2004 Ford Explorer Sport Trac

The 2004 Ford Explorer Sport Trac is a unique vehicle blending the practicality of a pickup truck with the comfort of an SUV. It was offered with two engine options: a 4.0L SOHC V6 producing 210 horsepower and 254 lb-ft of torque and a 4.6L SOHC V8 generating 239 horsepower and 282 lb-ft of torque. Both engines were available with a 5-speed automatic transmission. Owners often appreciate the Sport Trac’s versatility and relatively comfortable ride, while common dislikes include its fuel economy, smaller bed size compared to traditional trucks, and some reliability concerns.

Engine

4.0L SOHC V6

• Timing Chain Tensioner Failure
  • Description/Symptoms: Rattling noise, especially upon cold start. Can eventually lead to timing chain failure and significant engine damage.
  • Solution: Replace the timing chain tensioners, guides, and chains.
  • Estimated Cost to Fix: $1,000 - $2,000+
  • Recalls: None Found
• Intake Manifold Gasket Leak
  • Description/Symptoms: Coolant leak, overheating, rough idle, poor fuel economy.
  • Solution: Replace the intake manifold gasket.
  • Estimated Cost to Fix: $300 - $600
  • Recalls: None Found

4.6L SOHC V8

• Spark Plug Thread Damage/Ejection
  • Description/Symptoms: Loud popping noise, misfire, spark plug ejected from the cylinder head. This is more prevalent with the earlier 2V (two-valve) design.
  • Solution: Repair or replace the cylinder head, often using thread inserts to reinforce the spark plug threads.
  • Estimated Cost to Fix: $500 - $2,000+ (depending on repair method)
  • Recalls: None Found
• Coolant Leaks
  • Description/Symptoms: Coolant loss, overheating, low coolant level warning light.
  • Solution: Inspect and replace leaking hoses, water pump, thermostat housing, or radiator as needed.
  • Estimated Cost to Fix: $100 - $1,000+ (depending on the source of the leak)
  • Recalls: None Found

Transmission

5R55S 5-Speed Automatic

• Valve Body Failure
  • Description/Symptoms: Harsh or delayed shifting, slipping between gears, failure to shift.
  • Solution: Replace or rebuild the valve body.
  • Estimated Cost to Fix: $500 - $1,500
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: Shuddering at low speeds, stalling, poor acceleration, transmission overheating.
  • Solution: Replace the torque converter.
  • Estimated Cost to Fix: $800 - $1,800
  • Recalls: None Found

Suspension

• Rear Leaf Spring Sagging/Broken Leaves
  • Description/Symptoms: Rear end sagging, reduced ride height, rough ride, clunking noise from the rear.
  • Solution: Replace the rear leaf springs.
  • Estimated Cost to Fix: $400 - $800
  • Recalls: None Found
• Ball Joint Failure
  • Description/Symptoms: Clunking noise from the front suspension, loose steering, uneven tire wear.
  • Solution: Replace the ball joints (upper and lower).
  • Estimated Cost to Fix: $200 - $600
  • Recalls: None Found

Electrical

• Blend Door Actuator Failure
  • Description/Symptoms: Inconsistent temperature control, clicking noise from behind the dashboard.
  • Solution: Replace the blend door actuator.
  • Estimated Cost to Fix: $150 - $400
  • Recalls: None Found
• Instrument Cluster Issues
  • Description/Symptoms: Gauges not working properly (speedometer, fuel gauge, temperature gauge), flickering lights, or complete cluster failure.
  • Solution: Repair or replace the instrument cluster.
  • Estimated Cost to Fix: $200 - $600
  • Recalls: None Found
• ABS Module Failure
  • Description/Symptoms: ABS light illuminated, loss of ABS functionality, poor braking performance.
  • Solution: Replace or rebuild the ABS module.
  • Estimated Cost to Fix: $300 - $800
  • Recalls: None Found

Exterior

• Rust on Rocker Panels and Wheel Wells
  • Description/Symptoms: Visible rust forming on the rocker panels and around the wheel wells, potentially leading to structural damage.
  • Solution: Cut out the rusted areas and weld in new metal patches, followed by body filler, primer, and paint.
  • Estimated Cost to Fix: $500 - $2,000+ (depending on the severity of the rust)
  • Recalls: None Found

Interior

• Cracked Dashboard
  • Description/Symptoms: Cracks appearing on the dashboard, especially in sun-exposed areas.
  • Solution: Replace the dashboard (expensive) or use a dashboard cover.
  • Estimated Cost to Fix: $200 (dashboard cover) - $1,000+ (dashboard replacement)
  • Recalls: None Found
• Power Window Motor Failure
  • Description/Symptoms: Window not going up or down, slow or erratic window movement.
  • Solution: Replace the power window motor.
  • Estimated Cost to Fix: $150 - $400
  • Recalls: None Found

Summary

The 2004 Ford Explorer Sport Trac can be a practical and versatile vehicle, but it’s important to be aware of potential issues. The most common concerns revolve around engine problems (timing chain tensioners in the 4.0L V6 and spark plug thread issues in the 4.6L V8), transmission issues (valve body and torque converter failures), and suspension wear (leaf springs and ball joints). Electrical problems and rust are also common. The severity and cost of these repairs can vary significantly, with engine and transmission repairs potentially costing over $2,000 in some cases. Careful inspection and maintenance are crucial to keeping a 2004 Explorer Sport Trac running reliably.