26 Complaints: 2004 Ford Expedition Electrical System Problems The 2004 Ford Expedition has 26 NHTSA complaints for the electrical system at 81,738 miles average. NHTSA — Electrical System Problems. And now I'm reading the fuse box has caught fire FORD EXPEDITION Problems - 2004 FORD EXPEDITION Electrical Sep 21, 2017Electrical System Problem on the 2004 FORD EXPEDITION. Car problem(s) with the 2004 FORD EXPEDITION. 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.