1.6
hardly worth mentioning- Crashes / Fires:
- 0 / 0
- Injuries / Deaths:
- 0 / 0
- Average Mileage:
- 107,874 miles
About These NHTSA Complaints:
The NHTSA is the US gov't agency tasked with vehicle safety. Complaints can be spread across multiple & redundant categories, & are not organized by problem. See the Back button — blue bar at the very top of the page — to explore more.
The gas gauge never works and sometimes the vehicle thinks that it doesnt have gas when it does.
- Lakewood, CO, USA
The contact owns a 2004 Ford Expedition. While driving various speeds, the vehicle suddenly stalled and shut off. Later, after restarting the engine, the vehicle operated normally. The vehicle was taken to an independent mechanic who diagnosed that the fuel pump relay circuit board had malfunctioned and burnt out. The circuit board was replaced and the failure was remedied. An unknown local dealer was contacted. The manufacturer was not contacted. The failure mileage was 180,000.
- Mesquite, TX, USA
While driving a 2004 Ford Expedition 178,000 kept stalling on the highway and streets. I had it towed several times because it won't start back on the next day it would turn on. Had the fuel pump replaced and still having the same problems it turn off on my 18 year old son like 5 times going to school and work where it almost got to the point where we felt it wasn't a reliable due the fact it stalls while on the road or even just turning and almost caused my sons life. Finally we found out it's the relay gets hot and it causes for the car to stop and I'm aware that Ford knows about this very frustrating and disappointing they have not done a recall on this the relay can not be change by its self has to be the whole circuit board
- Mesquite, TX, USA
The contact owns a 2004 Ford Expedition. While driving 60 mph, the vehicle stalled without warning. The contact was able to restart the vehicle after waiting several minutes. The vehicle was taken to cowles parkway Ford (located at 13779 noblewood plaza, woodbridge, va 22193, (703) 986-5500) where it was diagnosed that the fuel pump needed to be replaced. The vehicle was repaired, but the failure recurred a day later. After further research, the contact became aware that the fuel pump relay needed to be replaced. The vehicle was not repaired. The manufacturer was contacted. The approximate failure mileage was 188,000.
- Alexandria, VA, USA
The vehicle shuts off while driving (at any speed) and often without warning. In addition, the vehicle may also not start at all then start without explanation. The most common recommendation is to replace the fuel relay. To do so, you must replace the smart junction box/fuel relay panel. This appears to be a common problem with numerous mentions and is often difficult to diagnose and commonly becomes a process of elimination. The biggest concern is the safety issue and odds of accident or fatality. Diagnoses typically requires complete failure because the symptoms can rarely be duplicated. This has happened frequently with complete failure happening. Hardwiring the fuel pump rules that out. Fuel relay is found to be hot to the touch.
- Virginia Beach, VA, USA
NHTSA id #10017888/10018745/10023943/10004051/10010731/10012977/#10014086/10018069/10014100/10028736
- Upland, CA, USA
Multiple and intermittent engine stoppage. The engine stalls suddenly while driving in traffic causing hazard to self and others. Sudden loss of power steering makes control of vehicle difficult as power steering is non functional as you attempt to pull to the side of a busy road. Braking systems also are mostly non functional without the vacuum created by the running engine making it very difficult to stop quickly. This presents a dire emergency condition for the surprised driver, and a hazard to other occupants as well as other drivers nearby. A driver who is small in stature may be unable to man-handle the stiff steering condition. Once stopped, the engine may restart right away or not, stranding occupants in unsafe conditions and cause an accident chain involving life and death. Fuel pump relay failure is the cause and very common, (100S of thousands of posts online about this problem). This problem affects these Expedition vehicles in a widespread fashion similar to the lcm safety issue with another Ford product, the Crown Victoria. (a recall was ordered on this issue for some of the model years) this has happened to me 8 times in 3 weeks since owning this 2004 vehicle. It is currently at the Ford dealer who state they may need to keep the vehicle for up to 3 weeks to observe the failure mode. (it is intermittent)
- Temecula, CA, USA
The contact owns a 2004 Ford Expedition. The contact stated that the vehicle randomly stalled at any rate of speed. The vehicle was able to restart. Two dealers (downtown Ford, 1-866-899-7296) and (future Ford of sacramento, 916-547-2285) were unable to replicate and diagnose the failure. The vehicle was not included in NHTSA action number: DP5005 (engine and engine cooling). There were nine tsbs for engine and engine cooling, two tsbs for the fuel system, and thirteen tsbs for the electrical system. Neither dealer provided diagnostic testing. The manufacturer was notified of the failure. The failure mileage was not available.
- Pinegrove, CA, USA
When driving home from seattle wa. To walla walla wa. At a speed of 70 mph the vehicle died and I had to get off the road, it then restarted and did it to me 3 more times. When I took it to the shop the mechanic stated that it was in the fuse box. He had just did a replacement on the same type vehicle that had caught fire. It is the fuel relay in the fuse box that malfunctions and catches fire. I feel this is a safety issue.
- Walla Walla, WA, USA
My vehicle, without any warning at any speed, including highway speeds, shuts off completely, without any warning or indication that it is about to do this. Always on a straight road with almost a full tank of gas. The cause a relay switch which is soldiered into the memory board that controls the vehicle's brain box that shorts out. After doing research on the internet, I am both shocked and disgusted that the nhsta has not investigated this faulty design by Ford and made them recall all of the 2003- 2008 Expedition. You only have to pull it up on you-tube or google to see the 1000's upon 1000S of complaints from Expedition owners concerning this constant and dangerous problem, which clearly endangers every Expedition owner and their family. The worst part of this, the Ford dealerships want you to spend $1000 of dollars needlessly to try and diagnose this same, old problem, before they finally deal with replacing the entire fuse block panel, just for the relay switch, which is the cause, the shorting out relay switch. The internet shows again and again, that this problem is so rampant, that it isn't if it happens, but when, because it was a faulty and defective design, which endangers all Expedition owners made these years. The faulty fuse block's fuel pump relay switch burns out and between that and the thin wires grounding out under the hood, drivers, unsuspectingly are left in panic modes on the highway, scrambling to get out of harms way, as a result of your vehicle turning off at all speeds, ie, 70 mph. Imagine a semi is behind you and you don't have the safe means of escaping the dangerous predicament you are now left in to get over to the side of the road? a recall is needed asap before too many people are needlessly killed as a result. Expedition's are family vehicle's and usually have lots of children in them! this is too dangerous to keep overlooking.
- Boiling Springs, SC, USA
Also like many other complaints I have seen, the 2004 Ford Expedition I have has shut off on me several times while driving and I was told to switch out the entire fuse box. I called the dealer and they said to replace it, it would be about $500 for it. It's ridiculous Ford hasn't issued a recall because this seems like a problem many people are having as well. We have almost gotten into a couple of accidents because of this issue! we can't keep having to rely on one less vehicle, but what other alternative do we have if it's going to cost us, the consumer, a lot of money to replace for something the manufacturer should be responsible for.
- Las Vegas, NV, USA
While driving in the city on local streets, the engine just stops with no ability to drive. I am an instant safety problem on the road. This happened 3 times in one day. Fortunately, no one was injured. After a few minutes, the car starts up again. My mechanic can't duplicate the problem. Anyone help before there is a major life-threatening accident!! thanks!
- Lake Forest, CA, USA
Our 2004 Ford Expedition eddie bauer suddenly turns off while we are driving at any speed. In a year's time, it has turned off four or more times. Most of those times, we were traveling at speeds of about 60mph. All of the power shuts off, steering and brakes included. We turn the key off and it does restart. Luckily we have not been in any terrible accidents!
- Castaic, CA, USA
The contact owns a 2004 Ford Expedition. While driving at various speeds, the vehicle stalled without warning. The vehicle was restarted and taken to a dealer and an independent mechanic; however, the cause of the failure was unable to be determined. The contact mentioned that the alternator, battery, transmission, fuel pump, and fuel bypass switch were replaced; however, the failure recurred. The manufacturer was notified of the failure. The failure mileage was 126,000.
- Valley Grove, WV, USA
The vehicle has been shutting down randomly (highway, streets, stops, etc) and it is very much a safety situation at high speed on the freeway since the steering wheel locks up and brakes do not work. I've taken it to two different places for diagnosis including the local Ford dealership and they have not been able to diagnose the problem. It is understood the vehicle is 10-11 years old but the inability for the dealership to diagnose the problem is really frustrating. From reading complaints, there are others that sound similar and appears to be associated with the vehicle's fuse relay box.
- Elk Grove, CA, USA
4 separate times my 2004 Expedition has died while running down the road, one time it died in a very dangerous spot (blind S-curve with no shoulder). It always seems to restart after it has cooled down after a while. This last time we tried multiple things to get it running because it was stuck at a busy intersection and it was over 100 degrees outside, but nothing we did helped. I ended up getting it towed to a shop who told us it needed a new fuel pump ($1100). We decided to take it home, and thank goodness we did. After charging the battery it started right up. We have research this problem and it seems to happen to many Expedition and Ford pickups. It looks like this has caused many people a lot of money and has left them stranded many times. From our research it is probably the fuel pump relay (R303) or the fuel pump driver module (if it has one). Unfortunately our exp. Has the relay instead of the module making it harder to replace. I would like to know why their hasn't been a recall on the relay or module!!! I am very thankful my children weren't with me when I was left stranded with the temp above 100 degrees out. Something needs to get done before someone gets hurt!
- Colton, WA, USA
Was driving my SUV and was coming close to my turn off let off the gas and my vehicle cut off had to steer to side of the road. Had fuel pump replaced was driving the next day after pump was replaced stopped still and the vehicle started shaking and cut off. It started up about ten minutes later. The next time was riding down the road going 55 and my SUV just shut down I veered it to the side of the road was able to start it tried to head home vehicle shut down a good 5 miles and was able to start again after waiting this happened again 4 more times in the same nite before my vehicle didn't start anymore that was March 31,2014 it left me stranded on the side of the road with my three children. Eleven days later my vehicle is still not starting and diagnostic test is not showing anything wrong!
- Raeford, NC, USA
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.
- Pass Christian , MS, USA
- Denton, TX, USA