One problem related to brake disc caliper has 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.
On 6/22, the right wheel bearing assembly failed while traveling ~20 mph. As a result, a fire occurred. I put the fire out in our driveway at home with a water hose. Significant damage occurred to the right wheel assembly, bearing housing, 1/e axle, rotor, caliper, brake pads, emergency brake, etc. . . Luckily, were close to home and were not traveling 70 mph. No other vehicles were involved and there were no injuries as my wife and I were able to get all of our children out of the Expedition safely. Our Expedition is a 2004.