2004 Ford Expedition structure problems
24 owner complaints filed with NHTSA name the structure on the 2004 Ford Expedition — 8% of all complaints for this model year.
What owners report
“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…”
filed Nov 21, 2022
“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.”
filed Aug 5, 2020
Verbatim excerpts from complaints filed with NHTSA. Reports are not independently verified.
Related service bulletins
For 2000-2024 Ford and Lincoln vehicles, swapping a module from a vehicle for diagnosis purposes is likely to cause errors and is not recommended. It is also not recommended to order a replacement module using a vehicle…
SSM 51536 · Service Bulletin/Repair Instructions · issued Apr 4, 2023This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled…
TSB 20-2233 · Service Bulletin/Repair Instructions · issued Jul 13, 2020Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel…
TSB 19-2026 · Service Bulletin/Repair Instructions · issued Feb 7, 2019Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel…
TSB 19-2026 · Service Bulletin/Repair Instructions · issued Feb 7, 2019
Structure problems in other Expedition years
| Year | Reports | Share |
|---|---|---|
| 2025 Expedition | 2 | 7% |
| 2024 Expedition | 4 | 6% |
| 2023 Expedition | 4 | 6% |
| 2022 Expedition | 12 | 11% |
| 2021 Expedition | 10 | 4% |
| 2020 Expedition | 16 | 4% |
| 2019 Expedition | 10 | 2% |
| 2018 Expedition | 13 | 4% |
| 2017 Expedition | 6 | 2% |
| 2016 Expedition | 3 | 1% |
| 2015 Expedition | 8 | 5% |
| 2014 Expedition | 6 | 8% |
Other reported problem areas on the 2004 Ford Expedition
Counts are unique NHTSA complaints naming this component group. Complaints are unverified owner reports; mileage is computed only from complaints that included a usable odometer reading.