Wheels Problem on the 2004 FORD EXPLORER
Car problem(s) with the 2004 FORD EXPLORER.
This database includes information received by NHTSA from consumers either directly or as recorded by the Vehicle Safety Hotline. This information may be used by NHTSA during the investigation process.
You may file your own complaint by calling the NHTSA Monday-Friday 8am to 8pm at (888) 327-4236, TTY: (800) 424-9153. You can also file your complaint online.
Problem with Wheels
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May 14, 2013 - Paden, OK - Wheels
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT WHILE DRIVING 40 MPH, THE VEHICLE SHOOK. UPON INSPECTION, THE DRIVER NOTICED THAT THE REAR PASSENGER SIDE LUG NUTS HAD LOOSENED AND THE TIRE WAS ONLY BEING HELD IN PLACE BY ONE LUG NUT. THE CONTACT MENTIONED THAT THE FAILURE RECURRED ON THE REAR DRIVER SIDE TIRE BUT IN THIS OCCASION THE TIRE DETACHED WHILE DRIVING 70 MPH. IN ADDITION, THE CONTACT STATED THAT THE VEHICLE FAILED TO SHIFT INTO THIRD GEAR. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN DIAGNOSED THAT THE TRANSMISSION, STUDS, LOG NUTS, ROTORS, AND TIRES NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 124,000 AND THE CURRENT MILEAGE WAS 132,000.
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Nov 19, 2012 - Whitmore Lake , MI - Wheels
WHILE DRIVING NORTH ON US23 AT BRIGHTON MI THE RIGHT FRONT WHEEL AND TIRE SEPARATED FROM THE VEHICLE BECAUSE OF THE FRACTURE OF THE 5 WHEEL LUGS. ACCORDING TO THE MSP THIS IS A COMMON OCCURANCE BECAUSE OF METAL FATIGUE CAUSED BY THE IMPROPER USE OF IMPACT AND NOT TORQUE WRENCHES WHEN THE VEHICLE IS SERVICED. THE PROBLEM IS BEING IGNORED BY THE AUTO MANUFACTURERS, AND I HAVE FOUND PUBLICATIONS ON THIS SUBJECT MATTER. THERE ARE LIKELY MILLIONS OF AFFECTED VEHICLES IN SERVICE, AND THE WHEEL LOSS WOULD PRODUCE RESULTS SIMILAR TO THE PREVIOUS FORD/FIRESTONE TIRE PROBLEM.
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Mar 28, 2012 - Glendibe, MT - Wheels
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 30 MPH, HE HEARD A LOUD NOISE. AFTER INSPECTING THE VEHICLE HE NOTICED THAT THE BOLT TO THE LUG NUTS WERE SEPARATED FROM THE REAR DRIVER AND PASSENGER TIRES. THE VEHICLE WAS TAKEN TO A TIRE SPECIALIST WHERE THE LUG NUTS WERE REPLACED. THE MANUFACTURER WAS CONTACTED AND THEY OFFERED NO ASSISTANCE. THE FAILURE AND THE CURRENT MILEAGES WERE UNKNOWN. THE VIN WAS UNAVAILABLE.
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Feb 17, 2012 - Blue Grass, IA - Wheels
ON THE HIGHWAY, PASSING A TRACTOR TRAILER AND THE RIGHT REAR WHEEL BEARINGS GAVE OUT. WHEEL FROZE AND CAUGHT ON FIRE. PULLED OVER AND FORTUNATELY OTHERS HAD STOPPED AND ASSISTED IN PUTTING FIRE OUT. WAS TERRIFYING - OUR CHILDREN WERE SITTING IN THE BACK! WE THEN ENDED UP STRANDED AWAY FROM HOME AS WE WERE ON A FAMILY TRIP.
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Jan 15, 2012 - Akron, PA - Wheels
WAS DRIVING MY VEHICLE ON THE HIGHWAY AND GOT OFF WENT TO TURN. THE LUG NUTS SHEARD OFF, THOUGHT IT WAS A FLAT TIRE. THIS HAS HAPPENED THREE TIMES. THERE IS NO RECALL FOR THIS. I HAD MY KIDS IN THE VEHICLE ALL THREE TIMES. I WOULD LIKE TO HAVE THIS MATTER RESOLVED.
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Jul 11, 2011 - Kansas City, KS - Wheels
REAR WHEEL STUDS SHEER OFF CAUSING WHEEL TO COME OFF WHILE DRIVING. GAVE NO WARNING, AND WAS NOT VISIBLE DUE TO WHEEL CAP COVERING. HAS HAPPENED TWICE IN 2 MONTHS, TWO DIFFERENT WHEELS. BOTH REAR. HAD TO REPLACE ALL 5 STUDS, LUGS, AND ROTOR ON FIRST FAILURE. REPLACED STUDS, LUGS, AND WHEEL ON SECOND. LUGS ARE STILL INTACT WITH THE STUDS. STUDS SHOW STRESS FRACTURING PRIOR TO BREAKING OFF. HAVE THE STUDS/LUGS FROM LAST BREAK.
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Apr 05, 2011 - Nelson, NH - Wheels
WITHOUT WARNING MY REAR WHEEL HUB ASSEMBLY KEEP BRAKING. SUDDENLY THE VEHICLE STARTS TO SHIMMY AND PULL AND MAKE GRINDING NOISES AND THE WHEEL IS PRACTICALLY FALLING OFF BY THE TIME I GET HOME. THIS HAS HAPPENED TO ME 6 TIMES IN THE PAST YEAR! SO FAR I HAVE BEEN LUCKY AND MY WHEEL HASN'T FALLEN COMPLETELY OFF, ONLY BECAUSE I HAVE REPLACED THE REAR DIFFERENTIAL TWICE IN THE LAST 2 YEARS SO AS SOON AS I FEEL SOMETHING OUT OF THE ORDINARY I HAVE IT CHECKED! IT IS TERRIFYING WHEN IT HAPPENS, THE WHOLE WHEEL WOBBLES AND GOING SLOW ONLY MAKES IT SEEM WORSE. I'VE HAD TO REPLACE THE WHOLE HUB ASSEMBLY AT A COST OF $300.00 PLUS EACH TIME!
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Jan 11, 2011 - Ramsey, MN - Wheels
3 OUT OF 4 WHEEL BEARINGS HAVE HAD TO BE REPLACED ON 2004 FORD EXPLORER BETWEEN 71,000 AND 82,000 MILES. DRIVERS SIDE FRONT WAS REPLACED BETWEEN 71,000 AND 72,000 MILES, DRIVERS SIDE REAR REPLACED SHORTLY AFTER AND NOW THE PASSENGER FRONT NEEDS REPLACING AT 82,000 MILES. SEVERAL POSTS ON THE INTERNET WITH THE SAME COMPLAINT FOR THE SAME MAKE/MODEL/YEAR OF THIS VEHICLE. I WAS TOLD BY THE FORD DEALER THAT IF I DIDN'T FIX THEM THE TIRE COULD FALL OFF AT ANY TIME WITH OUT WARNING.
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Nov 19, 2010 - Wallingford, CT - Wheels
WHILE DRIVING, I TOOK A LEFT TURN AND FELT A BUMPING IN MY RIGHT REAR TIRE. I PULLED OVER THINKING IT WAS A FLAT TIRE. IN FACT, THE WHEEL BOLTS HAD BEEN SHEARED OFF COMPLETELY. WHEN I HAD THE CAR TOWED TO A REPAIR SHOP, THEY DISCOVERED THAT A TOTAL OF 10 BOLTS/NUTS NEEDED TO BE REPLACED AND 8 OUT OF THE OTHER 10 BOLTS WERE LOOSE OR WORN. I ALSO NEEDED TO GET A NEW WHEEL. THIS MORNING WHILE DRIVING TO WORK, I TOOK A LEFT TURN AND THE EXACT SAME THING HAPPENED, AGAIN WITH THE RIGHT REAR TIRE. THE BOLTS WERE SHEARED OFF. I HAVE NOT YET BROUGHT THE VEHICLE IN FOR REPAIRS FOR THE LATEST INCIDENT BUT I HAVE NO DOUBT THERE WILL BE ADDITIONAL BOLT DAMAGE ON AT LEAST SOME OF THE OTHER TIRES.
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Oct 01, 2010 - Miami, FL - Wheels
RIGHT REAR TIRE KEEPS COMING OFF. THE LUG NUTS KEEP BREAKING OFF, THIS IS THE THIRD TIME IT HAPPENS. THE RIM WAS REPLACED, BUT STILL ARE BREAKING OFF.
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Aug 27, 2010 - Newington, CT - Lugs/Nuts/Bolts
TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT WAS DRIVING LESS THAN 10 MPH AND APPROACHING AN INTERSECTION TO ATTEMPT A LEFT TURN. SUDDENLY, THE FRONT END OF THE VEHICLE COLLAPSED AND THE FRONT PASSENGER WHEEL FRACTURED FROM THE VEHICLE. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER YET THE TECHNICIAN WAS UNABLE TO LOCATE THE PROBLEM. THE MANUFACTURER REFERRED THE CONTACT TO AN INDEPENDENT MECHANIC FOR FURTHER INVESTIGATION. THE VEHICLE WAS REPAIRED FOR THE FRONT END DAMAGES AND THE TECHNICIAN WAS UNABLE TO PROVIDE AN EXPLANATION TO THE CAUSE OF THE FAILURE. THROUGH RESEARCH, THE CONTACT DISCOVERED THE FAILURE WAS A COMMON OCCURRENCE WITH THIS MODEL, AS A RESULT OF DEFECTIVE WHEEL LUG BOLTS. THE VEHICLE WAS TAKEN BACK TO THE DEALER AND THE LUG BOLTS WERE REPLACED ON THE FOUR WHEELS. THE FAILURE MILEAGE WAS APPROXIMATELY 77,000.
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Jun 02, 2010 - Bloomfield, CO - Wheels
TL CONTACT OWNS A 2004 FORD EXPLORER. WHILE DECELERATING AT APPROXIMATELY 5 MPH, THE FRONT PASSENGER SIDE TIRE BROKE OFF OF THE VEHICLE RESULTING IN A CRASH. A POLICE REPORT WAS FILED. NO INJURIES WERE REPORTED. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC FOR INSPECTION. THE CURRENT AND FAILURE MILEAGES WERE UNKNOWN. THE VIN WAS NOT AVAILABLE.
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Apr 09, 2010 - Indianola, IA - Wheels
2004 FORD EXPLORER FACTORY INSTALLED CHROME WHEELS THIS IS THE SECOND SET - I PAID $1600 TO REPLACE FIRST SET HAVE SEVERE PEELING, CRACKING AND FLAKING AROUND LUG NUTS INCLUDING INSIDE, OUTSIDE AND TOP OF RIMS ON WHEELS. POSSIBLE CONSEQUENCES CRACKING, PEELING AND FLAKING OF WHEEL MATERIALS COULD RESULT IN FAILURE OF WHEEL AND /OR TIRE SEAL FAILURE WHILE DRIVING. FORD SERVICE TECH STATED THE ALL WHEELS MUST BE REPLACED FOR SAFETY REASONS.
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Mar 06, 2010 - Fredericksburg, VA - Wheels
LEFT SIDE FRONT AND REAR WHEEL BEARING NEEDING REPLACEMENT. THE REAR WHEEL BEARING WAS SO BAD IT WAS ACTUALLY WOBBLING.
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Feb 04, 2010 - Mount Pleasant, PA - Lugs/Nuts/Bolts
TL DRIVER OWNS A 2004 FORD EXPLORER. THE DRIVER STATED THAT FOUR OF THE STUDS ON THE RIGHT REAR ROTOR BROKE OFF AND THAT THE WHEEL ALMOST FELL OFF. HE HEARD A LOUD NOISE WHILE DRIVING APPROXIMATELY 25 MPH. THE VEHICLE WAS TOWED TO A REPAIR SHOP. A LOCAL MECHANIC INFORMED HIM THAT THE STUDS BROKE AND REPLACED ALL FIVE STUDS. THE CONTACT NEITHER TOOK THE VEHICLE TO THE DEALERSHIP NOR SPOKE WITH THE MANUFACTURER TO-DATE. THE CURRENT MILEAGE WAS APPROXIMATELY 80,000. THE FAILURE MILEAGE WAS APPROXIMATELY 79,950.
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Jan 19, 2010 - Prather , CA - Lugs/Nuts/Bolts
TL CONTACT OWNS A 2004 FORD EXPLORER WHICH WAS PURCHASED IN SEPTEMBER 2007. WHILE DRIVING 25 MPH AND MAKING A RIGHT TURN, THE REAR DRIVER'S SIDE WHEEL CAME OFF OF THE VEHICLE. THE VEHICLE HIT THE GROUND AND WOULD NOT MOVE ANY FURTHER. THE LUG NUTS AND BOLTS SHEARED OFF OF THE WHEEL ASSEMBLY. THE VEHICLE WAS TOWED TO A LOCAL SERVICE CENTER WHERE THEY REPLACED THE LUG NUTS AND BOLTS. ON A SEPARATE OCCASION, WHILE DRIVING AT SPEEDS OF LESS THAN 30 MPH GOING THROUGH AN INTERSECTION, SHE HEARD A LOUD NOISE. SHE THEN MANEUVERED THE VEHICLE TO THE SIDE OF THE ROAD WHERE SHE FOUND THE BOLTS HAD SHEARED OFF INTO THE WHEEL COVER AND CAUSED THE LUG NUTS TO COME OFF OF THE PASSENGER'S SIDE REAR TIRE. THERE WERE NO RECALLS FOR THE FAILURE. THE CONTACT WAS AWAITING REPAIRS A SECOND TIME. THE FAILURE MILEAGE WAS 39,000 AND THE CURRENT WAS 56,000. THE VIN WAS NOT AVAILABLE.
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Dec 08, 2009 - Cleveland, OH - Wheels
FIRST THE ABS LIGHT CAME ON. THEN A LOUD NOISE CAME FROM THE FRONT. AFTER THE AUTO SHOP CALLED AND INFORMED ME THAT IT WAS ALL WHEEL BEARING AND BACKING PLATES WENT BAD AND$1500.00 DOLLARS LATER I LOOKED INTO PROBLEMS ON LINE WITH FORD EXPLORERS I SEEN OVER 42 COMPLAINTS WITH THE SAME THING. THAT IS A LOT OF MONEY SEEING AS HOW IM STILL PAYING OF THE LOAN!
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Oct 18, 2009 - North Granby, CT - Wheels
I HAVE A 2004 FORD EXPLORER. I HAVE HAD TO REPLACE BOTH FRONT BEARINGS AND NOW THE REAR BEARINGS ARE BAD AND I WAS TOLD THAT THEY NEED TO BE REPLACED. APPARENTLY IT IS A SAFETY ISSUE AND FORD IS DOING NOTHING ABOUT THIS. DO YOU HAVE ANY SUGGESTIONS AS TO WHAT CAN BE DONE BEFORE AN ACCIDENT OCCURS WITH MY VEHICLE. I CANNOT AFFORD THE REPAIR. WHAT STEPS CAN BE TAKEN TO HAVE FORD RECALL THE EXPLORERS WITH THIS PROBLEM. IT SEEMS THAT THERE ARE MANY OUT THERE WITH THE SAME ISSUE.
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Oct 18, 2009 - Saratoga, CA - Wheels
I TOOK MY CAR FOR A NEW SET OF TIRES AT AMERICA'S TIRE (DISCOUNT TIRE). AFTER CHANGING THE TIRE, ONE THE TECHNICAL NOTICED I HAVE A "LOOSE HUB ASSEMBLY" ON MY LEFT REAR WHEEL AND HE SUGGESTED THAT I SHOULD GET THAT FIXED IMMEDIATELY BECAUSE IT'S A SAFETY ISSUE. THERE IS A POSSIBILITY THE WHEEL MAY COME OFF AT FREEWAY SPEED. I TOOK MY CARS IN TO MY MECHANIC THE NEXT DAY, AND HE JACKED UP MY CAR. THE MECHANIC PUT ONE OF HIS HAND AT 12 AND THE OTHER AT 6 O'CLOCK ON THE TIRE, AND ROCKS IT. THE TIRE WAS WOBBLING BACK AND FORTH WHEN HE DID THAT, WHICH SUGGESTED A BAD WHEEL BEARING, OR POSSIBLE BAD HUB ASSEMBLY. AT THE END, IT WAS DETERMINED THAT I HAD A BAD WHEEL BEARING, WHICH WAS REPLACED FOR $400. USUALLY A HUB ASSEMBLY/WHEEL BEARING SHOULD STILL BE IN GOOD CONDITION AT 52,000 MILES. I GUESS BECAUSE IT'S A FORD. I HAVE MANY PROBLEM WITH THIS VEHICLE, THE REAR RIGHT WINDOW SOMETIMES DOESN'T WORK, THE FUEL TANK SYSTEM MALFUNCTION (CHANGED IT UNDER WARRANTY), THE "SERVICE ENGINE SOON" LIGHT COMES ON EVERY 5,000 MILES. I'M NOT BUYING ANOTHER FORD. I THOUGHT AMERICAN CARS' QUALITY IS NOW COMPARABLE TO THE JAPANESE, UNFORTUNATELY THEY'RE STILL LAGGING.
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Jun 16, 2009 - Congers, NY - Wheels
LOUD WHEEL NOISE. INCREASED / DECREASED WITH SPEED. FRONT AND REAR BEARINGS HAD TO BE REPLACED AT 50,000 MILES. FORD HAS A TSB FOR THE REPLACEMENT. LEMON STATE LAWYER STATED THEY HAVE HAD HUNDREDS OF CALLS FOR SAME PROBLEM, AT SAME MILEAGE.
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Jun 09, 2009 - Des Plaines, IL - Wheels
2004 FORD EXPLORER FACTORY INSTALLED CHROME WHEELS HAVE SEVERE PEELING, CRACKING AND FLAKING AROUND LUG NUTS INCLUDING INSIDE, OUTSIDE AND TOP OF RIMS ON WHEELS. POSSIBLE CONSEQUENCES CRACKING, PEELING AND FLAKING OF WHEEL MATERIALS COULD RESULT IN FAILURE OF WHEEL AND /OR TIRE SEAL FAILURE WHILE DRIVING. FORD SERVICE TECH STATED THE ALL WHEELS MUST BE REPLACED FOR SAFETY REASONS.
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Jan 07, 2009 - Sterling Heights, MI - Wheels
I DRIVE MY CAR LIKE A NORMAL MAN WOULD. I DON'T TAKE IT OFF ROAD AND DON'T ABUSE IT IN ANY WAY. I HAVE ALREADY HAD WHEEL BEARINGS REPLACED BEFORE NOW THEY ARE GOING OUT AGAIN. FORD EXPLORERS SEEM TO HAVE THIS PROBLEM OFTEN AND I AM AFRAID TAKING THIS CAR ON THE ROAD THAT THE WHEELS ARE JUST GOING TO COME RIGHT OFF WITH ME DRIVING ON THE FREEWAY BECAUSE THE BEARINGS AND HUBS ON THESE VEHICLES ARE IMPROPERLY ASSEMBLED AND IT IS ONLY A MATTER OF TIME BEFORE MINE GO OUT AGAIN WITH ME IN IT DRIVING AT A HIGH RATE OF SPEED AND BEING KILLED. I AM NOT THE ONLY ONE WITH THIS PROBLEM!! FORD NEEDS TO DO SOMETHING QUICKLY BEFORE SOMEONE IS INJURED OR KILLED.
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Nov 03, 2008 - Lombard, IL - Wheels
I WAS DRIVING TO WORK WHEN MY 2004 FORD EXPLORER LOST THE REAR PASSENGER RIM AND TIRE. THE CAR RATTLED AND THEN THERE WAS A LOUD THUD AND SPARKS COMING FROM THAT AREA. THIS HAS ONLY OCCURRED ONCE BUT IT STRIPPED AND BROKE SOME OF THE STUDS WERE THE WHEEL ATTACHES. I HAD THE CAR TOWED WHERE I HAD THE TIRES REPLACED, BRAKES CHECKED AND FIXED, ALIGNMENT, AND BROKEN STUDS FIXED AND REPLACED.
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Aug 27, 2008 - Rochester, NY - Wheels
REAR RIGHT TIRE CAME OFF SUV AS I WAS TRAVELING WITH 3 CHILDREN AND WIFE IN SUV AT 60 MPH IN A 55 MPH ZONE, AS PER THE TOW AND MECHANIC PERSON THEY STATED WE COULD HAVE BEEN KILLED DUE TO SUV GOING FROM ONE SIDE OF THE ROAD TO THE OTHER ON COMING TRAFFIC SIDE, MY SON IS HAVING NIGHTMARES ABOUT THIS.
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Nov 08, 2007 - Indianola, IA - Wheels
2004 FORD EXPLORER LIMITED-OWNED SUV FOR 38K BEEN IN SHOP REPEATEDLY-FROM MINOR TO MAJOR THINGS. SUV IS A $ 34,000 TURD. CURRENTLY NEEDING TO GO BACK TO SHOP FOR MULTIPLE REPAIRS. THE DAY OUR WARRANTY EXPIRES CAR IS GONE.
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Apr 04, 2007 - Naperville, IL - Lugs/Nuts/Bolts
RIGHT-REAR WHEEL FELL OFF WHILE TRAVELING 40 MPH. FORTUNATELY NOBODY WAS HURT THIS TIME. AFTER READING OTHER POSTS ABOUT PROBLEMS WITH WHEELS FALLING OFF AND WITH LUG:NUTS I DECIDED TO POST OUR INCIDENT TOO.
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Feb 26, 2007 - Laurel, NY - Lugs/Nuts/Bolts
WITHOUT WARNING THE REAR WHEEL OF MY 2004 FORD, EXPLORER BROKE OFF GOING 65 ON THE INTERSTATE. ALL FIVE LUGS SNAPPED OFF. NO ONE TOOK RESPONSIBILITY. I HAD TO PAY FOR REPAIRS. IT WAS EITHER A DEFECT OR NEGLIGENCE ON THE PART OF THE DEALER WHERE I HAD IT SERVICED.
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Aug 19, 2005 - Berkley, MI - Rim
I NOTICED AN INCREASING NOISE COMING FROM MY FRONT TIRES OF MY 2004 FORD EXPLORER 2WD EDDIE BAUER ON 8/18/05 - 8/19/05. I CHECKED AND DISCOVERED THAT 2 OF THE 5 RIGHT FRONT WHEEL LUGS NUTS WERE BROKEN OFF. WHEN I FURTHER CHECKED THE TENSION OF THE 3 REAMINING LUG NUTS, I DISOVERD THAT 2 OF THEM WERE ALSO BROKEN OFF BUT WEDGED IN THE RIM. I HAD ONE LUG NUT HOLDING THE WHEEL ON IN PLACE. NEEDLESS TO SAY, THIS COULD HAVE RESULTED IN A TERRIBLE ACCIDENT AS I DRIVE HOME FROM MY EMPLOYER AAA MICHIGAN AT SPEEDS OF 55 MPH. I ROTATED THESE TIRES 1,000 MILES AGO, JUST AS I HAVE ROTATED TIRES ON 20 CARS OVER THE COURSE OF 35 YEARS. I HAD HAND TIGHTENED THE LUG NUTS. SOMEONE NEEDS TO CHECK THE QUALITY OF THESE LUG NUTS FOR POTENTIAL DEFECTS.
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Jul 08, 2005 - Brownstown, MI - Rim
DT: THE CHROME ON THE WHEELS WAS CHIPPING OFF AND THE CONSUMER FEELS THAT HE SHOULD NOT HAVE TO PAY TO GET THEM FIXED AND THAT THE CRACKING IS A SAFETY ISSUE. THE DEALER SAYS THAT THE WARRANTY EXPIRED AND THAT THEY WILL NOT FIX THEM FOR FREE. THE MANUFACTURER SAID THAT THEY WILL ASSIST THE CONSUMER IN PAYING FOR THE PROBLEM BUT THE CONSUMER TURNED THEM DOWN.
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