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.
2004 Ford Explorer Problem Reports
Most Reported 2004 Ford Explorer Problem Reports
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.
The intake manifold O-ring gaskets commonly leak, causing stalling and poor idle quality; the Check Engine Light will illuminate.
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.
If you experience difficulty starting the engine when cold, stalling at idle, or hesitations during acceleration, it may be the idle air bypass valve. This valve helps the vehicle idle steady when the accelerator pedal is not pressed.