2004 Ford Explorer Repair and Maintenance
A guide to problems, costs, maintenance and repair for your 2004 Ford Explorer
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2004 Ford Explorer ProblemsPlastic 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.
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.
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.
2004 Ford Explorer Questionsfuse location (1 answer)
interior lamp fuse location on diagram. fuse panel diagram in handbook does not show.
I have no power on any Windows but the sunroof works.