NHTSA vehicle safety data

2004 Ford Expedition Recalls, Ratings & Complaints

The 2004 Ford Expedition has 4 NHTSA recall campaigns and 297 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Ford dealer.

NHTSA recall and complaint data for the 2004 Ford Expedition, plus NCAP crash-test ratings. Recall data is refreshed daily from NHTSA.

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2004 Ford Expedition owner complaints

Owners have filed 297 complaints with NHTSA about the 2004 Ford Expedition, describing incidents dated January 4, 2003 to October 7, 2026.

Most-cited components

Engine 55 complaints
Air Bags 46 complaints
Service Brakes 42 complaints
Electrical System 36 complaints
Power Train 27 complaints
Tires 26 complaints

Of the 297 complaints on file, 49 report a crash and 15 a fire; across all 297 complaints, owners report 60 injuries and 1 death (owner-reported, not verified by NHTSA).

Newest complaints

ODI #11771286 · Filed October 15, 2026
I was in a collision with another car. The brakes failed.\n Going over 3540 miles per hour, airbag and passenger side and drivers side neither one deployed.
ODI #11722224 · Filed March 5, 2026
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…
ODI #11646759 · Filed March 6, 2025
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…

Read all 297 complaints

Owner-reported

2004 Ford Expedition mileage at failure

227 of the 297 complaints on file for the 2004 Ford Expedition give the vehicle's mileage when the problem happened.

Mileage at failure by component, from owners' complaints to NHTSA
Component	Median	Middle half	Based on
Engine	Median 110,000 miles	Middle half 75,000–155,000 miles	Based on 44 complaints
Air Bags	Median 85,000 miles	Middle half 30,000–135,000 miles	Based on 37 complaints
Service Brakes	Median 17,000 miles	Middle half 7,000–75,000 miles	Based on 32 complaints

A component's median is its 50th percentile, and its middle half runs from its 25th to its 75th percentile.

Owners give the mileage themselves, often as a round number, and NHTSA doesn't check it. A complaint that names several components counts under each one, and mileages that can't be right, such as 999,999, or 50 miles on a five-year-old car, are left out.

These figures describe the complaints owners filed. They don't predict when a particular vehicle will have a problem, and vehicles that never had one aren't counted.

Most complaints NHTSA received since May 17, 2021 give no mileage. So that they aren't undercounted, each one received since then that gives a mileage also stands in for those that gave none, which can put a component's median above most of the mileages it is based on.

Mileage from NHTSA's complaints file of October 31, 2026. How these figures are worked out

NHTSA defect investigations

NHTSA's investigations file lists the 2004 Ford Expedition in 2 investigations. A listed model year means only that an investigation names it; it says nothing about any particular vehicle. An open investigation is not a finding that a safety defect exists, and NHTSA can close one without a recall.

Preliminary Evaluation PE08-070: STEEL WHEEL FRACTURE
Closed April 15, 2009
Defect Petition DP05-005: SPARK PLUG EJECTION FROM CYLINDER HEAD
Closed January 4, 2006

Open and recently closed NHTSA defect investigations

FMVSS 108/AFTERMARKET COMBINATION LAMPS

NHTSA #09E012000 · Exterior Lighting · NHTSA notice

Reported April 7, 2009 · SABERSPORT

Potentially affected: 16,270 vehicles

Owners notified May 11, 2009

Defect description

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, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.

Safety consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Manufacturer 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.

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 SABERSPORT.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> .

FMVSS 108/AMBER SIDE REFLECTORS

NHTSA #06E064000 · Exterior Lighting · NHTSA notice

Reported July 17, 2006 · TRADESONIC

Potentially affected: 4,029 vehicles

Defect description

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 EQUIPMENT.

Safety consequence

LACK OF AMBER SIDE REFLECTORS IN THE LAMPS WILL DECREASE LIGHTING VISIBILITY TO OTHER DRIVERS AND MAY POSSIBLY RESULT IN A VEHICLE CRASH.

Manufacturer 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.

Notes

THIS RECALL ONLY PERTAINS TO TRADESONIC 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.

FMVSS 108/AMBER SIDE REFLEX REFLECTORS

NHTSA #06E026000 · Exterior Lighting · NHTSA notice

Reported March 23, 2006 · PRO-A MOTORS, INC.

Potentially affected: 61,944 vehicles

Owners notified April 3, 2006

Defect description

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.

Safety consequence

WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.

Manufacturer 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.

FMVSS 108/HEADLAMP/AMBER SIDE REFLEX REFLECTOR

NHTSA #06E023000 · Exterior Lighting — Headlights · NHTSA notice

Reported March 13, 2006 · ANZO USA, INC.

Potentially affected: 292,000 vehicles

Owners notified May 9, 2006

Defect description

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 EQUIPMENT."

Safety consequence

WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH.

Manufacturer 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.

Notes

THIS RECALL ONLY PERTAINS TO AFTERMARKET HEADLAMP ASSEMBLIES MANUFACTURED BY ANZO AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON THE LISTED PASSENGER VEHICLES.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.

2004 Ford Expedition 4-DR.

—

out of 5

Overall Safety Rating

Not Rated

Frontal Crash

Not Rated

Driver: 5, Passenger: 5

Side Crash

Not Rated

Driver: Not Rated, Passenger: Not Rated

Side Pole

Not Rated

Rollover

Not Rated

Safety Technology

2 investigations

297 owner complaints have been filed with NHTSA for the 2004 Ford Expedition.

Steering; Air Bags; Service Brakes

ODI #11771286

Crash 2 injuries

Incident: October 7, 2026 · Filed: October 15, 2026

I was in a collision with another car. The brakes failed.\n Going over 3540 miles per hour, airbag and passenger side and drivers side neither one deployed.

Power Train; Engine

ODI #11722224

Incident: February 25, 2026 · Filed: March 5, 2026

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.

Electrical System; Exterior Lighting; Tires

ODI #11646759

Incident: February 6, 2025 · Filed: March 6, 2025

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.

Exterior Lighting

ODI #11501797

Incident: January 11, 2003 · Filed: January 14, 2023

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

Steering; Power Train; Structure

ODI #11494447

Incident: November 5, 2022 · Filed: November 21, 2022

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.

Engine

ODI #11488840

Incident: October 11, 2022 · Filed: October 11, 2022

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.

Engine

ODI #11465508

Incident: May 14, 2022 · Filed: May 20, 2022

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.

Electrical System

ODI #11448740

Fire

Incident: January 24, 2022 · Filed: January 25, 2022

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.

Power Train

ODI #11429658

Incident: August 18, 2021 · Filed: August 18, 2021

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.

Engine

ODI #11425528

Incident: July 12, 2021 · Filed: July 19, 2021

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.

Other Ford Expedition model years

Check your 2004 Ford Expedition VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Ford Expedition at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

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