2004 Ford Explorer
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Ford › Explorer › 2004
These records cover every 2004 Ford Explorer. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
4 recalls name the 2004 Ford Explorer. Newest first.
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…
Risk and remedy
Risk
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.
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…
Risk and remedy
Risk
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.
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.
Risk and remedy
Risk
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.
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.
Risk and remedy
Risk
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.
Owner complaints
1,304 complaints58 involved a crash15 involved a fire83 injuries
What owners report most
Latest complaints
- Service 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…
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 low pressure and brake line. Wife's Eddie Bauer 2004 v8 was reported to FORD Motor Co. Case# [XXX] defective copper brake lines on suv. No good will offered no warrantee fue to latent defective brake line copper tubing coming from ABS modular. ABS LIGHT COMES ON AT TIMES. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
- Fuel/propulsion 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…
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 big safety problem. Ford provided the contacts phone number to the junkyards but the contact doesn't want the gas tank from a junkyard who probably put holes in them to drain the gasoline out of the tank.
- Fuel/propulsion system
Smoke for a good 5 mins under the hood oil leeking
- Engine · Fuel/propulsion system · Structure › Body
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.
- Air bags
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…
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 to the hospital for their injuries. Her son was treated for soreness in various parts of his body and was released the same day. Her son's friend had to remain in the hospital overnight and his injuries were unknown. A police report was filed. The vehicle was towed from the independent collision center where it remained in their possession. The dealer nor the manufacturer had yet to be notified of the failure. The vehicle had yet to be repaired or destroyed. The failure mileage was approximately 153,000.
- Engine · 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…
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 to increase idle to compensate for more power steer demands. Part is $35 at Partgeek but mechanics dont know where the harness the sending switch is located, if one exists or is it in power steering pump. Call Ford NADA! Call two local Ford dealers. One says dont work on cars 15 years old, other says go to liabary to get diagrams, Ford says obsolete parts in 10 years.Bummer! Husband ordered 8/10/20 New 2021 Bronco. Pushed into 2022 due to supply chain. Found out Bronco built at MAP same as Ranger, will not get stronger 10r80 transmission,but Explorer 10r60, 25% weaker ; and gets Explorer 2.3L EgoBoost non- Ranger improved 4×4 engine , although they say same transmission and improved engine as Ranger in ads. Ford Buit Tought? MY2022! PLEASE INVESTIGATE THIS HIGHWAY TRAFFIC SAFETY ISDUE. NO BRAKING NOR STEERING WHEN SENSON IN POWER STEERING STALLS 4.6L ENGINE. Cannot apply gas and brake to keep from stalling when making sharp turns. I am 75 years old and with COPD. Serpertine belt replace before incidents.
- Wheels
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…
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 7/12/21 Mt. Sina Tire r/0 7828-18 when fixing a tire flat, found r/r one broken stud,one addition lug nut missing from r/r wheel. Immediately Ramo service manager denied his tech improperly reassembled r/r wheel nuts on all five wheel assembly studs. With three studs the Ford vehicle was in inimanent highway danger. Such lost of 40% of wheel nuts may have caused lost of life. Mt. Sinai tire replaced fourth missing nut, fixed flat and scheduled fifth wheel assembly stud. Ramp 's general manager was imformed of poor and dangerios service and stated he was not a mechanic! Reimbursement for 5/6/21 were denied by dealer! Dealers .denies any warantees of labor since customer signed their disclaimer. All repairs are provided by the dealer facility1520504 AS IS WITHOUT ANY WARRANTY OF GUARANTEE! This disclaimer was only signed by non-owner after inspector left dealer. Inspector has pictures and stated he did not see the reassembly of r/r brakes, calebre, wheel nuts after inspection was completed. This was a dangerious omission of not properly torquing nut to Ford Motor spec. FORD MOTOR denies any warantee of repairs by Ramp.
- Tires
Michelin crossterrain tires suffering tread separation. Three out of four so far. Had I not been paying attention to this problem it would have happened on the highway..
- Unknown or other
Tires! Tires! Tires! again! a second tire has suffered tread separation and failed completely. why can't I get anyone to take this problem seriously?
- Engine · Vehicle speed control
Engine dies when driving with cruise control operating and heading down slight hill at speed of around 35 mph. cruise IS designed to maintain driving speed going down the hill (up or down hill for that matter). the tachometer indicates a slowing of engine rpm. at higher speeds, the slowing of…
Engine dies when driving with cruise control operating and heading down slight hill at speed of around 35 mph. cruise IS designed to maintain driving speed going down the hill (up or down hill for that matter). the tachometer indicates a slowing of engine rpm. at higher speeds, the slowing of rpm does not fall too low. however, at the slower speed around 35mph, the rpm drops below 500 rpm and the engine stalls. I lose power steering and breaks. I have a difficult time steering and breaking. this IS a safety problem on a curve or if a red light IS ahead. I can't steer the car on the curve. I may not be able to stop the car at the traffic light and end up in an intersection and be hit by vehicles with a green light. I may hit a car in front of me that has stopped at a light or stop sign. I may not be able to stop for a pedestrian crossing at the intersection (with the light). I may not be able to avoid a child ... Who darts into the roadway. this IS a problem for many owners of the 2004 explorer. there are many complaints about it on the web. it IS a problem that has been noted for years. I complained about it to dealers several times. dealers dismissed it as nothing can be found, replicated or just not a problem. it IS time to recalll the vehicle to fix this safety problem. this IS an ongoing problem. I try to avoid using cruise control control at the 35mph range. it seems ok at highway speeds. the last of many instances was in november 2020. the problem first happened when there about 30,000 miles on the car.
- Tires
While driving home from work last week I noticed a slight 'bumping' feel like an unbalanced tire, so I took a look when I got to my driveway but found nothing. The next day on my way to work the "bumping' was much worse so I stopped to check and found a large bulge on the tread of the right front…
While driving home from work last week I noticed a slight 'bumping' feel like an unbalanced tire, so I took a look when I got to my driveway but found nothing. The next day on my way to work the "bumping' was much worse so I stopped to check and found a large bulge on the tread of the right front tire. After slowly returning home I removed it and set it aside. A few hours later the threads were separating badly so I let the air out before it blew apart. I ordered a replacement tire (different brand) but I've still got three more of these on the vehicle .they have 36K miles on them and a 60K warranty with only modest thread wear but I still check them every day. I don't feel safe.*dt consumer stated he still has a defective tire.*jb
- Air bags
This past weekend I was driving an 04 ford explorer when both side airbags spontaneously deployed. I was not in an accident. I was driving down a two-lane road at less than 35 miles per hour when the airbags deployed. I was able to pull over but not before sustaining an injury to my ear and not…
This past weekend I was driving an 04 ford explorer when both side airbags spontaneously deployed. I was not in an accident. I was driving down a two-lane road at less than 35 miles per hour when the airbags deployed. I was able to pull over but not before sustaining an injury to my ear and not before the passenger sustained an injury to her right arm. I reported this to ford, which advised to carry the vehicle to a dealership. took it to the dealership, where the service manager was unconcerned with the fact that the airbags spontaneously deployed. he looked at the vehicle for two days only to report he was not aware of why the airbags deployed and stated there was nothing he could do about it. I repeat, I was not in an accident and the airbags deployed while driving. this IS of course quite concerning to me but ford does not seem to care. please follow-up on the safety of ford's vehicles.
- Wheels
TL* the contact owns a 2004 ford explorer. The contact stated that the wheel studs detached on multiple tires while driving. The failure recurred three times on multiple wheels on different occasions. The contact stated that the vehicle was taken once to an independent mechanic where the studs were…
TL* the contact owns a 2004 ford explorer. The contact stated that the wheel studs detached on multiple tires while driving. The failure recurred three times on multiple wheels on different occasions. The contact stated that the vehicle was taken once to an independent mechanic where the studs were replaced; however, the failure continued. The contact also stated that she replaced multiple studs herself. The manufacturer and dealer were not made aware of the failure. The failure mileage was approximately 120,000.
- Air bags
The vehicle was moving at a slow rate of speed (approx 5-10 mph) on a bumpy road. The driver was looking for a parking space. The side airbags deployed. The insurance company has determined that there was no collision or reason for the airbags to deploy and therefore they will not cover the damage.
- Power train
My 2004 ford explorer has recently and quickly began shifting very badly. I always come to a complete stop and shift into neutral before shifting into reverse or drive because when shifting into reverse from p or d, it always takes a while, then clunks aggressively into place. While driving…
My 2004 ford explorer has recently and quickly began shifting very badly. I always come to a complete stop and shift into neutral before shifting into reverse or drive because when shifting into reverse from p or d, it always takes a while, then clunks aggressively into place. While driving sometimes downshifting will also clunk into place. This issue has been reported by countless other drivers and has caused many potentially dangerous situations. From accelerating slowly then banging gears and taking off, to stuttering while trying to accelerate, or even switching into reverse while parking, and having the car try to jump back a few inches IS only a few issues this problem has caused myself and countless others. People are replacing transmissions left and right to no avail, only a few 10 thousand miles after installing new transmissions, their car starts to experience the same issues as before. At low speeds and in parking lots this becomes a game of luck as you accelerate more than necessary to try to get going, then stopping and waiting a few seconds while you shift to neutral before shifting to reverse as fear of it banging into gear as you try to maneuver your car around people and other parked cars becomes a more dangerous task than it should be. In sum, while stationary, slow speed, or just cruising, the transmission while shifting gears, or shifting into reverse/drive, sometimes wants to bang into gear or lose power, or delay shifting only to bang into gear moments later. Some issues when taking cars into repair IS finding metal transmission shavings where they shouldnt be! Finally, the excessive banging can also damage the engine over time in addition to the transmission. please reference the following link to get a better idea of the issues: https://www.carcomplaints.com/ford/explorer/2004/transmission/transmission_slipping_shifts_hard.shtml thankyou
- Unknown or other
The ignition keys loses the program and I constantly have to have noth reprogramed. I was told this was a recall that ford knows about. The cause the car inability to start
- Electrical system · Exterior lighting · Structure › Body
Plastice parts are deteriorating, desolving in front inside drive sun visor-lighted visor broke off; centerl rear a/c and heat moon roof light console falls off-plastice clips desolved and will not fasten into roof assembly, causing blocked eyesight and at time on right turn hitting head or eyes .…
Plastice parts are deteriorating, desolving in front inside drive sun visor-lighted visor broke off; centerl rear a/c and heat moon roof light console falls off-plastice clips desolved and will not fasten into roof assembly, causing blocked eyesight and at time on right turn hitting head or eyes . This IS unsafe and ford motor knows of complainst. Part are not availble. This IS a highway safety issue. The model was the eddie bauer top of the line $40,,835 car fmv $5000 only 54000 miles pri level code 450240u74 ship wgt 4357
- Exterior lighting
TL* the contact owns a 2004 ford expedition. The contact stated that the brake lamps, turn signals, and emergency flashers failed to operate properly. This was a distraction to the contact's driving because he could not notify other drivers of the vehicle's movements. The vehicle was driven to an…
TL* the contact owns a 2004 ford expedition. The contact stated that the brake lamps, turn signals, and emergency flashers failed to operate properly. This was a distraction to the contact's driving because he could not notify other drivers of the vehicle's movements. The vehicle was driven to an independent mechanic, but they did not have time to diagnose the vehicle. The contact called a ford customer service line, but they did not assist. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was 264,000.
- Power train · Steering · Suspension
My steering column broke right off! Trying to put it in drive @99,735 mi. had to tow it to shop, and replace the steering column. I see other people had this same problem. there should be a recall for this!!! I also had to replace the transmission @ 103,000 miles it would skip 3RD gear. Seems…
My steering column broke right off! Trying to put it in drive @99,735 mi. had to tow it to shop, and replace the steering column. I see other people had this same problem. there should be a recall for this!!! I also had to replace the transmission @ 103,000 miles it would skip 3RD gear. Seems everyone else has to replace the transmission. also back bearings!! what a disgrace. recall this disgraceful workmanship! No honor!
- Unknown or other
I was getting stuff out of my back seat and my rear window just blew out shattering glass all over .the bottom piece that secures the glass to the door warpred about 6 inched on each side exploding the glass
- Structure › Body · Visibility/wiper
I have cracks in the plastic on the outside of my lift gate . Each time I use the handle to lift the cracks become worse. There are several posts online asking about the same problem. Every one I see in a parking lot or on the road has the same problem. Ford reports that it affects 1997-2007…
I have cracks in the plastic on the outside of my lift gate . Each time I use the handle to lift the cracks become worse. There are several posts online asking about the same problem. Every one I see in a parking lot or on the road has the same problem. Ford reports that it affects 1997-2007 explorers. I don't understand why this hasn't been addressed. I called ford and they referred me to your organization. some of these cracks I have seen reach to the back window which I believe would be a safety hazard.
- Air bags
TL* the contact owned a 2004 ford explorer. While the contact's son was driving 40 mph, he lost control of the vehicle and struck a tree, a light post, and an electrical box. The air bags did not deploy. The contact's son was not injured. A police report was filed and the vehicle was towed to a tow…
TL* the contact owned a 2004 ford explorer. While the contact's son was driving 40 mph, he lost control of the vehicle and struck a tree, a light post, and an electrical box. The air bags did not deploy. The contact's son was not injured. A police report was filed and the vehicle was towed to a tow yard. The vehicle was not taken to a dealer to be diagnosed and was deemed a total loss by the tow company. The manufacturer was not notified of the failure. The failure mileage was approximately 291,000.
- Power train
TL* the contact owns a 2004 ford explorer. While driving and attempting to shift gears, the contact's son pulled too hard and fractured the gear shifter. The contact stated that the gear shifter was currently too loose and would not shift into any gear. The dealer and manufacturer were not contacted. The vehicle was not diagnosed or repaired. The failure mileage and vin were unknown.
- Vehicle speed control
TL* the contact owns a 2004 ford explorer. While reversing, the contact's vehicle accelerated on its own and crashed into a chevrolet cobalt. There were no warning indicators illuminated. The air bags did not deploy. There were no injuries. A police report was filed. The vehicle was taken to an…
TL* the contact owns a 2004 ford explorer. While reversing, the contact's vehicle accelerated on its own and crashed into a chevrolet cobalt. There were no warning indicators illuminated. The air bags did not deploy. There were no injuries. A police report was filed. The vehicle was taken to an independent mechanic, but the failure could not be diagnosed. The local dealer and manufacturer were not contacted. The vehicle was not diagnosed or repaired. The failure recurred multiple times, resulting in the contact crashing into a tree and other unknown vehicles. There were no warning indicators illuminated. The air bags did not deploy. There were no injuries. A police report was filed. The vehicle was towed to the contact's residence. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was contacted and did not assist. The failure mileage was 175,000. The vin was unknown. *Tt vin IS not valid *jb
- Seat belts
The drivers seat belt has come unlocked on several occasions. It has happened so many times I tug hard every time I buckle up to make sure it's clicked and it has unlocked while driving even though I double check it.
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Vehicle Rollaway Allegations
This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure…
This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for any particular failure mechanism, the failure of the Automatic Transmission Parking System, was 4.4/100K.The next-highest failure rate was for the BSI System, at 3.4/100K.For all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent years.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.For additional information regarding this investigation, see the complete closing resume in the document file for EA09-013. The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers:10168454, 10279630, 10280078.
- Vehicle rollaway allegations
In response to an information request (ir) letter sent by the office of defects investigation (odi), ford stated consumer reports of higher than expected efforts when shifting into and out of park could be a result of a groove being worn into the swing arm ramp of the steering column. The swing arm IS a component…
In response to an information request (ir) letter sent by the office of defects investigation (odi), ford stated consumer reports of higher than expected efforts when shifting into and out of park could be a result of a groove being worn into the swing arm ramp of the steering column. The swing arm IS a component bolted to the steering column that assists in shifting through the transmission gears.an engineering evaluation conducted by ford of returned steering columns found the groove could be created over time if consumer shift more quickly from the drive or reverse to park than the brake shift interlock (bsi) solenoid pin retracts after the brake pedal IS applied. In november of 2004, ford released a redesigned bsi solenoid with a shorter pin retracting time as a serviceable component. Ford has noted the shorter retraction time significantly lessens the likelihood of bsi solenoid pin to swing arm contact even with rapid consumer shifts.ford also issued a technical service bulletin, tsb 04-22-12, to instruct service technicians on the proper diagnosis and vehicle repair. Reviewing complaints to odi and data submitted by ford, odi has identified 200 alleged incidents of unintended vehicle movement after consumers believe they have shifted the vehicle into park, resulting in 85 alleged crashes and 32 alleged injuries.in addition to the reports of alleged incidents of unintended vehicle movement, odi has also identified 883 reports of consumers alleging difficulty or the inability to shift the vehicle into park.this preliminary evaluation has been upgraded to an engineering analysis (ea09-013) to further assess the scope, frequency and risk to motor vehicle safety of the alleged defect in the subject vehicles.
- Rear liftgate glass hatch failure
This investigation was opened on june 23, 2008, based on 34 complaints involving eight injuries in which the rear liftgate glass hatch on model year 2004 ford explorers or mercury mountaineers broke off and fell, usually while individuals were operating the glass hatch or loading or unloading items from the rear of…
This investigation was opened on june 23, 2008, based on 34 complaints involving eight injuries in which the rear liftgate glass hatch on model year 2004 ford explorers or mercury mountaineers broke off and fell, usually while individuals were operating the glass hatch or loading or unloading items from the rear of the vehicle.ford conducted recall 04v-442 in 2004 to address similar problems on model year 2002 and certain model year 2003 ford explorers and mercury mountaineers.the information ford provided in response to odi's information request letter indicated that failures with 2004 vehicles were primarily liftgate glass hatch hinge failures related to corrosion at the hinge pin, whereas the failures that prompted the recall with the earlier models were primarily related to problems with the glass hatch's struts or fracture of a prior hinge design at the boss/bolt connection at the glass.odi's review of ford's warranty, complaint, and injury data for the 2004 vehicles indicates that these rates are significantly lower than those for the recalled population.a potential defect trend has not been identified at this time.odi will continue to monitor complaints and take appropriate action as necessary.this investigation IS closed.
- Spark plug ejection from cylinder head
On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton V-8 and V-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or…
On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton V-8 and V-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi IS not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi IS aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi?s analysis showed, it IS possible for a spark plug to detach from the engine cylinder threads in the subject vehicles.however, odi?s analysis of 474 complaints describing such incidents found only a very few alleged any safety-related consequences.none of these showed any evidence of a serious safety consequence.given the large population and relatively long exposure time of the subject vehicles, the complaint analysis indicates that the risk to motor vehicle safety from the alleged defect IS very low.in view of the foregoing, it IS unlikely that nhtsa would issue an order for the notification and remedy of the alleged defect at the conclusion of the investigation requested in the petition.therefore, in view of the need to allocate and prioritize nhtsa?s limited resources to best accomplish the agency?s safety mission, the petition IS denied.
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 10156863Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition
- 10155551Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition
- 10109070The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate when reading these PIDs and cannot display quickly enough to validate a concern. The PCM automatically monitors these inputs more accurately and will set diagnostic trouble codes (DTCs) when appropriate. Using these PIDs for diagnostics will lead to inaccurate results and improper ETB replacements. If a concern is intermittent and no DTCs are present, refer to historical DTCs and the PC/ED, Section 3 No DTCs Present Index chart for further information.
- 10048099Ford/lincoln/mercury: may have sludge buildup in throttle body leading to less airflow or engine idling rpm fluctuation and hard starts or battery disconnect or dead battery after keep alive memory (kam) clear. Models 2003-05 thunderbird, 05-06 mustang, 06-08 fusion, 04-05 explorer, 05-06 expedition, 05-07 F-150; 2003-06 LS, 06 zephyr, 05-06 navigator; 06-08 milan.
- 10045340Ford/lincoln/mercury: if battery was disconnected or dead, vehicles/trucks may experience hard starts and engine idle rpm fluctuation and exhibit diagnostic trouble codes (dtcs) p0505, p0506, p2111 and p2112.
- 10028736Ford: some vehicles may exhibit oil separation from the internal lube found in the unitized cartridge seal. Oil separation appears to be and IS often misdiagnosed, as an axle lube leak.
- 10023943Some 1997-2008 vehicles equipped with a 4.6L 2V, 5.4L 2V, or 6.8L 2V engine--spark plug thread repair procedure--not covered under new vehicle limited warranty. This includes F-53 motorhome chassis. Updated 2/23/10.
- 10021052Mil on with dtc p0463 or erratic fuel gauge operation.
- 10021038Mil on with p0463 or erratic fuel gauge operation.
- 10019947Neutral tow capability - service kit requirements.
- 10019384Low tire indicator on - TPMS system sensor wake up.
- 10019379Malfunction indicator lamp on with pcm diagnostic trouble code p0463 and/or ic diagnostic trouble code b1201 - fuel gauge drops to empty or slow to update after refueling.
- 10018938Vibration diagnosis - tire/wheel runout.
- 10018937Mil on with dtc p0191 with or without various drivability symptoms and/or additional dtcs.
- 10018934Neutral tow capability -- service kit requirements.
- 10018745Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running.
- 10018064Noise from rear wheel hub bearings.
- 10017931No start/hard start on cold soak - 4.0L engine.
- 10017905Wrench lamp on and no diagnostic trouble code (dtc) stored.
- 10017898Delayed or harsh reverse engagements - 5r55s transmission - vehicles built prior to 09/23/2004.
- 10017892Rear axle noise repair.
- 10017882No start/hard start on cold soak.
- 10017860Malfunction indicator lamp coming on with diagnostic trouble codes (dtcs) p0171, p0172, p0174 and/or p0175 (fuel system too rich or lean).
- 10016832Backglass difficult to close and an intermittent door ajar lamp.
- 10016789Rear axle noise repair.
- 10014668Axle seal leaks.
- 10014664Front seat(s) slight movement when accelerating and/or decelerating.
- 10014659Axle whine howl. This includes 1997-05 ford vehicles.
- 10014277Increased effort during low speed sharp turns on 4X4 vehicles.
- 10014165Aluminum corrosion - service tip.
- 10014138Safety belt retraction speed.
- 10014100Limited slip axle chatter, shudder, binding sensation, or vibration during low speed turning maneuvers.
- 10014086General (pcm) power train control module programming procedures.
- 10014062Rear window defroster grid/integral antenna diagnosis and repair - terminal tab repair.
- 10013399Throttle pedal response on tip in vehicles built before 10/4/2004 equipped with a 4.0L engine.
- 10013398Gear selector lever - increased effort to shift from drive to park.
- 10013388Fuel gauge slow to update after refueling.
- 10013383Rough idle in drive.
- 10013371Malfunction indicator lamp (mil) and electronic throttle control (etc) lamps on with both diagnostic trouble code (dtc) p2106 and p2135.
- 10013319Open fuse F2.20 (5 amp) and/or F2.1 (30 amp) which may result in loss of function of several systems including power seats, adjustable pedals and power door locks.
Every Ford Explorer model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.