2004 Ford Explorer Repair and Maintenance

A guide to problems, costs, maintenance and repair for your 2004 Ford Explorer

2004 Ford Explorer Problems

Plastic Intake Manifold May Crack Causing Coolant Leak

The composite (plastic) intake manifold may crack near the thermostat housing and cause a coolant leak. Ford released an updated manifold that was reinforced to prevent a recurrence. No recall was issued for this problem but Ford did extend the warranty to seven years on some models from the date of purchase.

Heater Stuck on Hottest Setting Due to Broken Heater Blend Door

A failed heater blend door or actuator can cause the temperature control for the HVAC system to stop working. A clicking sound from the dash area would commonly indicate an actuator fault. If the heater gets stuck on the hottest setting, the heater blend door may be broken requiring replacement of the heater box to repair the issue.

Worn Timing Chain Cassettes May Cause Rattling Noise From Engine

A rattling noise from the engine may indicate that the timing chain cassette is worn. Our technicians tell us that installing an updated cassette and timing chain tensioner should correct this concern.

See More Problems (10)

2004 Ford Explorer Questions

fuse location (1 answer)

interior lamp fuse location on diagram. fuse panel diagram in handbook does not show.

What can cause my truck not to crank up (2 answers)

How do I replace fuse on passenger door? (1 answer)

I have no power on any Windows but the sunroof works.

See More Questions (255)

2004 Ford Explorer Reviews

I have a 2004 ford explorer and this sub has been trouble sense i bought it first it sarted loosen power and later on after dealing with that and getting that fix finally the rear hatch just one day part while someone was in it the windsheild and shatter and the hatch just busted out of it's position this is a very defective suv hate i bought it.
310000 and still going strong. Just basic maintence.....if something breaks, fix it!
Transmission had to be replaced at 13,500 under extended warranty and constant battles with 2 dealers and Ford, but finally admitted that tranny was faulty. Not so lucky next time....at 60,550 engine seized after timing chain broke and just after it passed 60,000 mile warranty. $7200 to replace engine. New engine runs better than original, but after reading other owners comments on V6, sou...

See More Reviews (10)