Eight problems related to body have been reported for the 2004 Ford Expedition. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2004 Ford Expedition based on all problems reported for the 2004 Expedition.
Rusted out rocker panels, brake lines, front end radiator mounts, fender mounts. The entire under carriage is rusting away. We have had to replace all the brake lines as they have rusted away, redid the rocker panels rust away. Now we have to replace the entire front end because of rust. Will not pass PA state inspection due to rust. Is the Expedition in the recall for rust?.
Frame was broken and rigged and painted unsafe and I am concerned when he puts my kids in the car it is not safe.
My truck has started making a very loud noise coming from the front under side of the vehicle. Upon further investigation we have discovered that there was excessive rust and corrosion on the frame. This has caused parts of the engine to shift and rub/ collide with other parts and cause the noises. Our mechanic and my husband both feel that the rust and corrosion have made the vehicle unsafe to drive. There is no way to tell when any part of the engine/vehicle could break free, possibly causing more damage and or an accident while driving. Our vehicle is very well maintained and the amount of rust and corrosion is excessive for the year and mileage on the vehicle. The lack of ability to tell when or where the framework may give out makes it unsafe in our opinion to drive. Especially with children in the vehicle most of the time. The corrosion is also so excessive we believe it is not repairable by any body shop. My frustration with this is that we had not planned on getting a new vehicle and were planning on driving it for quite awhile longer. Other then the rust and corrosion the vehicle is in fairly good condition. . I believe that the rust and corrosion sounds very similar to that described on the windstars and should be investigated along with the windstars problems. Finally there is also excessive bubbling of the paint in various locations of the vehicle.
Observed significant rust-through and deterioration of the body structure at the two front body to frame mounting points. Metal structure supporting the air conditioning condenser coil has completely disintegrated and the coil has dropped approximately 1" from its designed position. Metal structure suppporting the radiator is almost completely disintegrated. Surrounding metal supporting the body to frame sown significant deterioration and rust-through. Concerned with saftey and structural integrity of the body to frame connection and support of components.
The contact owns a 2004 Ford Expedition. While driving in rainy weather conditions approximately 30 mph, the interior dome light began leaking a small amount of water. The vehicle was taken to an authorized dealer and they recommended the vehicle be taken to an auto collision center for inspection. The vehicle was taken to an auto collision center and the technician stated the roof of the vehicle would need to be replaced and also informed the contact that eventually, the water leakage would result in electrical issues. The manufacturer was made aware of the problem. The approximate failure mileage was 67,000.
Bubbling paint on rear tail gate. Clearly a paint preparation issue, otherwise paint on the rest of the car is near perfect.
The contact owns a 2004 Ford Expedition. The paint near the front hood, the rear lift gate, the door latch and the wind-shield wiper has corroded. The vehicle has not been inspected or repaired for the failure. The failure mileage was 90,000. The current mileage was 93,000. Updated 11/12/09 the consumer stated the vehicle has never been in an accident. The vehicle is stored in a garage overnight. Updated 11/17/09.
Roof canel rust, had repaired it 4 times since 2007. Ford is unwilling to take ownership of the defect and with each repair, the roof is weaker. Spoke to two dealerships and this defect keeps them in business since this is all they do.