What are common problems with the 2004 Ford Expedition?
The most frequently reported issues for the 2004 Expedition involve the transmission, engine performance (including ignition-related misfires), electrical system faults, and wear in brakes and suspension components. Reliability varies with maintenance history and how the vehicle was driven, but these categories appear most often in owner reports and service data.
This article outlines the main trouble areas gathered from owner forums, repair bulletins and common maintenance experiences. It explains what to watch for, how these problems typically present themselves, and general steps to address them.
Powertrain and drivetrain
The powertrain section covers issues that affect how the vehicle moves, shifts and performs under load. The most commonly reported concerns center on the transmission and related components, as well as ignition and engine performance.
- Transmission slipping, harsh or delayed shifts, and overall unreliable shifting, particularly in the heavy-duty 4R100/4R70W family used in many Expeditions of this era.
- Delayed engagement when shifting from Park/Neutral to Drive, or sudden hard shifts that feel approximate to clunking.
- Transmission fluid leaks from the pan, cooler lines, or valve body gasket, which can lead to low fluid levels and overheating if not addressed.
- Torque converter issues, including overheating or failure signs like slipping and shuddering during acceleration.
- Engine misfires or rough running tied to ignition system components such as coil packs and spark plugs; some 5.4L/4.6L engines may experience plug-thread wear or ignition coil failures over time.
Regular transmission maintenance—fluid and filter changes at recommended intervals, careful monitoring of shifting behavior, and addressing leaks early—can help mitigate many of these problems. If transmission symptoms appear, a professional diagnosis is advised before further driving.
Electrical and interior systems
Electrical faults can trigger warning lights, affect comfort features or impair starting and running. This section covers the kinds of electrical and sensor issues that owners commonly report.
- ABS/traction control warning lights coming on due to aging wheel speed sensors or related wiring.
- Instrument cluster intermittent or persistent gauge and indicator failures, which can obscure important information about engine temperature, fuel level, and RPM.
- Power window regulators and door lock actuators that fail or become slow, particularly on older models.
- Headlight switches, central power distribution or BCM/PCM communication faults that can cause intermittent accessory failures or no-start conditions.
- HVAC control and blend door issues resulting in inconsistent cabin temperature or airflow.
Electrical problems often stem from aging wiring, corroded connectors, or worn relays. Routine inspections of harnesses, connectors and fuses, plus targeted repairs, can reduce the impact of these issues.
Brakes, steering and suspension
Brake and suspension wear is common on high-mileage Expeditions, especially given the heavy use these vehicles see. This section highlights the kinds of symptoms owners report.
- Brake rotor warp or pulsation causing a shaking sensation during stopping, usually accompanied by audible vibration.
- Worn brake components or leaks in calipers and lines that reduce braking efficiency or cause uneven braking.
- Front-end wear such as worn ball joints or tie rod ends, leading to loose steering feel or alignment changes.
- Power steering system concerns, including pump noise, fluid leaks, or stiff steering in older models.
- Suspension component wear, including bushings or related hardware, which can produce clunks, creaks or a rougher ride.
Good maintenance of braking systems and front-end components is essential. If you notice decreased braking performance, pulling to one side, or unusual steering behavior, have a technician inspect the brakes and suspension promptly.
Cooling, fuel delivery and emissions
Cooling and fuel systems can develop leaks or performance issues that affect engine temperature and reliability. Emissions-related problems are less common but can arise as the vehicle ages.
- Radiator, heater core or coolant reservoir leaks, which can lead to coolant loss and overheating if not repaired.
- Water pump or thermostat failure that causes overheating or fluctuating engine temperature readings.
- Fuel pump or fuel pressure regulator failures resulting in hard starting, stalling, or rough running under load.
- EGR valve sticking or vacuum/PCV system issues that may cause rough idle or reduced performance and increased emissions.
Addressing cooling system leaks promptly and ensuring fuel delivery components are functioning correctly can prevent overheating and related damage. Regular coolant changes and fuel system maintenance are prudent for this generation of Expedition.
Summary
The 2004 Ford Expedition is a sturdy large SUV, but it shares some measurable reliability concerns with high-mileage, heavy-use trucks from the era. Transmission behavior and longevity are among the top concerns, followed by ignition/electrical reliability and wear in brakes, steering and suspension. Proactive maintenance—especially around the transmission, cooling system, electrical connections, and front-end components—can help reduce the likelihood of major failures. If you own or are considering a used 2004 Expedition, a thorough pre-purchase inspection and a documented maintenance history are valuable tools for estimating long-term reliability.
