Model year report

2004 Ford Expedition: what breaks, and at what mileage

What breaks on the 2004 Ford Expedition

On the 2004 Ford Expedition, the failure owners report most often is other engine problem, and the reports cluster around 110,000 miles. The earliest to appear is other speed control problem, reported by a median of 5,000 miles. Overall it scores 76 out of 100, severe risk for a 2004.

Severe risk for a 2004 — 31st riskiest of the 329 2004 vehicles we can rate. 381 owner reports; fleet size estimated from this year's own recall paperwork.

What breaks on the 2004 Ford Expedition

Owners have reported 59 named failure modes on the 2004 Ford Expedition, and the three most-reported carry 17% of everything filed, which is an unusually even spread for one model year.

Other engine problem leads with 26 reports, about 9.4 per 1,000 vehicles and with the middle half of reports between 74k to 165,000 miles.

Other wheel or tire problem follows with 21 reports, usually reported between 16k to 45,000 miles.

Other electrical problem follows with 19 reports, usually reported between 53k to 145,000 miles.

By system, the reports fall mostly into engine (61), brakes (48) and body (31).

When these failures get reported

288 of the reports on the 2004 Ford Expedition came with an odometer reading, and half of those were filed before 80,000 miles.

Cumulatively, 36% by 50,000 miles, 63% by 100,000 miles and 85% by 150,000 miles of the dated reports had been filed, with 12 filed above the top of the chart.

The busiest stretch is between 0 and 10,000 miles, which alone holds 15% of the dated reports.

30% of the dated reports were filed below 36,000 miles.

In the order they tend to show up: other speed control problem around 4k, other powertrain problem around 16k, loss of braking around 18k and other brake problem around 20k.

Median

Tick median reported mileage Solid middle half of reports Faint 10th to 90th percentile Colour how bad the failure is when it happens

Showing the 12 most-reported failure modes of 59. The full list is in the table below.

How reports accumulate

Share of reports filed by each mileage

half by 80.1k

Every report with an odometer reading, cumulative, from 0 to 200,000 miles. A further 12 reports came in above that, which is why the line stops short of the top. A curve that climbs early is a car with early problems, whatever its total.

Line share of reports filed by that mileage
Dashed the median reported mileage

How bad it is when it goes

Across the named modes, 33 mention a crash, 15 a fire and 20 an injury. Those are the words owners used in their own complaints, and NHTSA does not verify them, but they are the closest thing in this data to a measure of what a failure actually did.

The average severity weight across every report on this year is 5.72, where a stalled engine or a failed airbag weighs many times more than a rattling trim panel, and a figure this high means the reports are dominated by failures with safety consequences rather than annoyances. The weighting is set out in full on the methodology page.

What the top failures cost to put right, as editorial estimates for an independent US shop rather than figures from NHTSA: other engine problem at $300–$4,000, other wheel or tire problem at $200–$1,500, other electrical problem at $250–$2,000 and other powertrain problem at $400–$4,500. Dealer labour, a seized bolt or a part that is no longer made can push any of these past the top of its range.

26% of the reports on this year sit in the engine, transmission, drivetrain or cooling systems — the four where a repair bill is usually four figures.

Every reported failure mode

Mileage figures are percentiles of owner-reported readings. Click a column to sort.
Failure mode	System	Reports	With reading	25th	Median	75th	Per 1,000	Typical repair	Severity
Other engine problem	engine	26	20	74k	112k	164k	9.4	$300–$4,000	High
Other wheel or tire problem	wheels	21	14	16k	34k	47k	7.6	$200–$1,500	High
Other electrical problem	electrical	19	14	53k	104k	143k	6.9	$250–$2,000	Moderate
Other powertrain problem	transmission	18	12	13k	16k	57k	6.5	$400–$4,500	High
Other body or interior problem	body	17	11	21k	36k	69k	6.2	$200–$2,000	Moderate
Other brake problem	brakes	16	11	7k	20k	62k	5.8	$300–$1,800	High
Loss of braking	brakes	15	12	4k	18k	32k	5.4	$400–$3,000	Critical
Fuel pump failure	fuel	14	14	126k	160k	186k	5.1	$600–$2,600	High
Misfire or rough idle	engine	13	12	80k	100k	141k	4.7	$250–$1,600	Moderate
Cruise control failure	adas	10	8	3k	73k	161k	3.6	$200–$1,400	High
Other speed control problem	adas	10	9	1k	4k	72k	3.6	$250–$2,000	Critical
Stalling while driving	engine	8	5	—	159k	—	2.9	$300–$2,500	Critical
Steering rack, gear or tie rod failure	steering	8	6	—	65k	—	2.9	$700–$2,600	High
Other fuel system problem	fuel	8	5	—	115k	—	2.9	$300–$2,200	High
Airbag failed to deploy in a crash	airbag	7	6	—	87k	—	2.5	$1,000–$5,000	Critical
Other steering problem	steering	7	5	—	41k	—	2.5	$350–$2,400	High
Other visibility problem	glass	7	4	—	88k	—	2.5	$150–$1,400	Moderate
Radiator or coolant leak	cooling	6	6	—	125k	—	2.2	$350–$1,900	High
Brake line, hose or caliper failure	brakes	6	2	—	134k	—	2.2	$250–$1,600	Critical
No-start or intermittent start failure	engine	5	3	—	100k	—	1.8	$200–$1,800	Moderate
Premature brake pad or rotor wear	brakes	5	5	—	8k	—	1.8	$300–$1,400	Moderate
Rust or structural corrosion	body	5	4	—	103k	—	1.8	$500–$6,000	High
Wiper or washer failure	glass	5	5	—	97k	—	1.8	$120–$800	Moderate
Head gasket failure	engine	4	2	—	54k	—	1.5	$1,400–$4,000	Critical
Differential or transfer case failure	drivetrain	4	4	—	111k	—	1.5	$900–$4,200	High
Wiring harness or short circuit	electrical	4	4	—	86k	—	1.5	$400–$3,500	High
ABS module or sensor failure	brakes	4	4	—	54k	—	1.5	$500–$2,400	High
Seat belt or retractor failure	airbag	4	3	—	220k	—	1.5	$200–$900	High
Tire blowout or tread separation	wheels	4	4	—	48k	—	1.5	$200–$1,500	Critical
Tire pressure monitor failure	wheels	4	1	—	4k	—	1.5	$80–$600	Low
Air conditioning failure	hvac	4	4	—	84k	—	1.5	$400–$2,800	Moderate
Other suspension problem	suspension	4	2	—	43k	—	1.5	$350–$2,000	Moderate
Complete engine failure or seizure	engine	3	0	—	—	—	1.1	$4,500–$12,000	Critical
Complete transmission failure	transmission	3	3	—	54k	—	1.1	$2,800–$8,000	Critical
Wheel bearing or hub failure	drivetrain	3	3	—	88k	—	1.1	$350–$1,200	Moderate
Liftgate, tailgate or trunk failure	body	3	3	—	70k	—	1.1	$250–$1,500	Moderate
Engine bay fire	engine	2	1	—	75k	—	0.7	$4,000–$20,000	Critical
CV axle or driveshaft failure	drivetrain	2	2	—	104k	—	0.7	$450–$2,200	High
Parking brake failure	brakes	2	1	—	2k	—	0.7	$250–$1,300	Moderate
Airbag warning light or occupant sensor fault	airbag	2	2	—	134k	—	0.7	$300–$1,600	High
Steering column or shaft failure	steering	2	0	—	—	—	0.7	$600–$2,500	Critical
Alignment fault and uneven tire wear	suspension	2	2	—	82k	—	0.7	$150–$1,200	Moderate
Door latch or handle failure	body	2	2	—	90k	—	0.7	$250–$1,200	High
Window regulator or power window failure	body	2	2	—	88k	—	0.7	$250–$900	Moderate
Other lighting problem	lighting	2	1	—	109k	—	0.7	$120–$1,200	Moderate
Other driver assistance problem	adas	2	1	—	80k	—	0.7	$250–$1,800	High
Electrical fire or melted wiring	electrical	1	0	—	—	—	0.4	$1,500–$9,000	Critical
Overheating	cooling	1	1	—	17k	—	0.4	$400–$3,500	High
Fuel tank, filler or EVAP failure	fuel	1	1	—	23k	—	0.4	$250–$1,800	Moderate
Alternator or charging system failure	electrical	1	0	—	—	—	0.4	$450–$1,600	High
Control module (ECM/PCM/BCM) failure	electrical	1	1	—	13k	—	0.4	$700–$3,000	High
Instrument cluster or gauge failure	infotainment	1	1	—	70k	—	0.4	$350–$1,400	Moderate
Airbag deployed without a crash	airbag	1	1	—	88k	—	0.4	$2,500–$8,000	Critical
Loss of power steering	steering	1	1	—	115k	—	0.4	$600–$2,800	Critical
Control arm, ball joint or bushing failure	suspension	1	0	—	—	—	0.4	$400–$2,200	High
Paint peeling or clear coat failure	body	1	0	—	—	—	0.4	$600–$6,000	Low
Sunroof failure or glass breakage	body	1	1	—	80k	—	0.4	$700–$4,500	High
Catalytic converter failure	emissions	1	0	—	—	—	0.4	$900–$3,500	Moderate
Exhaust leak or fumes in the cabin	emissions	1	0	—	—	—	0.4	$250–$2,000	High
Unclassified problem	other	44	37	35k	89k	136k	16.0	—	Moderate

Rate per 1,000 uses a fleet-size estimate derived from recall paperwork for this exact model year. It is a lower bound. Repair costs are typical independent-shop ranges for the failure, not figures from these reports.

How often, against how many were built

Scaled by an estimate of how many of these cars exist, the 2004 Ford Expedition draws about 138 per 1,000 vehicles, which puts it in the 97th percentile of complaint rates among 2004 vehicles we can rate.

That denominator is the weakest number on the page and it is fair to say so plainly. Rate per 1,000 uses a fleet-size estimate derived from recall paperwork for this exact model year. It is a lower bound.

The working figure is 2,754 vehicles. If the true number is twice that, every rate on this page is half what it says; the ranking against other 2004 vehicles, which is what the risk score uses, is far more robust than the rate itself.

What owners wrote

Verbatim from NHTSA complaint narratives, trimmed for length. The odometer reading is the one the owner gave.

Recalls on the 2004 model year

NHTSA has issued 4 recall campaigns covering the 2004 Ford Expedition, affecting an estimated 2,990 vehicles. A recall is a different kind of evidence from a complaint: it is the regulator and the manufacturer agreeing that something has to be fixed, and the fix is free for as long as the car exists.

The campaigns cover exterior lighting and exterior lighting:headlights. Whether the work was actually done on the car in front of you is a question only the VIN can answer, and the manufacturer or NHTSA will answer it free.

Recalls also distort complaint counts. Publicity about a campaign reminds owners that complaining is possible, so reports for a recalled component often spike after the recall rather than before it.

09E012000

EXTERIOR LIGHTING

16,270 vehicles 2009-04-07

Defect: 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.
Consequence: Decreased lighting visibility may result in a vehicle crash.
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.

06E064000

EXTERIOR LIGHTING

4,029 vehicles 2006-07-17

Defect: 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.
Consequence: Lack of amber side reflectors in the lamps will decrease lighting visibility to other drivers and may possibly result in a vehicle crash.
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.

06E026000

EXTERIOR LIGHTING

61,944 vehicles 2006-03-23

Defect: 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.
Consequence: Without the amber reflectors, the vehicle will be poorly illuminated, possibly resulting in a vehicle crash without warning.
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.

06E023000

EXTERIOR LIGHTING:HEADLIGHTS

292,000 vehicles 2006-03-13

Defect: 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."
Consequence: Without the amber reflectors, the vehicle will be poorly illuminated, possibly resulting in a vehicle crash.
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.

Recall work is free at a franchised dealer regardless of the car's age. Check the VIN at nhtsa.gov/recalls before assuming it was done.

How it ranks in the 2004 field

The score at the top of the page, placed among its peers. The zones are the same thresholds the scorer applies, read out of the scorer itself, so the picture and the band word cannot disagree.

Risk score against the rest of the 2004 field

Scores are ranked within the model year, never across years, because an older car has had longer to accumulate reports.

Left fewer and less serious reports
Right more, or worse
Marker this vehicle

Better and worse years of the same car

Severe risk for a 2004 — 31st riskiest of the 329 2004 vehicles we can rate. Because the ranking is against the same model year only, age cancels out of it.

Across the 30 model years of this car that carry enough reports to score, 2026 comes out best at 58 and 2003 worst at 78, with 2004 itself at 76.

If the model year is negotiable, 2026, 2014, 2013, 2000, 2002, 2001, 1999, 2010, 2025, 2011, 1998, 1997, 2007, 2008, 2015, 2016, 2022, 2023, 2017, 2009, 2012 and 2024 score lower than 2004 by a margin worth acting on. Same body, same engines, different luck — usually a supplier change or a mid-cycle fix, which the complaint data can show but never explain.

Within the 2003–2008 generation specifically, 2007 is the strongest year at 68 and 2003 the weakest at 78.

Scores compare each year against other cars of the same model year, so a low number on an older car is a real result and not an artefact of age.

Risk score by model year, out of 100

Shorter is better. Years with too few reports to score are shown without a bar rather than as a zero, because no data is not good news.

Within the 2003-2008 generation, 2007 Ford Expedition scores best at 68 and 2003 Ford Expedition worst at 78.

What to look at before buying one

The mileages below are where the first quarter of reports for each mode had already been filed, which makes them the point at which a fault is worth looking for rather than the point at which it happens: other speed control problem from about 1k, cruise control failure from about 3k, loss of braking from about 4k and other brake problem from about 7k.

On a 2004 Ford Expedition with more miles than that on it, the useful question to put to a seller or a mechanic is whether other speed control problem has been dealt with, and if so with what parts and at whose expense. A car that has already had the repair is in a different position from one that has not.

None of this is a diagnosis. It is a list of what other owners of the same model year reported, ordered by when they reported it, which is a good place to point an inspection and a poor place to stop.

The limits of complaint data

381 owner reports; fleet size estimated from this year's own recall paperwork. Every count on this page is therefore a floor: it is the number of owners who went to the trouble of filing with a federal agency, which is a small and self-selected fraction of the owners who had the fault.

Of those 381 reports, 288 carried an odometer reading, so the mileages here describe 76% of the sample rather than all of it. Owners also round: readings pile up on multiples of ten thousand, which is why this site publishes "about 90,000 miles" and not "91,438".

Named failure modes come from matching phrases in the complaint text, so a badly worded complaint can land in the wrong bucket. The effect washes out across hundreds of reports and does not wash out across five.

And nothing here predicts what one car will do. These are other people's complaints, filed years apart, on cars maintained by strangers. Read the page as a map of where this model year has previously gone wrong, then have the specific car in front of you inspected.

Questions this page answers

What are the most common problems with the 2004 Ford Expedition?

The most-reported failures are other engine problem (26 reports, median 110,000 miles), other wheel or tire problem (21 reports, median 35,000 miles) and other electrical problem (19 reports, median 105,000 miles). Counts come from owner complaints filed with NHTSA, which are voluntary, so they show what owners bothered to report rather than every fault that occurred.

At what mileage do 2004 Ford Expedition problems start?

Other speed control problem is the earliest failure mode to show up, with a median reported mileage of 5,000 miles and a quarter of reports before 1,200 miles. Across all failure modes on this year, the median report sits at 80,000 miles.

Is the 2004 Ford Expedition reliable?

It scores 76 out of 100 on our risk index, which is severe — 31st riskiest of the 329 2004 vehicles we can rate. The score is a comparison against other 2004 vehicles, not a prediction about any individual car, and it is built from complaint rates, severity and how early failures appear.

Which year of the Ford Expedition is best?

Within the 2003–2008 generation, 2007 scores best at 68 out of 100 and 2003 worst at 78. Same body, same engines, different luck.

Where this comes from. Every figure above is computed from NHTSA owner complaints and recall records for this exact make, model and year. Complaints are voluntary and self-selected, so treat counts as a floor. The methodology page writes out each formula, and the same numbers are available as JSON.

What breaks at my mileage Compare with another car

Source Owner complaints and recall records published by the US National Highway Traffic Safety Administration, model years 1996–2027 Figures rebuilt 30 August 2026 Published by AtWhatMileage How every figure is computed