2004 Ford Expedition electrical problems

Filed Mar 6, 2025 · Electrical, Lights · MD

The contact owns a 2004 Ford Expedition. The contact stated that the turn signals, the hazard lights, and the cigarette lighter had become inoperable. The TPMS warning light was illuminated. The dealer and the manufacturer were not notified of the failure. The vehicle was not diagnosed or repaired. The failure mileage was unknown.

Filed Jan 25, 2022 · Electrical · AK · fire

Electrical fire today. Vehicle was parked outside garage. A clicking noise was heard and noticed the mirror was trying to move/click and car was filled with smoke. Mirror switches didn't work when tried. Knocked mirror off and fire stopped. Wiring Harness around the emergency brake area melted. Fire melted a hole in the dash corner by windshield. Vehicle was last driven about 25 hrs. earlier with no issues. Approx. 128K miles. Glad it wasn't in garage and the clicking was heard or garage/house would have burned. We haven't done anything to it yet.

Filed Dec 2, 2020 · Electrical, Engine · 158,612 miles · TX

Vehicle lost power for 3-5 seconds at highway speeds approximately 65 MPH on three separate events. Vehicle slowed down due to power loss while in heavy traffic. Three other times at idle speed in drive and in park engine stalled and immediately restarted. Loss of power steering due to engine not running when stall event happened. I performed inspection of fuel pump relay which is internal to passenger side fuse block. Found inadequate solder joint on integrated relay printed circuit and burn marks on outside of fuel pump relay. Located salvage fuse block same make and model and inspected. Same damage on salvage fuse block assembly. Replaced with aftermarket fuse block with revised solder joint and updated relay.

Filed Jun 9, 2020 · Electrical, Fuel system · CO

The gas gauge never works and sometimes the vehicle thinks that it doesnt have gas when it does.

Filed Sep 10, 2019 · Electrical, Fuel system · TX

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

Filed Aug 1, 2018 · Electrical · 187,000 miles · SC

Tl* the contact owns a 2004 ford expedition. While driving various speeds, the vehicle stalled without warning. The contact stated that the vehicle would restart erratically. The vehicle was taken to an independent mechanic where the contact was informed that the fuse box needed to be replaced. The vehicle was repaired, but the failure recurred multiple times. The manufacturer was not made aware of the failure. The failure mileage was 187,000. The VIN was not available.

Filed Sep 21, 2017 · Electrical, Engine · CA

Tl* 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 the federal safety agency 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.

Filed Jul 20, 2017 · Electrical, Fuel system · 124,000 miles · WA

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.

Filed Jul 2, 2017 · Acceleration, Electrical · 190,000 miles · SC

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 expeditions. 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.

Filed Jun 22, 2017 · Electrical, Engine · 82,000 miles · NV

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.