2004 Ford Expedition: water leaks into the cabin

Filed Jun 4, 2015 · Electrical · 100,000 miles · NJ

I am the 2nd owner of this vehicle. Had problem w/ drivers seat & mirror fuse blowing out since I purchased truck in august 2011. Some time in 2012 I started having additional problems w/ my truck like radio &/or heating/air not coming on when started. Check engine light going on & off & back windshield wiper stopped working. Then it was the vehicle was dying quickly by leaving the radio on for 10 min after vehicle was turned off. We replaced the battery & terminals that connect at the positive & negative. We had plenty of other issues like the entire brake lines needing replacing due to rusting. There is now rusting on other parts of the truck. Blew fuse to air conditioner 2x. Things seem to be ok after battery was replaced until the truck shut off several times while driving it over the past year. Sometimes if you waited 5-10 minutes it would restart. Vehicle has been in shop & nothing comes back on diagnostic test. We have had the alternator & fuel pump tested. The cables to the battery were just found rotted & replaced but something is still killing my battery. The fuse box has been making loud click noises when the truck struggles to start. Today it wouldn't start again until jumped & now the radio wouldn't go on. At the shop again & the mechanic is stumped but working on it! From research it seems to be either a fuel pump relay that is apparently sodder into the fuse box & almost impossible to replace w/ replacing the whole box or it is the fuse box itself. I am also seeing claims of water leaking down windshield & getting into fuse box. All I know is ford should acknowledge & recall before someone gets killed! My children were in the car several times now when it staled while I was driving or stuck in parking lot & even a severe thunderstorm when it won't start. And now I'm reading the fuse box has caught fire in some of these cars! I rely on this vehicle!

Filed Sep 23, 2011 · Body · 67,000 miles · FL

Tl* 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.

Filed May 19, 2010 · Body, Electrical · NC

Tl*the contact owns a 2004 ford expedition. The contact turned the engine off and exited the vehicle. Suddenly, a fan blowing noise came from underneath the hood area and the interior lights blinked continuously. The engine was restarted and turned off. However, the failure continued to occur. When the battery cable was disconnected the failures stopped. The failures occurred under rainy conditions on several separate occasions. The vehicle was taken to an authorized dealer for inspection. The technician stated the failure was contributed to water leaking into the smart junction box apart of the electrical system. The contact scheduled an appointment for diagnostic testing. The vehicle had not been repaired at the time of the complaint. The failure mileage was unknown. Updated 7/16/10 *cn the consumer stated the failure has been corrected, even though she had to pay out of pocket. Updated 07/22/10

Filed Jan 3, 2009 · Visibility · 80,000 miles · TX

The seal around the windshield is coming lose presenting a potential fire hazard to the electrical components within the vehicle due to water leaking through the lose seal.

Filed Jun 26, 2008 · Electrical · 56,000 miles · AZ

I have had problems with my 2004 ford expedition with the electrical system. It seems any time it rains or I wash the car there is some kind of electrical short that shuts it down. I've heard there is a problem in the windshield that water leaks to the electrical box causing problems. I am having the same problems, but what worries me is that I smell something burning. I am concerned that this problem my eventually cause a fire while driving.

Filed Nov 15, 2004 · Seats · NJ

Vehice had water in the back seat. There was water leaking from the top of the ceiling down to the seat. This was dangerous considering that the dvd player was near where the water was leaking.