2004 Ford Explorer Sport Trac Problems & Issues
2004 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated October 2026
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Ford Explorer Sport Trac has 1 documented issue, with 1 rated critical. The most serious is Frame Rust ($200-$2,000 repair). Across all issues with published estimates, repair costs range from $200 to $2,000. DIY maintenance guides at au7o.io.
2004 · All trims · All engines
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All 1 Known Issue
NHTSA Recalls7 recalls
EXTERIOR LIGHTING
CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
VEHICLE SPEED CONTROL
ON CERTAIN PICKUP TRUCKS, PASSENGER VEHICLES, SPORT UTILITY VEHICLES, AND MOTOR HOMES CHASSIS, THE SPEED CONTROL DEACTIVATION SWITCH MAY, UNDER CERTAIN CONDITIONS, LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
SEATS:FRONT ASSEMBLY:RECLINER
ON CERTAIN SPORT UTILITY VEHICLES EQUIPPED WITH HIGH BACK SEATS, THE UPPER BOLT ON THE DRIVER'S SIDE HIGH BACK SEAT, THAT ATTACHES THE SEAT RECLINER MECHANISM TO THE SEAT BACK FRAME, COULD FRACTURE. IF THE BOLT FRACTURES AND DOES NOT JAM IN THE SEAT BACK FRAME, THE SEAT BACK MAY RECLINE UNTIL IT MAKES CONTACT WITH AN OBJECT BEHIND THE SEAT, SUCH AS THE SECOND ROW SEAT CUSHION.
TIRES:TREAD/BELT
THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. EQUIPMENT DESCRIPTION: FORD IS REPLACING ALL FIRESTONE WILDERNESS AT 15, 16, AND 17 INCH TIRES MOUNTED ON FORD TRUCKS AND SUVS. FORD REPORTS TREAD SEPARATION CAN OCCUR DUE TO A COMBINATION OF THE SENSITIVITY OF THE TIRE DESIGN TO STRESS, AGING, AND MANUFACTURING DIFFERENCES BETWEEN PLANTS. FORD IS REPLACING THESE TIRES TO PREVENT POSSIBLE PREMATURE TIRE FAILURE. VEHICLE DESCRIPTION: THE VEHICLES LISTED BELOW MAY HAVE BEEN ORIGINALLY EQUIPPED WITH FIRESTONE WILDERNESS AT TIRES OR MAY HAVE HAD WILDERNESS AT TIRES INSTALLED DURING THE FIRESTONE RECALL LAUNCHED IN AUGUST 2000. CERTAIN 1991 THROUGHT 2002 FORD EXPLORER CERTAIN 2001 THROUGHT 2002 EXPLORER SPORT, AND SPORT TRAC CERTAIN 1997 THROUGH 2002 MERCURY MOUNTAINEER CERTAIN 1991 THROUGH 2001 RANGER CERTAIN 1999 THROUGH 2001 EXPEDITION CERTAIN 1991 THROUGH 1994, AND 1997 MODEL YEAR F-SERIES CERTAIN 1991 THROUGH 1994 BRONCO NOTE: BOTH ORIGINAL EQUIPMENT AND REPLACEMENT TIRES ARE AFFECTED.
FUEL SYSTEM, GASOLINE
CERTAIN AFTERMARKET FUEL FILTERS SOLD UNDER THE PUROLATOR BRAND NAME, P/N F65277, SHIPPED FROM JANUARY 16 THROUGH JUNE 2, 2006, FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. DUE TO INCORRECT DESIGN, THE QUICK CONNECTORS MAY NOT FULLY SEAT WITH THE TUBE INTERFACE, EVEN THOUGH THE PERSON MAKING THE CONNECTION MAY BELIEVE THAT THE QUICK CONNECTOR IS FULLY ATTACHED.
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Frequently Asked Questions
What are the most common Ford Explorer Sport Trac problems?
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Ford Explorer Sport Trac has 1 documented issue. The documented issue is: Frame Rust. Of these, 1 is rated critical and should be addressed promptly.
Is the Ford Explorer Sport Trac reliable?
The 2004 Ford Explorer Sport Trac has 1 known issue compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 1 issue is rated critical: Frame Rust. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
How much does it cost to fix common Ford Explorer Sport Trac problems?
Repair costs for known Ford Explorer Sport Trac issues range from $200 to $2,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Frame Rust, typically costs $200-$2,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What is the 2001-2005 Ford Explorer Sport Trac Frame Rust?
The frame rails are prone to severe rust, especially in northern climates. The bed is separate from the cab and traps moisture underneath. Frame rot near the rear leaf spring mounts is a safety concern. Repairs typically run $200-$2,000. Severity: high.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.