One problem related to structure has been reported for the 2004 Ford Explorer Sport. The most recently reported issues are listed below.
I own a 2004 Ford Explorer Sport. The glass hatch has become increasingly hard to close in the last couple of months, because of this at times the hatch is not completely latched and will pop open unexpectedly. This past Saturday, 05/02/09, the glass hatch hinge completely broke off when I went to close it. My frustration is that I am willing to pay for problems through normal wear and tear and of course through my own error, but this is manufacturing defect.