There are 17 stored owner reports matching the body & structure leading-label group for the 2004 Ford Expedition in our NHTSA-sourced dataset. These are unverified consumer reports and may not reflect confirmed defects.
This group counts stored reports whose component label starts with one of this site's matching prefixes, ignoring case. Each matching report counts once within the group. Components mentioned later in the label or only in the narrative are not searched. How component counts work
Loaded 17 of 17 matching reports.
Open the full vehicle complaint log (all categories)FRAME WAS BROKEN AND RIGGED AND PAINTED UNSAFE AND I AM CONCERNED WHEN HE PUTS MY KIDS IN THE CAR IT IS NOT SAFE
TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, THERE WAS AN ABNORMAL NOISE COMING FROM THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE PASSENGER SIDE REAR FRAME RAIL SECTION HAD RUSTED THROUGH AND SEPARATED. THE DEALER ALSO DIAGNOSED THAT THE WHEEL BEARING AND HUB ASSEMBLY NEEDED TO BE REPLACED AS WELL. THE CONTACT STATED THAT THE DEALER STATED THAT THE VEHICLE WAS NO LONGER ROAD WORTHY DUE TO RUST OF THE FRAME AND SHOULD NOT BE DRIVEN. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 66,000.
THE FRAME IS RUSTING. SEE PHOTOS. THE BODY IS RUSTING AWAY ALSO THE BRAKE LINES. THE ENTIRE VEHICLE IS RUSTING AWAY. WHY HAS THIS 2004 FORD NOT INCLUDED IN A RECALL FOR RUST.
PAINT FAILURE REF. TSB# 06-25-15 [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. THE CONTACT STATED THAT UPON INSPECTION, IT WAS FOUND THAT THE SUB FRAME WAS RUSTED. THE CONTACT ALSO INDICATED THAT THE RADIATOR MOUNTS DETACHED FROM THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO CONFIRMED THE FAILURE. THE MANUFACTURER WAS NOTIFIED. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 180,000.
OBSERVED SIGNIFICANT RUST-THROUGH AND DETERIORATION OF THE BODY STRUCTURE AT THE TWO FRONT BODY TO FRAME MOUNTING POINTS. METAL STRUCTURE SUPPORTING THE AIR CONDITIONING CONDENSER COIL HAS COMPLETELY DISINTEGRATED AND THE COIL HAS DROPPED APPROXIMATELY 1" FROM ITS DESIGNED POSITION. METAL STRUCTURE SUPPORTING THE RADIATOR IS ALMOST COMPLETELY DISINTEGRATED. SURROUNDING METAL SUPPORTING THE BODY TO FRAME SOWN SIGNIFICANT DETERIORATION AND RUST-THROUGH. CONCERNED WITH SAFETY AND STRUCTURAL INTEGRITY OF THE BODY TO FRAME CONNECTION AND SUPPORT OF COMPONENTS. *TR
TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. WHILE DRIVING IN RAINY WEATHER CONDITIONS APPROXIMATELY 30 MPH, THE INTERIOR DOME LIGHT BEGAN LEAKING A SMALL AMOUNT OF WATER. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND THEY RECOMMENDED THE VEHICLE BE TAKEN TO AN AUTO COLLISION CENTER FOR INSPECTION. THE VEHICLE WAS TAKEN TO AN AUTO COLLISION CENTER AND THE TECHNICIAN STATED THE ROOF OF THE VEHICLE WOULD NEED TO BE REPLACED AND ALSO INFORMED THE CONTACT THAT EVENTUALLY, THE WATER LEAKAGE WOULD RESULT IN ELECTRICAL ISSUES. THE MANUFACTURER WAS MADE AWARE OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 67,000.
BUBBLING PAINT ON REAR TAIL GATE. CLEARLY A PAINT PREPARATION ISSUE, OTHERWISE PAINT ON THE REST OF THE CAR IS NEAR PERFECT. *TR
TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. WHILE DRIVING WATER BEGAN POURING FROM THE ROOF CONSOLE . WATER ENTRANCE HAS CAUSED CORROSION AND HOLES ON THE ROOF-TOP. THE DEALER WAS CONTACTED AND THEY STATED THAT THE VEHICLE WAS DESIGNED DEFECTIVELY. SINCE THE WARRANTY EXPIRED AND THE FAILURE OCCURRED PREVIOUSLY, THEY AGREED TO PAY FOR HALF OF THE REPAIR. MEANWHILE THE TECHNICIAN GAVE HER A BLACK CAULK TO FILL IN THE HOLES. THE TEMPORARY REPAIR WAS NOT A REMEDY. THE FAILURE MILEAGE WAS UNKNOWN. THE CURRENT MILEAGE WAS 48000.
1 OWN A 2004 FORD EXPEDITION AND THE ORIGINAL PAINT IS BUBBLING UP ON THE TAILGATE AROUND THE LICENSE PLATE HOLDER AND DOOR HANDLE THERE HAVE BEEN HUNDREDS OF COMPLAINTS AND FORD DOES NOT WANT TO EXCEPT RESPONSIBILITY. *TR
TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. THE CONTACT STATED THAT THERE WAS CORROSION ON THE REAR LIFTGATE. THE VEHICLE WAS TAKEN TO THE DEALER WHO STATED THERE WERE NO RECALLS FOR THE FAILURE. THE MANUFACTURER WAS ALSO CONTACTED WHO CONFIRMED THAT THERE WERE NO RECALLS AND OFFERED NO FURTHER ASSISTANCE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 97,000.
TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. THE PAINT NEAR THE FRONT HOOD, THE REAR LIFT GATE, THE DOOR LATCH AND THE WIND-SHIELD WIPER HAS CORRODED. THE VEHICLE HAS NOT BEEN INSPECTED OR REPAIRED FOR THE FAILURE. THE FAILURE MILEAGE WAS 90,000. THE CURRENT MILEAGE WAS 93,000. UPDATED 11/12/09 *CN THE CONSUMER STATED THE VEHICLE HAS NEVER BEEN IN AN ACCIDENT. THE VEHICLE IS STORED IN A GARAGE OVERNIGHT. UPDATED 11/17/09.*JB
BLACK PLASTIC TRIM MOLDING ON DOORS OF 2004 FORD EXPEDITION ARE FADING. ALL OF THEM ON THE ROAD OF THIS VINTAGE HAVE THE SAME DEFECT. *JB
ROOF CANEL RUST, HAD REPAIRED IT 4 TIMES SINCE 2007. FORD IS UNWILLING TO TAKE OWNERSHIP OF THE DEFECT AND WITH EACH REPAIR, THE ROOF IS WEAKER. SPOKE TO TWO DEALERSHIPS AND THIS DEFECT KEEPS THEM IN BUSINESS SINCE THIS IS ALL THEY DO. *TR
PAINT PEELING,CREATING CORROTION ON THE ROOF. *TR
TL*THE CONTACT OWNS A 2004 FORD EXPEDITION. THE CONTACT STATED THAT THE RADIO LIGHT HAS BEEN ILLUMINATING INTERMITTENTLY FOR THE PAST YEAR. CURRENTLY, IT HAS TURNED COMPLETELY OFF AND THE ODOMETER LIGHT ILLUMINATES INTERMITTENTLY EVERY OTHER DAY. THE CONTACT STATED THAT DURING THE ENTIRE WINTER SEASON, WHEN SHE WOULD CLOSE THE TWO PASSENGER DOORS, THEY WOULD POP BACK OPEN. SINCE THE WEATHER HAS WARMED UP, THE DOORS ARE CLOSING AND STAYING CLOSED MORE OFTEN. SHE ALSO STATED THAT THE CHECK ENGINE LIGHT ILLUMINATES AND WAS TOLD THAT THIS WAS DUE TO THE FUEL INJECTION. THE VIN AND ENGINE SIZE WERE UNKNOWN. THE CURRENT MILEAGE IS 113,000 AND FAILURE MILEAGE WAS 70,000.
THE 2004 FORD EXPEDITION IS BUILT TOO LOW TO SAFELY TAKE OFF ROAD. BECAUSE OF ITS LACK OF CLEARANCE FORD INSTALLED SKID PLATES TO PROTECT THE EXHAUST MANIFOLD, CATALYTIC CONVERTER, ETC. THE SKID PLATES COLLECT LEAF LITTER WHICH ACCUMULATES RIGHT NEXT TO VERY HOT COMPONENTS. THIS IS A FIRE HAZARD. IT IS DIFFICULT TO KEEP THE SKID PLATES LITTER FREE BECAUSE OF THE MANY ANGLES AND TIGHT SPACES. THE LITTER DOES NOT BLOW OUT ONCE BACK ON THE HIGHWAY. AFTER A DAY OF DRIVING OFF ROAD, I NOTICED TAR-LIKE MATERIAL FROM SMOLDERING LEAF LITTER DRIPPING FROM THE SKID PLATES. I HAD TRIED SEVERAL TIMES DURING THE DAY TO KNOCK THE LITTER OUT BUT IT DID NO GOOD. IT SHOULD NOT BE NECESSARY FOR A DRIVER TO PUT THEIR FACE UNDER A VEHICLE NEAR VERY HOT COMPONENTS, ON A DAILY BASIS, IN ORDER TO MAINTAIN A SAFE VEHICLE. *LA
Complaints are unverified consumer reports submitted to NHTSA. A high complaint count may reflect vehicle popularity, not defect severity. Data sourced from NHTSA public records.
NHTSA source checks for this vehicle year
Checks are recorded separately for each dataset, not for the whole page. Dates use UTC. A missing check date does not mean no records exist.
Vehicle import recorded: May 4, 2026. This is the stored import date, not confirmation that every source was successfully refreshed.