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2004 Ford Expedition Recalls, Problems & Maintenance

The 2004 Ford Expedition has no open NHTSA recalls. Owners report 7 recurring issue clusters, led by “Spark plug ejected from cylinder head.” Ford uses the Intelligent Oil-Life Monitor (IOLM) to determine when oil changes are due based on actual driving load — not just mileage. Ford's published cap is 10,000 miles or 1 year, whichever comes first. The schedule below reflects Ford's Normal service intervals; F-Series trucks and Super Duty have additional towing-specific items.

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No open recalls on file. NHTSA lists no unrepaired safety recalls for this year, make and model. A recall can be issued at any time, and a specific car can still have one open — check yours by VIN at nhtsa.gov/recalls.

Known issues & problems for this vehicle

What drivers and federal regulators have officially reported about the 2004 Ford Expedition.

Reported to NHTSA

Spark plug ejected from cylinder head

ENGINE AND ENGINE COOLING

16 NHTSA complaints · 2009-07 → 2022-05

“SPARK PLUG BLEW OUT OF BLOCK: OUT OF NOWHERE, MY SPARK PLUG BLEW OUT OF THE BLOCK ON MY 2004 FORD EXPEDITION. MY CAR DROVE PERFECTLY FINE COMING HOME FROM WORK”
— Owner report, NHTSA ODI #10928687
“I WAS DRIVING DOWN THE INTERSTATE WHEN I HEARD A POP FROM THE ENGINE COMPARTMENT & SMELLED GAS FUMES. A SPARK PLUG (PASSENGER SIDE, 3RD PLUG BACK) HAD EJECTED AND RUINED THE COIL”
— Owner report, NHTSA ODI #10498063
“ON TWO SEPARATE OCCASIONS, WHILE DRIVING MY 2004 FORD EXPEDITION, A SPARK PLUG HAS BEEN EJECTED FROM THE ENGINE. ONE TIME, AT CITY SPEEDS, A SECOND TIME AT 65 MILES PER HOUR”
— Owner report, NHTSA ODI #10405488

Read all complaints on NHTSA →

Rust and corrosion of frame, body and brake lines

STRUCTURE

10 NHTSA complaints · 2012-09 → 2020-08

“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”
— Owner report, NHTSA ODI #11343564
“BRAKE LINE FAILURE DUE TO RUST. CARS PREVIOUSLY HAD DUAL HYDRAULIC SYSTEMS. IF ONE FAILED, THE OTHER STILL WORKED. THAT IS NO LONGER TRUE. IT'S ALL ONE HYDRAULIC SYSTEM AND IF A LEAK OCCURS, THERE IS NO SECONDARY SYSTEM; ONLY THE EMERGENCY BRAKE IS AVAILABLE TO STOP THE VEHICLE”
— Owner report, NHTSA ODI #10909590
“OBSERVED SIGNIFICANT RUST-THROUGH AND DETERIORATION OF THE BODY STRUCTURE AT THE TWO FRONT BODY TO FRAME MOUNTING POINTS”
— Owner report, NHTSA ODI #10480924

Read all complaints on NHTSA →

Tire tread separation and sidewall failure

TIRES

9 NHTSA complaints · 2007-05 → 2012-10

“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”
— Owner report, NHTSA ODI #10479805
“TREAD SEPARATION ON CONTINENTAL CONTITRAC SUV TIRES. WITH 48,000 MILES ON VEHICLE, AND ROUTINE SERVICE, TREAD IN GOOD VISUAL CONDITION. TREAD SEPARATION ON TWO DIFFERENT TIRES W/I 30 DAYS. ALL FOUR TIRES REPLACED. SOME MINOR DAMAGE TO SUV BODY. SCARED ME. *AK”
— Owner report, NHTSA ODI #10191510
“ON 10/20/07, THE SIDEWALL OF MY GOODYEAR FORTERA (RIGHT REAR) FAILED. MY WIFE LOST PRESSURE AND HAD TO AAA CHANGE THE TIRE. GOODYEAR STATED (LA QUINTA DEALER) THE TIRE WAS DAMAGE BY A UNKNOWN OBJECT. ON 10/26/07, I WAS DRIVING DRIVING WHEN THE LEFT REAR TIRE FAILED”
— Owner report, NHTSA ODI #10208744

Read all complaints on NHTSA →

Engine stalling or shutting off while driving

FUEL/PROPULSION SYSTEM

31 NHTSA complaints · 2008-02 → 2022-10

“THE VEHICLE SHUTS OFF WHILE DRIVING (AT ANY SPEED) AND OFTEN WITHOUT WARNING. IN ADDITION, THE VEHICLE MAY ALSO NOT START AT ALL THEN START WITHOUT EXPLANATION. THE MOST COMMON RECOMMENDATION IS TO REPLACE THE FUEL RELAY”
— Owner report, NHTSA ODI #11055485
“MULTIPLE AND INTERMITTENT ENGINE STOPPAGE. THE ENGINE STALLS SUDDENLY WHILE DRIVING IN TRAFFIC CAUSING HAZARD TO SELF AND OTHERS”
— Owner report, NHTSA ODI #11025020
“WAS DRIVING DOWN THE ROAD AND MY EXPEDITION JUST SHUT DOWN. ALL POWER OFF AND STEERING WHEEL LOCKED UP. WAS STUCK IN MIDDLE OF THE ROAD. HAD IT TOWED TO FORD DEALERSHIP WHO REPLACED THE MAIN FUSE. IT HAPPENED AGAIN 6 MONTHS LATER. ONCE AGAIN HAD TO HAVE IT TOWED”
— Owner report, NHTSA ODI #10493562

Read all complaints on NHTSA →

Air bags not deploying in a collision

AIR BAGS

17 NHTSA complaints · 2006-09 → 2018-08

“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 report, NHTSA ODI #11120927
“IN HEAVY LOCAL TRAFFIC WHEN TRAFFIC CAME TO A SUDDEN STOP. APPLIED BRAKES BUT WAS UNABLE TO STOP IN TIME. REAR-ENDED A DODGE RAM PICKUP TRUCK. PASSENGER SIDE AIR BAG DEPLOYED BUT DRIVER SIDE DID NOT DEPLOY. SUFFERED NECK AND BACK SOFT TISSUE INJURIES”
— Owner report, NHTSA ODI #10549783
“I HAVE A 2004 EXPEDITION EDDIE BAUER. I REAR ENDED A 7 TON DUMP TRUCK GOING 40 MILES AN HOUR WHILE HE WAS AT A DEAD STOP. MY HOOD WAS IN A V AND NONE OF THE DOORS WOULD OPEN. THE FRONT AIRBAGS DID NOT GO OFF. IT WAS A VERY SOLID HIT IN THE FRONT OF THE VEHICLE”
— Owner report, NHTSA ODI #10176257

Read all complaints on NHTSA →

Side curtain air bags deploying without impact

AIR BAGS

11 NHTSA complaints · 2008-02 → 2018-06

“TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. WHILE THE CONTACT WAS DRIVING APPROXIMATELY 30 MPH, THE SIDE CURTAIN AIR BAGS INADVERTENTLY DEPLOYED ON ALL FOUR DOORS WITHOUT IMPACT. THERE WAS NO PERSONAL INJURY. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR DIAGNOSTIC TESTING”
— Owner report, NHTSA ODI #10345386
“MY SIDE CURTAIN AIR BAGS DEPLOYED FOR NO REASON. I HAVE TAKEN THE VEHICLE TO THE DEALER AND THEY SAID THEY COULD NOT DO ANYTHING ABOUT IT BECAUSE IT IS OUT OF WARRANTY. THE 5 YEAR SAFETY RESTRAINT WARRANTY ENDED A 1 MONTH AGO”
— Owner report, NHTSA ODI #10310361
“WHILE DRIVING ON SMOOTH PAVED ROAD, POW!! SIDE CURTAIN AIRBAGS ON PASSENGER AND DRIVER SIDE DEPLOYED. I DID NOT SWERVE, HIT A POTHOLE OR ANY TYPE OF IMPACT THEY JUST POPPED OUT AND SCARED ME TO DEATH! I HAVE HAD THE VEHICLE TOWED TO LOCAL FORD DEALERSHIP WHERE CAR WAS PURCHASED”
— Owner report, NHTSA ODI #10217080

Read all complaints on NHTSA →

Brake pedal or hydraulic braking failure

SERVICE BRAKES, HYDRAULIC

8 NHTSA complaints · 2006-10 → 2014-03

“TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. THE CONTACT WAS DRIVING 40 MPH AND CHANGING GEARS WHEN HE ATTEMPTED TO APPLY THE BRAKES BUT THERE WAS NO RESPONSE. THE CONTACT WAS UNABLE TO STOP THE VEHICLE AND CRASHED INTO A PILE OF SNOW IN ORDER TO STOP THE VEHICLE”
— Owner report, NHTSA ODI #10414700
“TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. THE CONTACT WAS COMING TO A STOP AND DEPRESSED THE BRAKE PEDAL WHEN THE VEHICLE WOULD NOT STOP OR SLOW DOWN. THE CONTACT CRASHED INTO A POLE AND A GAS METER BEFORE THE VEHICLE CAUGHT ON FIRE”
— Owner report, NHTSA ODI #10402977
“ON 9/16/06 AT APPROXIMATELY. 64,500 MILES ON ODOMETER WITHOUT ANY SIMILAR PROBLEM, I STARTED CAR AT LOS ANGELES INTERNATIONAL AIRPORT PARKING LOT #3 WITH FOOT ON BRAKE. BRAKE PEDAL WENT TO ALL THE WAY THE FLOOR AS ENGINE STARTED AND ESCAPING AIR TYPE SOUND HEARD”
— Owner report, NHTSA ODI #10169675

Read all complaints on NHTSA →

Issues on other model years

Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 20, 2026. Investigation data refreshed Sep 20, 2026.

We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.

Raw data + downloads for this vehicle →

Essential maintenance

Critical for safety and preventing major damage

Engine Oil & Filter

Every 7,500 mi

Replace synthetic-blend or full-synthetic Motorcraft oil per the IOLM, or every 7,500-10,000 miles. EcoBoost engines require full synthetic; Coyote 5.0L V8 specifies SAE 5W-30.

Estimated cost — typical U.S. ranges

Dealer

~$120–$160

Shop

~$85–$115

DIY

~$25–$55

Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.

Tire Rotation

Every 10,000 mi

Rotate tires every 10,000 miles, or with every other oil change. F-150 4x4 owners should rotate every 5,000-7,500 miles to even out drivetrain bias wear.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Often free at the shop where you bought the tires — worth asking before paying.

Brake Inspection

Every 10,000 mi

Inspect brake pads, rotors, and brake fluid level every 10,000 miles. Front pads on F-150 and Explorer typically last 40,000-60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.

Brake Fluid

Every 45,000 mi

Ford specifies brake fluid replacement on an inspection basis, but moisture testing every 3 years is recommended. Replace if reading exceeds 3% water content.

Estimated cost — typical U.S. ranges

Dealer

~$180–$200

Shop

~$125–$140

DIY

~$10–$25

DOT 3 or 4 — match the cap. Vacuum bleeders make this a one-person DIY.

Important maintenance

Keeps your vehicle running smoothly and efficiently

Engine Air Filter

Every 30,000 mi

Replace the engine air filter every 30,000 miles. EcoBoost turbocharged engines are sensitive to airflow restriction — don't extend.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

5-minute job on most cars; the airbox lid usually has clips, no tools needed.

Automatic Transmission Fluid

Every 150,000 mi

Ford 6R80, 10R80, and 8F transmissions use Mercon LV fluid rated 150,000 miles under normal service. Severe service (towing, plowing) drops this to 60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$330–$500

Shop

~$235–$355

DIY

~$60–$180

Some sealed transmissions have no dipstick — fill is precise and best left to a shop. Many drivers can still DIY drain-and-fill.

Transfer Case Fluid (4WD models)

Every 60,000 mi

On 4x4 models, replace transfer case fluid every 60,000 miles. Use Motorcraft XL-12 — do not substitute generic transfer case fluid.

Estimated cost — typical U.S. ranges

Dealer

~$105–$140

Shop

~$75–$100

DIY

~$15–$40

AWD/4WD vehicles only. Easy drain-and-fill on most platforms.

Rear Differential Fluid

Every 100,000 mi

F-Series and Expedition: replace rear axle fluid every 100,000 miles, or 50,000 miles if towing. Limited-slip rear ends require friction-modifier additive.

Estimated cost — typical U.S. ranges

Dealer

~$150–$195

Shop

~$105–$135

DIY

~$20–$50

Drain plug + fill plug — straightforward DIY. AWD vehicles have two; budget for both.

Spark Plugs

Every 100,000 mi

Iridium spark plugs on Coyote 5.0L, EcoBoost 2.7L/3.5L, and 2.3L are rated 100,000 miles. EcoBoost engines: never exceed the interval — gap erosion causes coil failure.

Estimated cost — typical U.S. ranges

Dealer

~$285–$390

Shop

~$200–$275

DIY

~$25–$100

Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.

Engine Coolant

Every 50,000 mi

Motorcraft Orange (Dex-Cool compatible) coolant: first change at 100,000 miles, then every 50,000. Older trucks with Yellow Motorcraft coolant: 50,000 miles throughout.

Estimated cost — typical U.S. ranges

Dealer

~$285–$330

Shop

~$200–$235

DIY

~$25–$60

Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.

Recommended maintenance

Extends the life of your vehicle and improves comfort

Cabin Air Filter

Every 20,000 mi

Replace the cabin air filter every 20,000 miles. On F-150, located behind the glove box; on Escape and Explorer, accessed from the passenger footwell.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

Usually behind the glovebox. Shops charge labor for a 10-minute job — easy DIY win.

Fatal crash history & reported problems

Occupant deaths in fatal crashes (FARS)

352 crashes 1990–2024

How the 352 occupant deaths break down

190

driver deaths

162

passenger deaths

352

occupant deaths

Crash years covered: 1990–2024 This model year first appears in 2004 crashes. Older models have had more years on the road to appear in these crashes, so a higher count here does not by itself mean a vehicle is less safe.

FARS counts every occupant death in a fatal crash, whatever the cause — it does not mean the vehicle was at fault or defective. Counts are not adjusted for how many of each vehicle are on the road. How to read this number

FARS 2024 data is an annual report file. NHTSA revises these records when the final file is published, so this count can change.

Why we show driver deaths too

Every vehicle has exactly one driver seat, so driver deaths line up fairly when you compare one model to another. Occupant deaths include passengers, so a three row SUV can show a higher number than a two seat car simply because it carries more people.

Both figures are plain counts, not rates. A rate would need to know how many of each vehicle are on the road, and that registration data is not public, so we do not publish rates or scores of any kind.

IIHS publishes driver death rates using this same driver only idea, paired with a registered vehicle years denominator we do not have. Their rates and these counts answer different questions, so do not read either number here as a safety rating.

Owner-reported problem signals

Separate from the federal fatality data above: complaints owners filed with NHTSA about this year and model. These are reports of problems, unverified, and are counted here only as signals.

48

complaints mentioning a crash

15

complaints mentioning a fire

Reviewed known issues for this vehicle

Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.

How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.

This maintenance schedule for the 2004 Ford Expedition reflects Ford's published service intervals and the Intelligent Oil-Life Monitor system. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.

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