2004 Ford Explorer

Here’s a comprehensive breakdown of common issues and complaints for the 2004 Ford Explorer, organized by category and component, as requested.

The 2004 Ford Explorer marked a significant redesign, shifting to an independent rear suspension. Engine options included a 4.0L SOHC V6 producing around 210 horsepower and 254 lb-ft of torque, and a 4.6L SOHC V8 offering approximately 239 horsepower and 282 lb-ft of torque. Both engines were typically paired with a 5-speed automatic transmission. Owners often praised the Explorer’s comfortable ride and spacious interior. Common complaints revolved around reliability issues, particularly concerning the transmission, suspension components, and electrical systems.

Engine

4.0L SOHC V6

• Timing Chain Tensioner Failure
  • Description/Symptoms: Rattling noise, particularly at startup. Can lead to engine damage if the tensioner fails completely, causing timing chain slack and potential valve damage.
  • Solution: Replace the timing chain tensioners, guides, and chains.
  • Estimated Cost to Fix: $800 - $1500+
  • Recalls: None Found
• Thermostat Housing Cracking/Leaking
  • Description/Symptoms: Coolant leak near the thermostat housing. Overheating may occur if coolant levels drop significantly.
  • Solution: Replace the thermostat housing. An updated, more durable design may be available.
  • Estimated Cost to Fix: $200 - $400
  • Recalls: None Found

4.6L SOHC V8

• Spark Plug Thread Damage/Ejection
  • Description/Symptoms: Misfire, loud popping noise, spark plug ejecting from the cylinder head. A common issue in earlier versions of this engine.
  • Solution: Repair or replace the cylinder head. Some repair shops offer thread repair inserts.
  • Estimated Cost to Fix: $500 - $2000+ (depending on the repair method and extent of damage)
  • Recalls: None Found
• Intake Manifold Gasket Leak
  • Description/Symptoms: Rough idle, coolant leak, possible overheating.
  • Solution: Replace the intake manifold gasket.
  • Estimated Cost to Fix: $300 - $600
  • Recalls: None Found

Transmission

5R55S 5-Speed Automatic Transmission (Both Engine Options)

• Valve Body Failure
  • Description/Symptoms: Hard shifting, slipping between gears, delayed engagement, complete loss of certain gears.
  • Solution: Replace or rebuild the valve body.
  • Estimated Cost to Fix: $500 - $1200+
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: Shuddering during acceleration, stalling, transmission slipping.
  • Solution: Replace the torque converter. Often recommended to also flush the transmission and replace the filter.
  • Estimated Cost to Fix: $800 - $1800+
  • Recalls: None Found

Suspension

• Rear Wheel Bearing Failure
  • Description/Symptoms: Grinding noise from the rear, especially at higher speeds. Excessive wheel play when checked.
  • Solution: Replace the rear wheel bearing(s).
  • Estimated Cost to Fix: $300 - $600 per side
  • Recalls: None Found
• Upper Ball Joint Failure
  • Description/Symptoms: Clunking noise from the front suspension, especially over bumps. Steering instability.
  • Solution: Replace the upper ball joint(s). Replacing the entire upper control arm is often recommended.
  • Estimated Cost to Fix: $200 - $500 per side
  • Recalls: None Found
• Rear Suspension Air Ride Compressor Failure (If Equipped)
  • Description/Symptoms: Rear of the vehicle sagging, air suspension warning light illuminated. The compressor may run constantly or not at all.
  • Solution: Replace the air suspension compressor. Check for leaks in the air lines and air springs.
  • Estimated Cost to Fix: $400 - $800+
  • Recalls: None Found

Electrical

• Instrument Cluster Issues
  • Description/Symptoms: Gauges malfunctioning (speedometer, fuel gauge, etc.), flickering lights, complete cluster failure.
  • Solution: Repair or replace the instrument cluster.
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found
• Power Window Motor Failure
  • Description/Symptoms: Window not operating, slow or erratic window movement.
  • Solution: Replace the power window motor.
  • Estimated Cost to Fix: $150 - $400 per window
  • Recalls: None Found
• Blend Door Actuator Failure
  • Description/Symptoms: Inconsistent temperature control, clicking noise behind the dashboard.
  • Solution: Replace the blend door actuator.
  • Estimated Cost to Fix: $200 - $500+ (labor intensive)
  • Recalls: None Found

Exterior

• Rear Liftgate Handle Failure
  • Description/Symptoms: Difficulty opening the rear liftgate. The handle may break or become loose.
  • Solution: Replace the liftgate handle.
  • Estimated Cost to Fix: $100 - $300
  • Recalls: None Found

Interior

• Sun Visor Sagging
  • Description/Symptoms: Sun visors don’t stay up
  • Solution: Replace Sun Visors
  • Estimated Cost to Fix: $50 - $150 per visor
  • Recalls: None Found

Summary

The 2004 Ford Explorer, while offering a comfortable ride and decent space, is prone to several common issues that can lead to significant repair costs. Transmission problems, particularly related to the valve body and torque converter, are frequent. Engine issues, such as timing chain tensioner failure in the V6 and spark plug thread damage in the V8, can also be costly to address. Suspension and electrical problems add to the potential ownership expenses. While some repairs are relatively inexpensive, others can quickly escalate into larger bills. Potential buyers should carefully inspect the vehicle’s history and condition, paying close attention to these known problem areas.