Has anyone had good (or bad) experiences with a softer cover for the armrest on a 2004 Expedition? My wife had elbow surgery and the incision happens to be right where her elbow hits the armrest.

There is a company called Snaprest that makes a nice looking cover for the F-150. I would just order one and hope that the armrest in the F-150 and Expedition are similar, but Snaprest says that their product is for 2009-2014.

 

To me it would make more sense for your wife to wear an elbow pad. That way no matter what she put her elbow down on the padding would be there.
Here are some samples: Elbow Pads at Sports Authority