2004 Ford Expedition.
The 2004 Ford Expedition is better than average by owner complaints: 113 complaints in its first 3 years and a Lemon Index of 79, where 100 is the average car. Owners complain most about brakes, it has 4 recalls, and it gets 13 to 15 mpg combined. The best Ford Expedition year is 2014.

Before you buy. What matters most for this car.
How serious. Out of 297 owner complaints, owners reported:
Older model year: fewer owners filed complaints back then, so treat the score as rough.
Every Ford Expedition year. 2004 is highlighted. Lower is better.
What owners complain about most. From owner complaints to the government.
Share of this year's owner complaints filed with NHTSA, not the share of cars that break. One complaint can name more than one area.
When owners reported problems. From owner complaints to the government.
Most owners who filed a complaint with NHTSA had 26K to 119K miles on the car (227 complaints listed the miles). This shows when people who had a problem reported it, not the odds that your car will have it.
- airbags complaints mostly came at 28K–137K miles
- electrical complaints mostly came at 55K–149K miles
- brakes complaints mostly came at 6K–37K miles
Recalls 4
- lights 2009
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.
- lights 2006
CERTAIN TRADESONIC COMBINATION LAMPS SOLD AS REPLACEMENT LAMPS FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES.
- lights 2006
CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE.
Show all 4 recalls
- lights 2006
CERTAIN ANZO COMBINATION HEADLAMP ASSEMBLIES SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES.
Recall repairs are free at any dealer. A recall only matters if it's still open on that exact car, so check its VIN.
Problems Ford told dealers about
Ford sent dealers 91 repair notes for this car. The ones about its biggest problems:
- Warning light/message
- Chatter, shudder, a binding sensation, or vibration during low speed turns on vehicles…
- Moaning noise from the exhaust system, or vibration in the rear passenger floor pan, when…
Ask a seller or mechanic if these were done. Some are free under warranty or a special program.
Government investigations
- ClosedSteel wheel fracture2008–2009
- ClosedSpark plug ejection from cylinder head2005–2006
NHTSA looks into a problem when enough owners report it. Many end in a recall.
Safety
Crash stars (older test): front ★★★★★ · side — · rollover —

Fuel cost and engines
About $4300–4950 a year in fuel (EPA estimate). Engines: 4.6L 8-cyl, 5.4L 8-cyl.
In owners' words
Excessive black dust from brakes of new 2004 Ford Expedition.
2004 Ford Expedition owner · NHTSA complaint 10104353
More owner reports
1) front end shimmies when brakes are applied. 2) creates a potentially unsafe driving condition, especially in snow or rain. 3) replaced brakes, replaced rotors, had rotors turned...still an issue.
NHTSA complaint 10156061
Huge amount of brake dust on front wheels happening in normal driving conditions .
NHTSA complaint 10056386
Quick answers
Is the 2004 Ford Expedition reliable?
Yes, better than average by government complaints. It drew 1.3× fewer complaints than average filed with NHTSA in its first 3 years, per car sold (Lemon Index 79; 100 is average, lower is better). The best Ford Expedition year by this measure is 2014.
What are the most common 2004 Ford Expedition problems?
In owner complaints to the government, the parts named most are brakes (25%), tires (15%) and airbags (14%). That is the share of complaints, not the share of cars that break.
How many recalls does the 2004 Ford Expedition have?
4 safety recalls (latest: lights). Recall repairs are free at any dealer; check a specific car's VIN at nhtsa.gov/recalls.
What gas mileage does the 2004 Ford Expedition get?
13 to 15 mpg combined, depending on the engine (EPA estimate).
At what mileage do 2004 Ford Expedition problems start?
Half of the owners who gave a mileage reported the problem between 26,000 and 119,700 miles. The middle report was at 76,000 miles, from 227 complaints.
Does the 2004 Ford Expedition have transmission problems?
Transmission and drivetrain issues make up 12% of its owner complaints.
How much does the 2004 Ford Expedition cost in fuel a year?
About $4300 to $4950 a year, by the EPA's current estimate.
What engines does the 2004 Ford Expedition have?
4.6L 8-cyl, 5.4L 8-cyl.
What Ford Expedition year is better than the 2004?
By owner complaints per car sold, the best recent years are 2014, 2012 and 2013.
Lemon Index = safety complaints filed with the U.S. government (NHTSA) in a car's first 3 years, per car sold, against the average car of the same model year. 100 is average; lower is better. A complaint is an owner's report, not a confirmed defect. How it works