2004 Ford Explorer Structure
Owner-reported problems and safety issues filed with NHTSA. Review common failures, severity levels, and complaint trends over time.
Complaint Timeline
Chronological view of owner reports
REAR PANEL VERTICAL CRACK BELOW WINDOW. *TR
CLOSING THE GLASS LIFTGATE ON A 2004 FORD EXPLORER, THE HINGE PIN PULLED THROUGH THE HINGE STRUCTURE CAUSING THE GLASS TO DROP. WHILE ATTEMPTING TO CATCH THE GLASS HAND WAS PINNED, BUT NO INJURY WAS SUFFERED. *TR
WENT TO OPEN REAR DOOR AND NOTICED A CRACK RUNNING DOWN THE BACK PANEL BELOW THE REAR WINDOW. MY FORD EXPLORER IS A 2004 WITH LESS THAN 60,000 MILES THIS SHOULD NOT OF HAPPENED THIS IS A DEFECT THAT FORD SHOULD TAKE CARE OF. INSTEAD I WAS TOLD TO CALL MY INSURANCE COMPANY ARE YOU KIDDING THIS IS FORDS PROBLEM NOT MINE. IT COULD FALL OFF WHILE I'M DRIVING AND HURT SOMEONE WHAT IS GOING ON IN AMERICA. *TR
2004 FORD EXPLORER HAS A CRACKED REAR PANEL SPLITTING THE ENTIRE BACK PANEL. I CONTACTED FORD AND THEY WILL NOT DO ANYTHING ABOUT IT. I THINK IT COULD BE A SAFETY CONCERN AS THE WHOLE PANEL COULD BREAK OFF BY THE REAR WINDOW. I'VE RESEARCHED THIS ON LINE AND THIS APPEARS TO BE A COMMON ISSUE WITH MY YEAR EXPLORER. FORD SHOULD TAKE RESPONSIBILITY FOR THEIR FAULTY PRODUCT.
CRACK SUDDENLY APPEARED IN THE REAR PANEL BELOW THE WINDOW. FROM THE GLASS TO THE BOTTOM OF THE HATCH. HAD WINDOW TIGHTENED. *TR
I AWOKE ONE MORNING AND I FOUND A LARGE CRACK IN THE REAR HATCH OF MY 04 FORD EXPLORER. IT WAS NOT LIKE THAT THE PREVIOUS EVENING WHEN I GOT HOME. I RESEARCHED THE PROBLEM ONLINE AND FOUND MANY SIMILAR STORIES. I ALSO FOUND THAT THERE IS CURRENTLY NO MANUFACTURER RECALL TO REMEDY THE SITUATION. PLASTIC REAR HATCH CRACKED UNDER EXTREME TEMPERATURE. REAR GLASS MAY BREAK WHILE DRIVING AND POSE HAZARD TO OTHER DRIVERS. PLAN ON REPLACING, HOWEVER I DON'T BELIEVE I SHOULD PAY FOR IT BECAUSE OF THE POOR QUALITY OF THE ORIGINAL PART. *TR
2004 FORD EXPLORER RIGHT REAR LIFTGATE HINGE PIN HAS CORROSION CAUSING THE HINGE TO BREAK LOOSE FROM THE GLASS. WHEN OPENING THE WINDOW IT BROKE AND FELL ON MY HUSBAND WHILE LOADING CARGO. THE RIGHT SIDE SHOCK (STRUT) HAS SEEMED TO GET STUCK AT TIMES MAKING IT HARD TO CLOSE THE HATCH. *TR
FORD 2004 EXPLORER PAINT BUBBLING AT FRONT OF ALUMINUM HOOD. CLEARLY A DEFECT. TOOK TO DEALER WHERE THE BODY SHOP MANAGER SAID HE REPAINTED 70 SO FAR THIS YEAR BUT FORD WILL NOT TAKE CARE OF IT. ASKED TO MEET WITH THE DISTRICT SUPERVISOR. SET UP A MEETING WHEN HE WOULD BE IN TOWN. HE WOULD NOT EVEN COME OUT TO TALK TO ME AND SENT SOMEONE ELSE OUT TO TELL ME FORD WILL NOT FIX IT BECAUSE IN MY WARRANTY IT READS, "RUST MUST PERMANENT FROM THE INSIDE OUT". I ARGUED THAT IT IS AN ALUMINUM HOOD AND WILL NEVER RUST! I THEN WROTE FORD MOTOR COMPANY AND HAVE NEVER HEARD BACK FROM THEM. I KEEP CHECKING FOR RECALLS AND HAVE SEEN NOTHING TO DATE. MY WIFE AND I SEE MANY OF THE SAME VEHICLES WITH THIS SAME PROBLEM ALL THE TIME. SHAME ON FORD!! I WOULD LIKE TO SEE SOMETHING TAKEN CARE OF WITH THIS. THIS IS CLEARLY A DEFECT AND NOT SOMETHING ANY OF US CONSUMERS EVER DID TO MAKE THIS HAPPEN. *TR
10/20/2010 - SPOKANE, WASHINGTON - REAR PANEL UNDER BACK GLASS AROUND FORD LOGO CRACKED AFTER A COOL MORNING 32-35 DEGREES. THE CRACK EXTENDS FROM THE WINDOW ALL THE WAY TO THE BOTTOM OF THE PANEL. *TR
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR LIFTGATE GLASS HINGE WAS FRACTURING FROM THE VEHICLE. THE DEALER INFORMED THE CONTACT THAT THE HINGE WOULD NEED REPLACING AND THERE WERE NO RECALLS FOR THE VEHICLE. ANY REPAIR TO THE VEHICLE WOULD BE AT THE CONTACTS EXPENSE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 115,000 AND THE CURRENT MILEAGE WAS 150,100.
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. ON OCTOBER 7, 2010, THE CONTACT NOTICED THAT THE REAR LIFTGATE GLASS HAD A CRACK IN THE PANEL. THE DEALER STATED THAT THERE WERE NO RELATED RECALLS. THE CONTACT CALLED THE MANUFACTURER WHO STATED SHE MIGHT BE ELIGIBLE FOR REIMBURSEMENT, IF THERE FAILURE BECAME A RECALL. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 57,000.
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE PLASTIC PANEL ON THE REAR HATCH WAS CRACKED AND COULD POTENTIALLY FALL OFF. THE CONTACT CALLED THE DEALER REGARDING THE CRACKED PANEL AND THE DEALER INFORMED HER THAT THERE WAS NO RECALL REGARDING THE PLASTIC PANEL AND STATED THAT THE PART WAS AVAILABLE FOR PURCHASE. THE CONTACT HAD NOT REPLACED THE PLASTIC PANEL. THE FAILURE MILEAGE WAS 74,000.
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR PANEL WAS CRACKED BY THE EMBLEM IN THE REAR LIFTGATE. THE VEHICLE HAD NOT BEEN INSPECTED OR REPAIRED AT THE TIME OF THE COMPLAINT. THE CONTACT CALLED THE MANUFACTURER WHO STATED THAT THERE WAS NO RECALL RELATED TO THE FAILURE. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 55,000.
2004 FORD EXPLORER CRACKED PANEL BELOW THE REAR WINDOW. *TR
CRACK SUDDENLY APPEARED IN THE REAR PANEL BELOW THE WINDOW, FROM THE GLASS TO THE BOTTOM OF THE HATCH.
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR HINGE ON THE TAILGATE WAS BROKEN WHERE THE GLASS WAS HANGING. THE DEALER WAS INFORMED ABOUT THE FAILURE AND STATED THAT THERE WERE NO RELATED RECALLS. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND THE CURRENT MILEAGE WAS 131,000.
REAR HATCH CRACKED ON MY 2004 FORD EXPLORER. *TR
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE LIFTGATE WAS FRACTURED DOWN THE CENTER. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE CONTACT WAS INFORMED THAT HE WOULD BE RESPONSIBLE FOR REPLACING THE ENTIRE LIFTGATE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 45,000 AND THE CURRENT MILEAGE WAS APPROXIMATELY 48,000. UPDATED 12/21/10*BF THE CONSUMER STATED NO REPAIRS WERE MADE. HE BELIEVED THE INTEGRITY OF THE REAR WINDOW LIFTGATE HAS BEEN COMPROMISED. UPDATED 12/29/10
THERE IS A CRACK IN THE REAR PANEL UNDER THE WINDSHIELD OF MY 2004 FORD EXPLORER XLT. ASIDE FROM BEING UNSIGHTLY, I'M AFRAID THAT THIS CRACK WILL WEAKEN THE PANEL WHICH IS INTEGRAL TO KEEPING THE REAR WINDSHIELD SEATED PROPERLY. *TR
PANEL BENEATH REAR GLASS CRACKS ON FORD EXPLORERS. SEVERAL REPORTS OF SAME OCCURRENCE ON INTERNET AND 3 (INCLUDING MYSELF) WHERE I WORK. ALMOST ALL SAME DESCRIPTION, "PANEL BREAKS NEAR FORD EMBLEM". *TR
TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE REAR LIFT GATE PANEL WAS CRACKED BELOW THE GLASS AND THE VEHICLE HAD NEVER BEEN INVOLVED IN ANY ACCIDENTS. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALERSHIP WHERE THE CONTACT WAS INFORMED THAT THE FAILURE WAS KNOWN BUT SHE WOULD BE RESPONSIBLE FOR REPAIR COSTS. THE VEHICLE HAD NOT BEEN REPAIRED AT THE TIME OF THE COMPLAINT. THE FAILURE MILEAGE WAS APPROXIMATELY 34,000. THE CURRENT MILEAGE WAS 35,373.
CRACKED REAR PANEL ON 2004 FORD EXPLORER. DROVE IT THROUGH A CAR WASH AND IT SHATTERED. IT CAN FLY OFF AND HIT SOMEONE. *TR
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT ATTEMPTED TO CLOSE THE REAR LIFT GATE WINDOW AND THE HINGES FRACTURED CAUSING THE GLASS TO FALL AND SHATTER OVER HER HEAD. SHE SUFFERED MINOR INJURIES AS A RESULT. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE SHE WAS AWAITING A DIAGNOSIS OF THE FAILURE AND REPAIRS. THE FAILURE AND CURRENT MILEAGE WAS 80,000.
I DISCOVERED A CRACK IN THE PLASTIC PANEL BELOW THE REAR WINDOW OF MY 2004 FORD EXPLORER LAST NIGHT WHILE UNLOADING GROCERIES. THERE HAD BEEN NO IMPACT TO THIS AREA OF THE VEHICLE SO I HAD NO IDEA WHERE IT CAME FROM. I CHECKED WITH A LOCAL BODY SHOP AND THE ESTIMATOR TOLD ME THIS IS A VERY COMMON ISSUE WITH FORD EXPLORERS AND MERCURY MOUNTAINEERS. IT WAS APPARENTLY A MANUFACTURING DEFECT AND THAT I SHOULD CHECK WITH FORD. I STOPPED BY THE LOCAL FORD DEALERSHIP BUT THE SERVICE MANAGER WAS OUT TO LUNCH. THE SALESMAN I TALKED TO SAID HE SAW THE PROBLEM A NUMBER OF TIME WHEN HE WORKED AT THE LINCOLN MERCURY DEALER. WAITING FOR THE SERVICE MANAGER TO CALL ME. *TR
TAILGATE/DOOR WITH GLASS CRACKED AND BROKE. FIBERGLASS WAS MADE FAR TOO WEAK AND CRACKED. THIS IS A COMMON PROBLEM WITH THIS VEHICLE. *TR
Trend Over Time
Complaints by year
Other Issues
Common problems reported
Quick Summary
The 2004 Ford Explorer has 347 Structure complaints on file. 1 crashes have been reported. Review the timeline above for detailed owner experiences.