side of the head and shrapnel from the airbag, hit me in the face and eyes and knocked me sideways toward the passenger seat. I was com…
05/28/2024 · Brakes
on [XXX] brought to local shop on power steering leak. Week before, Paid $50 for inspection. on [XXX] appointment was line and replaced. But tech said get pass brake line was rotted and was bad leak of brake fluid. On [XXX] my wife's Explorer was reinspected and rear driver side brake copper line also reported rotted after paying $539.95 for power steering…
02/09/2024 · Fuel system
I need a new gas tank for my vehicle and Ford stopped making the gas tank for my vehicle. That is a very big safety issue. I called Ford and they were helping to find one from junkyard's I don't want one from a junkyard that I have to repair. I asked for Ford to make a gas tank or pay for them to have mine fixed right at a Ford dealership, no help. That's a…
07/19/2023 · Fuel system · fire
Smoke for a good 5 mins under the hood oil leeking
04/22/2023 · Body / structure
Back windows fell off track and windows fell down, cannot roll them up. AC and Heater broke and won't work at all. Fuel system is too lean. Transmission is going out Timing Chain and tensioners making loud knocking noise. Burning oil.
08/31/2022 · Airbags · crash
The contact's son owned a 2004 Ford Explorer. The contact stated that while her son was driving in the rain at approximately 35 MPH, the vehicle hydroplaned as he rounded a corner. The vehicle slid into a ditch and hit a tree on the passenger side of the vehicle. The air bags did not deploy upon impact. The contact's son and his friend were both transported…
11/12/2021 · Steering
On two incidents this week when steering wheel is cut to maximum left or right in tight parking lot and narrow road while making tight turns at legal speeds the engine (V8 4.6L) stalls. Brought to non-Ford mechanic for inspection(NYS ANNUAL) and passes but mechanic looked for a power steering pressure sending sensor or switch that is to give signal to EMC t…
07/13/2021 · Wheels / tires
on 5/6/21 at Ramp Ford 4869 Nesconset Hwy.,Pt. Jeff.Sts.,NY at 10:00am dealer sevice Mgr. met with NYSDMV Auto Facilities Inspector on a claim against Mavis Discount Tire,556 Route 25A, Mt Sinai,NY case 1Pi-01937 on a right rear wheel. Ramp removed R/R wheel to inspect with state inspector, appears like axle nut on r/r has not been removed r/0361772. On 7/1…