FORD EXPEDITION · model year

2004 FORD EXPEDITION

379 NHTSA complaints, 57 crash reports, and 4 active recalls for this specific cohort.

NHTSA overall rating

Not crash-tested

New Car Assessment Program

The 2004FORDEXPEDITION carries 379 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 57 crashes, 16 fires, 70 injuries, and 1 fatality. No NCAP 5-star crash-test rating is available for this model year in the federal database.

Component-level analysis is where model-year complaints become actionable: the top complaint category for the 2004 EXPEDITION is air bags with 31 filings, followed by electrical system (30) and engine (28). Concentration in one or two component groups is the classic signature of a systemic defect; a flat distribution usually reflects normal aging, warranty complaints, or isolated build-plant variability. This model year has 4 active recall campaigns, which means the manufacturer is obligated to remedy the covered defect at no charge for the life of the vehicle, the full NHTSA campaign numbers are listed below.

NHTSA currently has 4 investigation files overlapping the 2004 EXPEDITION. Owners comparing this cohort against neighboring years should pair the counters above with the complaint-by-year trend on the parent model page, a spike in a single year often tracks to a platform refresh, a new transmission supplier, or an updated ECU calibration. Use the related-complaint feed below to read raw owner narratives before deciding whether any pattern here affects your specific use case.

379
Complaints
57
Crashes
16
Fires
70
Injuries
1
Deaths

Total Complaints

379 filings

Crashes Reported

57 reports

Source

NHTSA ODI

Federal complaints database

Complaints vs. fleet median (215)

Above median complaint volume, review patterns below.

Complaints by Component

ComponentCount
AIR BAGS31
ELECTRICAL SYSTEM30
ENGINE28
FUEL/PROPULSION SYSTEM19
TIRES17
VEHICLE SPEED CONTROL16
SERVICE BRAKES, HYDRAULIC15
STRUCTURE:BODY14
ENGINE AND ENGINE COOLING13
UNKNOWN OR OTHER11
AIR BAGS:FRONTAL10
ENGINE AND ENGINE COOLING:ENGINE9
POWER TRAIN9
POWER TRAIN:AUTOMATIC TRANSMISSION7
AIR BAGS:SIDE/WINDOW7

Recalls (4)

06E02600023/03/2006

EXTERIOR LIGHTING

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 D

06E06400017/07/2006

EXTERIOR LIGHTING

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

06E02300013/03/2006

EXTERIOR LIGHTING:HEADLIGHTS

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 EQUIPME

09E01200007/04/2009

EXTERIOR LIGHTING

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

Recent Complaints

20250306ELECTRICAL SYSTEM

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.

20250306EXTERIOR LIGHTING

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.

20250306TIRES:PRESSURE MONITORING AND REGULATING SYSTEMS

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.

20230114EXTERIOR LIGHTING

Just bought this truck I have no idea what has or has not been resolved, very poor lighting I noticed and there's a click noise coming from? It just clicks and clicks and clicks. Thanks

20221121STEERING

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.

Mileage: 110,665

20221121STRUCTURE:FRAME AND MEMBERS

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.

Mileage: 110,665

20221121POWER TRAIN

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.

Mileage: 110,665

20221011ENGINE

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.

Mileage: 127,708

20220520ENGINE

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.

Mileage: 87,000

20220125FireELECTRICAL SYSTEM

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.

20210818POWER TRAIN

Unknown, transmition left me stranded on busy highway. Managed to get it moved off the road before being hit. After getting it home and not driving for a period of time it can be started and moved with no issue. Drive to town no problem parked it to take care of some business and when I went to leave I couldn't back out of the parking place. Got it home and let it sit again. Needed to move it out of the way all was good started it and moved it across the yard and backed it in no problem. Had K&O auto look at it and was told it needs a transmission. I see allot of complaints about this issue from others without Ford being held responsible to correct the problem. Nice vehical said I can't afford to get it fixed, now driving a 500.00 used vehicle to get around, it is an eye sore but gets me around ok. Would rather enjoy the expidition if Ford would fix the issue that 1000's have had.

20210719ENGINE

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.

Mileage: 216,000

20201202ELECTRICAL SYSTEM

VEHICLE LOST POWER FOR 3-5 SECONDS AT HIGHWAY SPEEDS APPROXIMATELY 65 MPH ON THREE SEPARATE EVENTS. VEHICLE SLOWED DOWN DUE TO POWER LOSS WHILE IN HEAVY TRAFFIC. THREE OTHER TIMES AT IDLE SPEED IN DRIVE AND IN PARK ENGINE STALLED AND IMMEDIATELY RESTARTED. LOSS OF POWER STEERING DUE TO ENGINE NOT RUNNING WHEN STALL EVENT HAPPENED. I PERFORMED INSPECTION OF FUEL PUMP RELAY WHICH IS INTERNAL TO PASSENGER SIDE FUSE BLOCK. FOUND INADEQUATE SOLDER JOINT ON INTEGRATED RELAY PRINTED CIRCUIT AND BURN MARKS ON OUTSIDE OF FUEL PUMP RELAY. LOCATED SALVAGE FUSE BLOCK SAME MAKE AND MODEL AND INSPECTED. SAME DAMAGE ON SALVAGE FUSE BLOCK ASSEMBLY. REPLACED WITH AFTERMARKET FUSE BLOCK WITH REVISED SOLDER JOINT AND UPDATED RELAY.

Mileage: 158,612

20201202ENGINE

VEHICLE LOST POWER FOR 3-5 SECONDS AT HIGHWAY SPEEDS APPROXIMATELY 65 MPH ON THREE SEPARATE EVENTS. VEHICLE SLOWED DOWN DUE TO POWER LOSS WHILE IN HEAVY TRAFFIC. THREE OTHER TIMES AT IDLE SPEED IN DRIVE AND IN PARK ENGINE STALLED AND IMMEDIATELY RESTARTED. LOSS OF POWER STEERING DUE TO ENGINE NOT RUNNING WHEN STALL EVENT HAPPENED. I PERFORMED INSPECTION OF FUEL PUMP RELAY WHICH IS INTERNAL TO PASSENGER SIDE FUSE BLOCK. FOUND INADEQUATE SOLDER JOINT ON INTEGRATED RELAY PRINTED CIRCUIT AND BURN MARKS ON OUTSIDE OF FUEL PUMP RELAY. LOCATED SALVAGE FUSE BLOCK SAME MAKE AND MODEL AND INSPECTED. SAME DAMAGE ON SALVAGE FUSE BLOCK ASSEMBLY. REPLACED WITH AFTERMARKET FUSE BLOCK WITH REVISED SOLDER JOINT AND UPDATED RELAY.

Mileage: 158,612

20201202FUEL/PROPULSION SYSTEM

VEHICLE LOST POWER FOR 3-5 SECONDS AT HIGHWAY SPEEDS APPROXIMATELY 65 MPH ON THREE SEPARATE EVENTS. VEHICLE SLOWED DOWN DUE TO POWER LOSS WHILE IN HEAVY TRAFFIC. THREE OTHER TIMES AT IDLE SPEED IN DRIVE AND IN PARK ENGINE STALLED AND IMMEDIATELY RESTARTED. LOSS OF POWER STEERING DUE TO ENGINE NOT RUNNING WHEN STALL EVENT HAPPENED. I PERFORMED INSPECTION OF FUEL PUMP RELAY WHICH IS INTERNAL TO PASSENGER SIDE FUSE BLOCK. FOUND INADEQUATE SOLDER JOINT ON INTEGRATED RELAY PRINTED CIRCUIT AND BURN MARKS ON OUTSIDE OF FUEL PUMP RELAY. LOCATED SALVAGE FUSE BLOCK SAME MAKE AND MODEL AND INSPECTED. SAME DAMAGE ON SALVAGE FUSE BLOCK ASSEMBLY. REPLACED WITH AFTERMARKET FUSE BLOCK WITH REVISED SOLDER JOINT AND UPDATED RELAY.

Mileage: 158,612

20200805STRUCTURE:BODY

THE FRAME IS RUSTING. SEE PHOTOS. THE BODY IS RUSTING AWAY ALSO THE BRAKE LINES. THE ENTIRE VEHICLE IS RUSTING AWAY. WHY HAS THIS 2004 FORD NOT INCLUDED IN A RECALL FOR RUST.

Mileage: 85,000

20200622FireENGINE

TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. THE CONTACT STATED WHILE VEHICLE WAS IN A STAND STILL THE VEHICLE WAS LEAKING OIL ON THE MUFFLER SYSTEM AND STARTER. THE CONTACT ALSO STATED WHILE DRIVING 25 MPH, A BURNING ODOR WAS DETECTED COMING FROM THE MUFFLER AREA. THE CONTACT STATED THE CHECK ENGINE WARNING LIGHT WAS ILLUMINATED. THE CONTACT STATED A LOCAL DEALER WAS CONTACTED HOWEVER THE FAILURE HAD NOT BEEN DIAGNOSED OR REPAIRED. THE CONTACT STATED THAT HEAD GASKET WOULD NEED TO BE REPLACED. THE CONTACT STATED THAT THE FAILURE OCCURRED AT 75,000 MILES AND HE REPLACED THE HEAD GASKET. THE MANUFACTURER HAD BEEN INFORMED OF THE FAILURE AND REFERRED THE CONTACT TO NHTSA. THE FAILURE MILEAGE WAS APPROXIMATELY 210,000.

20200609POWER TRAIN

CHATTER WHEN WHEEL TURNED AT LOW SPEED. LOW SPEED TURNING , SHAKING AND VIBRATION. *TR

Mileage: 115,000

20200609ELECTRICAL SYSTEM

THE GAS GAUGE NEVER WORKS AND SOMETIMES THE VEHICLE THINKS THAT IT DOESNT HAVE GAS WHEN IT DOES. *TR

20200609FUEL/PROPULSION SYSTEM

THE GAS GAUGE NEVER WORKS AND SOMETIMES THE VEHICLE THINKS THAT IT DOESNT HAVE GAS WHEN IT DOES. *TR

Compare 2004FORDEXPEDITION to Similar Vehicles

NHTSA Investigations

Frequently Asked Questions

How many complaints does the 2004 FORD EXPEDITION have?
The 2004 FORD EXPEDITION has 379 NHTSA complaints, 57 crashes, 16 fires, 70 injuries, and 1 deaths reported.
Are there any recalls for the 2004 FORD EXPEDITION?
Yes, the 2004 FORD EXPEDITION has 4 recall(s). The most common affected component is EXTERIOR LIGHTING. Recalls are issued by NHTSA and manufacturers must provide a free remedy.
What are the most common problems with the 2004 FORD EXPEDITION?
The most-complained component for the 2004 FORD EXPEDITION is AIR BAGS with 31 complaints. Other frequently reported areas include ELECTRICAL SYSTEM and ENGINE.
Is the 2004 FORD EXPEDITION safe to buy?
Review the complaint history, crash and fire reports, safety ratings, and recall status on this page to make an informed decision. No NHTSA crash test rating is available for this model year. Compare with other model years using the links above.
Where does this data come from?
All complaint, recall, and safety rating data is sourced from the National Highway Traffic Safety Administration (NHTSA). Complaints are filed by vehicle owners through NHTSA's Office of Defects Investigation.

Vehicle Safety Guides

Data as of 2025. Sources: NHTSA Office of Defects Investigation (ODI) complaints database, NHTSA recall campaign API, NHTSA NCAP crash-test ratings, and NHTSA FARS for fatality cross-reference.