Worst Vehicle Models: 2004 Ford Explorer

The Ford Explorer lands itself on CarComplaints.com’s list of Worst Vehicles three times. Two of which are in the top ten. The 2002, 2003, and 2004 models were some of the worst years for this model. The 2004 Ford Explorer is at number #7 on the list. Here’s why.

The most commonly reported issue with the 2004 Ford Explorer is a cracked panel below the rear window. CarComplaints.com has 769 complaints for this defect! To fix the crack and replace the panel, owners can expect a cost of about $460. On average, this problem occurs before 75,000 miles.

Owners also report peeling paint at an average of around 64,000 miles, with an average repair cost of $540. Many owners reported having to strip and repaint their entire vehicle, which can be a real headache. Other than paint peeling, other corrosion and even rust is commonly reported as early as 84,000. This is much earlier than one would expect their vehicle to show exterior damage.

The 2004 Ford Explorer is no stranger to transmission problems. Owners of this model complain of a slipping transmission or difficulty shifting. Often times this is a precursor to transmission failure. On average, the 2004 Ford Explorer begins having transmission issues around 73,000 miles and transmission failure occurs around 84,000. The typical cost to repair is usually between $2,000 and $3,000. There have also been numerous complaints stating that the vehicle won’t go into reverse around 100,000 miles.

There are many complaints regarding the gear shift, as many owners complain of it snapping off around 80,000 miles. To repair this issue, the entire steering column must be replaced and can cost as much as $1,000.

Engine failure or stalling while driving is another issue that 2004 Ford Explorer owners may have. The typical repair cost to replace the engine is $3,700. Owners should be aware that this problem tends to occur around 75,000 miles, which is right about the time that the transmission starts to have issues in this particular model and year.

Another powertrain component that may start to have issues before 100,000 miles is the crankshaft pulley. Many owners reported that the crankshaft pulley failed and needed to be replaced at around 90,000 miles at a cost of around $600.

The 2004 Ford Explorer has a number of interior problems, some of which are quite severe. Many drivers reported the supports for the sun visor cracking. While this may seem like a small repair, it can cost as much as $200 to replace the part!

One of the more troublesome issues with this vehicle model is that the gas gauge is inaccurate. Some owners reported having to replace the fuel gauge and some reported having to replace the fuel pump. Either way, this repair will cost owners about $730 on average.