A cosmetic crack may develop on the plastic liftgate trim panel. Ford has released a service procedure to replace the applique without damage the the liftgate glass.
Problems for specific Ford Explorer years:
Car problem reports
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Most reported 2004 Ford Explorer problems
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.