2004 Ford Expedition Problems and Recalls (278 Complaints)

The most-reported problem on the 2004 Ford Expedition is Engine (15% of 278 owner reports). There are 4 safety recalls. Check the VIN and inspect Engine — this is the NHTSA file, not a score.

NHTSA Office of Defects Investigation Snapshot 2026-09-07 278 complaints · 4 recalls

What problems show up on the 2004 Ford Expedition?

43 of 278 filings named Engine (15% of the file). That is what owners wrote, not a shop diagnosis of the vehicle in the driveway.

Second is Airbags (37 reports).

There are 4 official safety recalls on this year. They were filed about Lights. Check the VIN at nhtsa.gov — a campaign on this page can still be open on a specific truck.

The 2003 has 578 reports on file; this year has 278. A smaller lifetime total is not a clean bill of health. If you need a fairer comparison, use the equal-time view.

What to check before you buy a 2004 Ford Expedition

A useful visit to this page takes five minutes. YearTell does not score years and cannot see the vehicle in front of you.

  1. Look up the VIN for open recalls at nhtsa.gov. This year has 4 campaigns on file below.
  2. Engine. Have a shop check for oil consumption, coolant leaks, rough idle and unusual engine noise.
  3. Airbags. Confirm the airbag light behaves normally and that open airbag recalls are closed.
  4. Brakes. Have a shop check pads, rotors, fluid and whether the pedal feels firm.
  5. Skim a few owner reports below for Engine. Look for the same symptom repeating.
  6. Take that list to a mechanic. Do not turn the complaint total into a score.

What owners reported

System named most often: Engine 43 complaints · 15.5% of the file
Crashes, fires, injuries and deaths in those filings:
  • Crashes 45
  • Fires 15
  • Injuries 48
  • Deaths 1
All Ford Expedition years →
NHTSA Consumer Complaints Snapshot 2026-09-07 Open source record Read our complete data methodology →

Complaint counts reflect self-selected reports and are not normalised for production sales volume. We publish no reliability scores, superlatives, or vehicle rankings.

Which systems owners named

Share of owner complaints filed against each vehicle system. These shares are not adjusted for how many vehicles were sold.

Which systems owners named Engine (ENGINE) appears in 43 of 278 owner complaints (15.5%) in this vehicle snapshot. Engine (ENGINE): 43 complaints, 15.5% of reports Engine (ENGINE) 7 fire reports 43 · 15.5% Airbags (AIR BAGS): 37 complaints, 13.3% of reports Airbags (AIR BAGS) 25 crash reports 1 fire reports 37 · 13.3% Brakes (SERVICE BRAKES): 37 complaints, 13.3% of reports Brakes (SERVICE BRAKES) 7 crash reports 2 fire reports 37 · 13.3% Electrical (ELECTRICAL SYSTEM): 21 complaints, 7.6% of reports Electrical (ELECTRICAL SYSTEM) 1 crash reports 2 fire reports 21 · 7.6% Transmission / driveline (POWER TRAIN): 21 complaints, 7.6% of reports Transmission / driveline (POWER TRAIN) 1 crash reports 21 · 7.6% Body / frame (STRUCTURE): 20 complaints, 7.2% of reports Body / frame (STRUCTURE) 20 · 7.2% Cruise / speed control (VEHICLE SPEED CONTROL): 20 complaints, 7.2% of reports Cruise / speed control (VEHICLE SPEED CONTROL) 5 crash reports 3 fire reports 20 · 7.2% Fuel system (FUEL SYSTEM): 16 complaints, 5.8% of reports Fuel system (FUEL SYSTEM) 16 · 5.8% Glass / wipers / cameras (VISIBILITY): 13 complaints, 4.7% of reports Glass / wipers / cameras (VISIBILITY) 13 · 4.7% Unclassified NHTSA leftover: 130 complaints, 46.8% of reports Unclassified NHTSA leftover 14 crash reports 4 fire reports 130 · 46.8% 0% 25% 50% 75% 100%

“Unclassified NHTSA leftover” is not a car part. It is a filing bucket and always sits last.

View component data as a table
System / Component Complaints Share of Reports Safety Reports (Crashes / Fires)
Engine (ENGINE) 43 15.5% 0 crashes · 7 fires
Airbags (AIR BAGS) 37 13.3% 25 crashes · 1 fires
Brakes (SERVICE BRAKES) 37 13.3% 7 crashes · 2 fires
Electrical (ELECTRICAL SYSTEM) 21 7.6% 1 crashes · 2 fires
Transmission / driveline (POWER TRAIN) 21 7.6% 1 crashes · 0 fires
Body / frame (STRUCTURE) 20 7.2% 0 crashes · 0 fires
Cruise / speed control (VEHICLE SPEED CONTROL) 20 7.2% 5 crashes · 3 fires
Fuel system (FUEL SYSTEM) 16 5.8% 0 crashes · 0 fires
Glass / wipers / cameras (VISIBILITY) 13 4.7% 0 crashes · 0 fires
Unclassified NHTSA leftover 130 46.8% 14 crashes · 4 fires
NHTSA Consumer Complaints, NHTSA Safety Recalls, and NHTSA Defect Investigations Snapshot 2026-09-07 Open source record

Complaint counts reflect self-selected reports and are not normalised for production sales volume. We publish no reliability scores, superlatives, or vehicle rankings.

When reports and recalls showed up

When owners filed reports, and when recall campaigns showed up.

When reports and recalls showed up Owner reports in this snapshot begin in Jan 2004; the first recall shown was reported in Mar 2006. 2004-Q1: 14 owner reports 14 2004-Q2: 9 owner reports 9 2004-Q3: 10 owner reports 10 2004-Q4: 15 owner reports 15 2005-Q1: 14 owner reports 14 2005-Q2: 7 owner reports 7 2005-Q3: 9 owner reports 9 2005-Q4: 1 owner reports 1 2006-Q1: 2 owner reports 2 2006-Q2: 5 owner reports 5 2006-Q3: 6 owner reports 6 2006-Q4: 5 owner reports 5 2007-Q1: 1 owner reports 1 2007-Q2: 5 owner reports 5 2007-Q3: 2 owner reports 2 2008-Q1: 5 owner reports 5 2008-Q2: 5 owner reports 5 2008-Q4: 1 owner reports 1 2009-Q1: 3 owner reports 3 2009-Q2: 1 owner reports 1 2009-Q3: 1 owner reports 1 2009-Q4: 8 owner reports 8 2010-Q1: 8 owner reports 8 2010-Q2: 6 owner reports 6 2010-Q3: 5 owner reports 5 2010-Q4: 3 owner reports 3 2011-Q1: 3 owner reports 3 2011-Q2: 7 owner reports 7 2011-Q3: 6 owner reports 6 2011-Q4: 4 owner reports 4 2012-Q1: 4 owner reports 4 2012-Q2: 6 owner reports 6 2012-Q3: 1 owner reports 1 2012-Q4: 2 owner reports 2 2013-Q1: 3 owner reports 3 2013-Q2: 2 owner reports 2 2013-Q3: 4 owner reports 4 2013-Q4: 7 owner reports 7 2014-Q1: 1 owner reports 1 2014-Q2: 6 owner reports 6 2014-Q3: 4 owner reports 4 2014-Q4: 3 owner reports 3 2015-Q1: 3 owner reports 3 2015-Q2: 2 owner reports 2 2015-Q3: 4 owner reports 4 2015-Q4: 3 owner reports 3 2016-Q1: 3 owner reports 3 2016-Q2: 1 owner reports 1 2016-Q3: 5 owner reports 5 2016-Q4: 4 owner reports 4 2017-Q1: 1 owner reports 1 2017-Q2: 2 owner reports 2 2017-Q3: 6 owner reports 6 2017-Q4: 4 owner reports 4 2018-Q2: 2 owner reports 2 2018-Q3: 4 owner reports 4 2018-Q4: 1 owner reports 1 2019-Q2: 2 owner reports 2 2019-Q3: 3 owner reports 3 2020-Q2: 3 owner reports 3 2020-Q3: 1 owner reports 1 2020-Q4: 1 owner reports 1 2021-Q3: 2 owner reports 2 2022-Q1: 1 owner reports 1 2022-Q2: 1 owner reports 1 2022-Q4: 2 owner reports 2 2023-Q1: 1 owner reports 1 2025-Q1: 1 owner reports 1 2026-Q1: 1 owner reports 1 Owner reports Jan 2004 Jan 2026 Recall campaign 06E023000 ◆ Recall campaign 06E023000 Recall campaign 06E026000 ◆ Recall campaign 06E026000 Recall campaign 06E064000 ◆ Recall campaign 06E064000 Recall campaign 09E012000 ◆ Recall campaign 09E012000 Investigation DP05005 ● Investigation DP05005 Investigation PE08070 ● Investigation PE08070
View timeline records as a table
Date Record type Count Record identifier
2004-Q1 Owner reports 14
2004-Q2 Owner reports 9
2004-Q3 Owner reports 10
2004-Q4 Owner reports 15
2005-Q1 Owner reports 14
2005-Q2 Owner reports 7
2005-Q3 Owner reports 9
2005-Q4 Owner reports 1
2006-Q1 Owner reports 2
2006-Q2 Owner reports 5
2006-Q3 Owner reports 6
2006-Q4 Owner reports 5
2007-Q1 Owner reports 1
2007-Q2 Owner reports 5
2007-Q3 Owner reports 2
2008-Q1 Owner reports 5
2008-Q2 Owner reports 5
2008-Q4 Owner reports 1
2009-Q1 Owner reports 3
2009-Q2 Owner reports 1
2009-Q3 Owner reports 1
2009-Q4 Owner reports 8
2010-Q1 Owner reports 8
2010-Q2 Owner reports 6
2010-Q3 Owner reports 5
2010-Q4 Owner reports 3
2011-Q1 Owner reports 3
2011-Q2 Owner reports 7
2011-Q3 Owner reports 6
2011-Q4 Owner reports 4
2012-Q1 Owner reports 4
2012-Q2 Owner reports 6
2012-Q3 Owner reports 1
2012-Q4 Owner reports 2
2013-Q1 Owner reports 3
2013-Q2 Owner reports 2
2013-Q3 Owner reports 4
2013-Q4 Owner reports 7
2014-Q1 Owner reports 1
2014-Q2 Owner reports 6
2014-Q3 Owner reports 4
2014-Q4 Owner reports 3
2015-Q1 Owner reports 3
2015-Q2 Owner reports 2
2015-Q3 Owner reports 4
2015-Q4 Owner reports 3
2016-Q1 Owner reports 3
2016-Q2 Owner reports 1
2016-Q3 Owner reports 5
2016-Q4 Owner reports 4
2017-Q1 Owner reports 1
2017-Q2 Owner reports 2
2017-Q3 Owner reports 6
2017-Q4 Owner reports 4
2018-Q2 Owner reports 2
2018-Q3 Owner reports 4
2018-Q4 Owner reports 1
2019-Q2 Owner reports 2
2019-Q3 Owner reports 3
2020-Q2 Owner reports 3
2020-Q3 Owner reports 1
2020-Q4 Owner reports 1
2021-Q3 Owner reports 2
2022-Q1 Owner reports 1
2022-Q2 Owner reports 1
2022-Q4 Owner reports 2
2023-Q1 Owner reports 1
2025-Q1 Owner reports 1
2026-Q1 Owner reports 1
Recall campaign 1 06E023000
Recall campaign 1 06E026000
Recall campaign 1 06E064000
Recall campaign 1 09E012000
Defect investigation 1 DP05005
Defect investigation 1 PE08070
NHTSA Safety Recalls Snapshot 2026-09-06 Open source record

Safety Recalls (4)

Official campaigns. Each one says what could go wrong and what the dealer was told to fix.

In short, these campaigns were filed about Lights.

  1. Recall campaign 06E023000

    Lights

    Report date
    Component:
    Lights (EXTERIOR LIGHTING)
    Consequence:
    WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH.
    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.
    View authoritative NHTSA record →

  2. Recall campaign 06E026000

    Safety recall 06E026000

    Report date
    Component:
    Not available in the source record
    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.
    View authoritative NHTSA record →

  3. Recall campaign 06E064000

    Safety recall 06E064000

    Report date
    Component:
    Not available in the source record
    Consequence:
    LACK OF AMBER SIDE REFLECTORS IN THE LAMPS WILL DECREASE LIGHTING VISIBILITY TO OTHER DRIVERS AND MAY POSSIBLY RESULT IN A VEHICLE CRASH.
    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.
    View authoritative NHTSA record →

  4. Recall campaign 09E012000

    Safety recall 09E012000

    Report date
    Component:
    Not available in the source record
    Consequence:
    DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
    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.
    View authoritative NHTSA record →
NHTSA Consumer Complaints Snapshot 2026-09-07 Open source record

Complaint counts reflect self-selected reports and are not normalised for production sales volume. We publish no reliability scores, superlatives, or vehicle rankings.

What owners actually wrote

Short excerpts from the public NHTSA file. Look for the same symptom repeating.

Data: NHTSA Office of Defects Investigation · snapshot 2026-09-07
Safety incident filters
Showing 9 of 278 complaints · page 1 of 12
2026-03-05Engine (ENGINE)
NHTSA ODI 11722224
CrashFireInjuryDeath
The contact owns a 2004 Ford Expedition. The contact recently purchased the vehicle and stated that while driving at an undisclosed speed, the transmission hesitated before upshifting with the accelerator pedal depressed. Additionally, while stopped at a traffic light, the vehicle rolled backwards when the accelerator pedal was depressed before responding as needed. There was no warning light illuminated. The contact attempted to return the vehicle to the independent dealer where the vehicle was purchased; however, the dealer declined to assist. Recently, the vehicle stalled, and it was towed to an independent mechanic to be diagnosed. The mechanic retrieved fault codes for the engine and stated that the TCM needed to be replaced. The vehicle was not repaired. The manufacturer was not informed of the failure. The failure mileage was unknown.
2025-03-06TIRESUnclassified NHTSA leftover
NHTSA ODI 11646759
CrashFireInjuryDeath
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.
2023-01-14EXTERIOR LIGHTING
NHTSA ODI 11501797
CrashFireInjuryDeath
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
2022-11-21Transmission / driveline (POWER TRAIN)
NHTSA ODI 11494447
CrashFireInjuryDeath
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.
2022-10-11Engine (ENGINE)
NHTSA ODI 11488840
CrashFireInjuryDeath
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.
2022-05-20Engine (ENGINE)
NHTSA ODI 11465508
CrashFireInjuryDeath
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.
2022-01-25Electrical (ELECTRICAL SYSTEM)
NHTSA ODI 11448740
CrashFireInjuryDeath
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.
2021-08-18Transmission / driveline (POWER TRAIN)
NHTSA ODI 11429658
CrashFireInjuryDeath
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.
2021-07-19Engine (ENGINE)
NHTSA ODI 11425528
CrashFireInjuryDeath
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.

Frequently asked questions

What are the most common problems on the 2004 Ford Expedition?

Owners named Engine most often — 43 of 278 reports (15%). That is the NHTSA file, not a diagnosis of every vehicle.

Are there recalls for the 2004 Ford Expedition?

NHTSA lists 4 safety recall campaigns. They were filed about Lights. Check the VIN at nhtsa.gov; a campaign on this page can still be open on a specific vehicle.

What should I inspect before buying a 2004 Ford Expedition?

Look up the VIN for open recalls. Have a shop check for oil consumption, coolant leaks, rough idle and unusual engine noise. Then skim owner filings for the same symptom and take that list to a mechanic.

Does a high complaint count mean I should skip this year?

No. Counts are reports people chose to file and they are not adjusted for sales volume. YearTell does not publish scores or a list of years to skip. Inspect the vehicle.

EPA Fuel Economy Database Snapshot 2026-08-21 Open source record

Estimated Ownership Cost

EPA fuel economy ratings and annual operating cost estimates

Data: US EPA Fuel Economy Guide · snapshot 2026-08-21
Supported range: 1,000–60,000 miles per year
Supported range: $1.50–$10.00 per gallon
55% city45% highway
Estimate unavailable

EPA fuel-economy data is unavailable for this vehicle.

No estimate is shown when required EPA values are unavailable.

 Open Ownership Cost Calculator →

Adjacent Model Years

Immediate preceding and succeeding model year records

NHTSA Consumer Complaints Snapshot 2026-09-07 Open source record

Complaint counts reflect self-selected reports and are not normalised for production sales volume. We publish no reliability scores, superlatives, or vehicle rankings.

Methodology & Data Integrity

Source: NHTSA ODI / recalls, snapshot 2026-09-07. YearTell is not a government agency.

Read our complete data methodology → Sources