Problems · NHTSA complaints

2004 Ford Expedition problems

Owners filed 297 complaints about the 2004 Ford Expedition with NHTSA between Jan 2004 and Oct 2026. The most-cited component is air bags (46).

Complaints
297
Filed with NHTSA
Crashes
49
Reported by owners
Fires
15
Reported by owners
Injuries
60
People reported injured
Deaths
1
Reported to NHTSA
01 —By component

Complaints by component

One complaint can cite several components
  1. Air bags46
  2. Electrical system36
  3. Service brakes, hydraulic34
  4. Engine29
  5. Power train27
  6. Tires26
  7. Engine and engine cooling26
  8. Structure24
  9. Vehicle speed control21
  10. Fuel/propulsion system19
  11. Visibility15
  12. Steering14
  13. Suspension11
  14. Service brakes7

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.

Data from NHTSA Complaints API · synced Oct 30, 2026NHTSA vehicle page
02 —Trend

When complaints were filed

Does it get worse with age? Complaints per calendar year filed
View as table
Model yearComplaints filed per calendar year
200452
200531
200620
200710
200815
200916
201023
201121
201214
201316
201414
201512
201613
201713
20187
20195
20205
20212
20224
20231
20240
20251
20262

Mileage at failure isn’t a structured field in NHTSA complaint data, so we don’t chart it. Some owners mention it in their reports below.

03 —Owner reports

Top problems in owners’ words

Verbatim from NHTSA complaints, newest first

Air bags

46 reports29 crashes1 fire
“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.”
Owner complaint to NHTSAFiled Aug 19, 2018Air bagsCrash reportedODI 11120927

Electrical system

36 reports1 crash2 fires
“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.”
Owner complaint to NHTSAFiled Mar 6, 2025Electrical system, Exterior lighting, TiresODI 11646759

Service brakes, hydraulic

34 reports8 crashes2 fires
“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.”
Owner complaint to NHTSAFiled Nov 16, 2011Service brakes, hydraulicODI 10436107

Engine

29 reports4 fires
“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.”
Owner complaint to NHTSAFiled Mar 5, 2026Power train, EngineODI 11722224

Power train

27 reports1 crash
“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.”
Owner complaint to NHTSAFiled Nov 21, 2022Steering, Power train, StructureODI 11494447

Tires

26 reports2 crashes
“TL* THE CONTACT OWNS A 2004 FORD EXPEDITION EQUIPPED WITH B.F. GOODRICH TIRES, SIZE: 265/75R17. THE CONTACT STATED THAT THERE WAS A BUBBLE PROTRUDING FROM THE SIDEWALL AND INTO THE TREAD AREA OF THE TIRE, CAUSING THE TIRE TO DELAMINATE. THE CONTACT REPORTED THE FAILURE TO THE STORE WHERE HE BOUGHT THEM AND THEY INSTRUCTED HIM TO BRING THEM BACK.”
Owner complaint to NHTSAFiled Oct 11, 2012TiresODI 10479805
Data from NHTSA Complaints API (owner reports, unverified) · synced Oct 30, 2026

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.