Two problems related to underbody shield 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.
Was driving when brakes went completely out when I went to stop at a stop sign. . Cause due to rust corrosion . Brakes giving out could have caused a fatal car accident . Rust has damaged all brake lines and fuel lines . Rust is now moving up the vehicle. Brake lines and fuel lines should have a protected coating or made with a non corrosion metal. I had no idea that my brake line was rusted out till my brakes gave out. These vehicle need to be recalled and have new lines. Also have a protected coating applied under the vehicle to stop rust. Very very dangerous driving around not knowing that you have rust under your vehicle eating away at your brake lines and fuel lines.
The 2004 Ford Expedition is built too low to safely take off road. Because of its lack of clearance Ford installed skid plates to protect the exhaust manifold, catalytic converter, etc. The skid plates collect leaf litter which accumulates right next to very hot components. This is a fire hazard. It is difficult to keep the skid plates litter free because of the many angles and tight spaces. The litter does not blow out once back on the highway. After a day of driving off road, I noticed tar-like material from smoldering leaf litter dripping from the skid plates. I had tried several times during the day to knock the litter out but it did no good. It should not be necessary for a driver to put their face under a vehicle near very hot components, on a daily basis, in order to maintain a safe vehicle.