NHTSA lists 4 safety recalls and 297 owner complaints for the 2004 Ford Expedition. Most complaints involve air bags (46) and electrical system (36). The EPA rates it 13–15 mpg combined.
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.
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.
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.
Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.
Complaints for each Expedition model year we’ve synced.
| Model year | NHTSA complaints |
|---|---|
| 1997 | 868 |
| 1998 | 851 |
| 1999 | 970 |
| 2000 | 942 |
| 2001 | 609 |
| 2002 | 383 |
| 2003 | 655 |
| 2004 | 297 |
| 2005 | 315 |
| 2006 | 299 |
| 2007 | 215 |
| 2008 | 146 |
| 2009 | 28 |
| 2010 | 58 |
| 2011 | 71 |
| 2012 | 118 |
| 2013 | 92 |
| 2014 | 72 |
| 2015 | 164 |
| 2016 | 217 |
| 2017 | 358 |
| 2018 | 383 |
| 2019 | 521 |
| 2020 | 426 |
| 2021 | 241 |
| 2022 | 116 |
| 2023 | 65 |
| 2024 | 79 |
| 2025 | 38 |
| 2026 | 10 |
“HEAD ON COLLISION WITH FORD F-250 AND NEITHER AIR BAGS DEPLOYED. WE DID NOT HAVE ANY RECALLS ON OUR FORD EXPEDITION. MY HUSBAND AND SON ARE VERY LUCKY I WILL NEVER OWN A FORD EVER AGAIN.”
“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.”
“TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. THE CONTACT STATED THAT WHILE EXITING A PARKING SPACE AND APPLYING THE BRAKES, THE BRAKE WAS DEPRESSED INTO THE FLOORBOARD ABNORMALLY. THE CONTACT DROVE THE VEHICLE TO A LOCAL MECHANIC AND NOTICE BRAKE FLUID LEAKING. THE MECHANIC ADVISED THAT THE RADIATOR SUPPORTER WAS RUSTED AND ALSO CAUSED THE BRAKE LINES TO RUST. THE MECHANIC REPLACED THE RADIATOR SUPPORT UNIT AND THE BRAKE LINE. THE CONTACT CALLED THE MANUFACTURER REGARDING THE FAULTY BRAKE LINES AND THE MANUFACTURER STATED THERE WAS NOTHING THEY COULD DO TO ASSIST. THE FAILURE MILEAGE WAS 73,000.”
Towing, payload and dimensions aren’t in the EPA or NHTSA data, so we don’t list them.
| Version | City | Hwy | Comb. | Fuel / yr | CO₂ g/mi |
|---|---|---|---|---|---|
| Expedition 2WD Auto 4-spd, 8 cyl, 4.6 L · Rear-Wheel Drive | 14 | 18 | 15 | $4,300 | 592 |
| Expedition 2WD Auto 4-spd, 8 cyl, 5.4 L · Rear-Wheel Drive | 12 | 16 | 14 | $4,600 | 635 |
| Expedition 4WD Auto 4-spd, 8 cyl, 4.6 L · 4-Wheel or All-Wheel Drive | 12 | 17 | 14 | $4,600 | 635 |
| Expedition 4WD Auto 4-spd, 8 cyl, 5.4 L · 4-Wheel or All-Wheel Drive | 12 | 16 | 13 | $4,950 | 684 |
| Item | Miles | Time | Note |
|---|---|---|---|
| Engine oil & filter | 5,000–10,000 mi | 6–12 months | Follow the oil-life monitor if fitted |
| Tire rotation | 5,000–7,500 mi | Every oil change | Check pressure monthly |
| Engine air filter | 15,000–30,000 mi | 1–2 years | Sooner in dusty areas |
| Cabin air filter | 15,000–25,000 mi | 1–2 years | |
| Brake fluid | — | 2–3 years | Absorbs moisture over time |
| Coolant | 60,000–100,000 mi | 5–10 years | Long-life coolants last longer |
| Spark plugs | 60,000–100,000 mi | — | Iridium/platinum plugs at the long end |
| 12V battery | — | 3–5 years | Heat shortens battery life |
4 safety recalls as of Oct 30, 2026, according to NHTSA. Recall repairs are free at a dealer. Check your VIN to see whether your car is included and whether the repair was done.
Owners filed 297 complaints with NHTSA. The most-cited components are air bags (46), electrical system (36), service brakes, hydraulic (34). Complaints are unverified owner reports and aren't adjusted for how many cars were sold.
The EPA rates the 2004 Ford Expedition at 13–15 mpg combined, depending on engine and drivetrain (4 versions rated).