2004 Ford Expedition Ford Expedition 2004

We are 103,000+ car owners sharing real-world car information.

Join Us

2004 Ford Expedition repairs by problem area

Engine (23%)

Transmission and Drivetrain (19%)

Brakes and Traction Control (6%)

Suspension and Steering (18%)

Electrical and Air Conditioning (27%)

Paint, Rust, Leaks, Rattles, and Trim (6%)

Other (1%)

Chart based on 83 repairs.
See TSBs and recalls for the 2004 Ford Expedition.

2004 Ford Expedition repair cost distribution

$2500+ (1%)

$1000 - $2499 (13%)

$500 - $999 (14%)

$100 - $499 (44%)

< $100 (27%)

Worried about potential repair costs? An extended warranty can provide peace of mind.

Chart based on 77 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

2004 Ford Expedition

Engine not specified

Ford Expedition in Michigan, United States
- Feb 2010
Feb 2010

1500 mi
1) Vehicle shifted eratically between 1st and 2nd gears. Toyota dealer performed transmission computer adjustment.  2) Vehicle rough ride bottoming out rear end with minimal loads in the truck. Toyota dealer diagnosed and replaced rear spring assy. 
Ford Expedition in Michigan, United States
Mar 2012 - Apr 2012
Apr 2012

161000 mi

US $300
Battery light came on, turned out I needed an alternator. 

Return to top

2004 Ford Expedition 4dr SUV

260-horsepower 5.4L V8 4-speed automatic RWD

Ford Expedition in California, United States
Mar 2011 - Jun 2017
Apr 2011

46000 mi

US $300
Two coil packs went bad. Mechanic said root cause was using wrong type of oil (5w30 used versus 5w20 specified by Ford). Wrong oil caused excessive oil consumption, fouling spark plugs, thus causing coil packs to fail. 
Jun 2016

75000 mi

US $20
HVAC air duct valves were malfunctioning due to vacuum leaks in vacuum hoses from engine. Repairs partially resolved problem. Apparently there are additional vacuum leaks that have not been isolated. 
Ford Expedition in California, United States
Sep 2011 - Sep 2013
Oct 2011

59000 mi
When we bought the vehicle, the airbag light was on. The dealership ordered a new sensor and paid to have it installed. 
Ford Expedition in Texas, United States
May 2011 - Sep 2017
Dec 2011

84000 mi

US $1200
trucked pulled hard to right, took in for alignment, needed "special" leveler? Feels like a scam. Going to different shop next time. 
Jul 2012

89200 mi

US $78
Minor transmission fluid leak. Cracked plug/cap. 
Ford Expedition in Ontario, Canada
Nov 2015 - Jul 2016
Mar 2016

102300 mi
Backup sensors do not work so I wanted to replace one to resolve the issue. The codes for all 4 backup sensors are coming up and the mechanic is unclear on how to proceed to further diagnose the issue. 
Ford Expedition in Maryland, United States
Jan 2010 - Feb 2014
Mar 2010

155000 mi

US $270
there was an intermittent squeal ft from the left front of the vehicle. 
Sep 2010

180000 mi
Replaced right headlight. 
Dec 2011

215000 mi

US $1100
wheel bearing were shot on the right side front and rear 
Jun 2013

232000 mi

US $190
ABS light illuminated turned out to be the wheel bearing assembly. Ended up replacing brakes and rotors 
Nov 2013

241000 mi

US $993
Spark plug, threads, and ignition coil separated from the head. 

Return to top

2004 Ford Expedition 4dr SUV

260-horsepower 5.4L V8 4-speed automatic 4WD w/low range

Ford Expedition in Minnesota, United States
Mar 2014 - Mar 2014
Jan 2014

101000 mi

US $3000
Replaced Transmission due to slow Park to First gear shifting. Likely failure in clutch. I do allot of heavy Boat towing, and my truck pulls the boat up my steeper than typical driveway, so It's not too surprising this wore out. Replaced Right Front Hub Assembly. I drove on this bad hub for 60,000 miles while it made a bunch of noise. 
Ford Expedition in Michigan, United States
Dec 2014 - Dec 2015
Aug 2015

143400 mi

US $1495
WIRE BROKEN IN 4wheel DRIVE CONTROL, ANTI SLIP 
Ford Expedition in Michigan, United States
Oct 2013 - Dec 2016
Apr 2014

155500 mi

US $5
Front brake hose assembly was blocked, causing the caliper to lock up, overheating brakes and cracking the rotor. Hose assembly, pads, rotor and caliper were replaced. Rubber vacuum hose connector was rotted, causing a vacuum leak and warning light for lean fuel mixture. 
Jun 2016

200000 mi

US $50
sta sta link failed 
Aug 2016

203700 mi

US $150
alternator failed 
Ford Expedition in Iowa, United States
Jun 2013 - Jun 2013
May 2013

95000 mi

US $225
truck has a power drain but no codes replaced altinator now has code, check charging system had it checked and all reads fine. 
Ford Expedition in Georgia, United States
Oct 2015 - Dec 2015
Dec 2015

150000 mi

US $200
Actuator replacement pretty easy did both front 
Ford Expedition in New York, United States
Mar 2013 - Jun 2013
Apr 2013

109000 mi

US $260
Line to transmission cooler needed replacement due to corrosion induced leaking 
Ford Expedition in Iowa, United States
Jan 2009 - Jul 2010
Aug 2009

55300 mi

US $270
replace rear blend door motor 
Sep 2009

57994 mi

US $175
replace aux. mode door actuator motor 
Ford Expedition in Wisconsin, United States
Dec 2015 - Sep 2017
Feb 2016

132400 mi

US $45
Replaced tensioner pulley. 
Oct 2016

145700 mi
The moonroof exploded out of nowhere. Nothing hit it. Sounded like a shotgun went off. Not repaired. Too expensive. Duct taped plastic over it for the winter. 
Nov 2016

150600 mi

US $225
Replaced coil packs, spark plugs & fuel filter Alternator went bad Drivers window regulator bad 
Jan 2017

154000 mi

US $300
Front wheel bearing assembly. 
Mar 2017

167000 mi

US $50
EGR valve 
Jun 2017

169000 mi

US $100
Cam position sensor 
Ford Expedition in Pennsylvania, United States
Aug 2014 - Oct 2014
Oct 2014

135000 mi
EGR sensor valve was replaced 
Ford Expedition in Ontario, Canada
Nov 2012 - May 2013
Mar 2013

189100 mi

C $2400
Replaced upper ball-joints on both front wheels. 
May 2013

190960 mi
Replaced right outer tie rod, left rear axle, left rear pinion seal, 8 spark plugs. Tune up. Four wheel alignment. 
Ford Expedition in Michigan, United States
Apr 2010 - Jun 2015
Dec 2011

89000 mi

US $100
Replaced battery 
Apr 2012

97200 mi

US $400
Replaced brake master cyliner 
Dec 2012

116000 mi

US $225
replaced failing Ford clutch-based limited slip differential (TSB on this) with an Eaton brand helical limited slip differential replace thermostat 
Mar 2013

122000 mi

US $638
Charging System Warning came on battery was draining 
Dec 2013

139000 mi

US $275
Driver side window failed in an open state Window failed to close again. System fixed, then failed again. Symptoms include: Loud whining sound from mechanism when lowered in temperatures under 20F and wind noise from seal in upper rear corner of same driver window. Usually returns within a week. 
Aug 2014

153000 mi

US $2000
Replacement of all four wheel bearings 
Sep 2014

156000 mi

US $1800
Cracked transfer case Rear of tranmission rebuilt including transfer case switchgear 
Jun 2015

170000 mi
Failed power steering. Wheezing sound coming from the intake. ABS light on the dash. 
Ford Expedition in Texas, United States
May 2011 - Jul 2016
Oct 2015

134300 mi

US $2200
Auto would not shift from lower gears to allow vehicle to smoothly accelerate to higher speeds 
Ford Expedition in Michigan, United States
Jan 2010 - Jun 2013
Jun 2010

85000 mi

US $170
Blower only worked on "high" setting, replaced a rheostat 
Sep 2010

89000 mi

US $160
Check engine light (replaced O2 sensor) and poor performance. 
Jul 2012

100300 mi

US $160
No cool air, turned out to be blown A/C clutch fuse 
Ford Expedition in Germany
Feb 2009 - Jun 2011
Aug 2009

36580 mi

€1200
dealer found metal in transmission fluid at routine maintenance, complete transmission repair needed  
Jul 2010

52700 mi
generator replaced in September 2009 on extended warranty, now again defect, replaced on parts warranty 
Ford Expedition in Massachusetts, United States
Aug 2010 - Jun 2011
Aug 2010

84000 mi

US $250
replaced front left wheel hub  
Nov 2010

92000 mi

US $500
Replaced rear wheel bearing assembly, both sides. replaced rear brake pads and rotors. 
May 2011

95800 mi

US $20
exhaust pipe gasket failed. successfully replaced 
Ford Expedition in Rhode Island, United States
Dec 2010 - Apr 2014
Sep 2011

113000 mi

US $530
Replaced left rear wheel bearing at 113,400 miles. Right rear wheel bearing and ABS sensor was replaced at 81,000 miles 
Nov 2011

114300 mi

US $200
Had to replace coil and spark plug (113,770 miles). 
Jan 2012

114500 mi

US $198
Spark plug coil and spark plug. 
Mar 2012

116000 mi

US $795
Replaced majority of brake lines due to corrosion. Bulk of cost was for labor. 
Dec 2012

121000 mi

US $225
Heat blower would only work on "high/Max". Replaced Blower Motor Resistor. 
Feb 2014

129500 mi

US $435
Front pinion seal leak. 
Ford Expedition in Alberta, Canada
Jan 2010 - Jul 2011
Mar 2010

107260 mi

C $450
Rear axle seal replacement 
Dec 2010

117800 mi
Air bag crash sensor located in front bumper failed due to corrosion. Sensor and electrical connector replaced. Rear window wiper would not function. Disassembled the Wiper arm and shaft assembly, cleaned, lubed and re-assembled. Function checked satisfactory. 
Mar 2011

122140 mi

C $700
Front axle hub assemblies replaced due to noisy wheel bearings 
Ford Expedition in North Carolina, United States
Sep 2011 - Aug 2014
Sep 2012

81000 mi

US $900
Vacuum boost leak. While in, had serpentine belt, fuel filter, transmission filter and coolant flushed 

Return to top

2004 Ford Expedition 4dr SUV

232-horsepower 4.6L V8 4-speed automatic RWD

Ford Expedition in Texas, United States
Dec 2012 - Feb 2014
Jan 2014

131000 mi

US $95
ingition coil 
Ford Expedition in Alabama, United States
Nov 2006 - Jun 2011
Jan 2006

37500 mi
leather seats in back were repaired due to pealing of leather. 
Nov 2006

50000 mi
navigation system replaced also warranty 
Dec 2006

51000 mi
leather seats replaced again in the back due to pealing of leather Very poor quality leather (warranty) 
Ford Expedition in North Carolina, United States
Feb 2018 - Jul 2023
Jul 2018

1545000 mi

US $84
Replaced the IAC Valve. 

Return to top

2004 Ford Expedition 4dr SUV

232-horsepower 4.6L V8 4-speed automatic 4WD w/low range

Ford Expedition in New Jersey, United States
Aug 2011 - May 2015
Oct 2011

140000 mi

US $100
Steering rack failed 
Feb 2012

142500 mi

US $780
Front wheel bearing 
Apr 2013

149000 mi

US $500
Rust over the rear wheel 
Jul 2013

149200 mi

US $270
system needed recharge and repair to compressor electrical connection 
Dec 2013

151000 mi

US $1246
Cooling lines wore against mounting clicks causing 2 leaks. The design of the connectors to the rad were rusted and no way to take apart requiring a rad replacement as well. 
Ford Expedition in Tennessee, United States
Jan 2014 - Feb 2015
Feb 2015

214000 mi

US $280
Oil leak. Oil filter adapter gasket replaced 
Ford Expedition in Florida, United States
Oct 2013 - Jun 2022
Feb 2014

131000 mi

US $275
Replaced oil filter hosing gasket 

Return to top

See TrueDelta's information for all SUVs
See TrueDelta's information for all Ford models.

2004 Ford Expedition Repair Histories

See our lemon odds and nada odds page to see vehicles with no repairs or vehicles with more than three repairs. To see how frequently 2004 Ford Expedition problems occur, check out our car reliability stats.