Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Ford Explorer owners, lightly cleaned up (personal details are redacted by NHTSA).
On two incidents this week when steering wheel is cut to maximum left or right in tight parking lot and narrow road while making tight turns at legal speeds the engine (V8 4.6L) stalls. Brought to non-Ford mechanic for inspection(NYS ANNUAL) and passes but mechanic looked for a power steering pressure sending sensor or switch that is to give signal to EMC to increase idle to compensate for more power steer demands. Part is $35 at Partgeek but mechanics dont know where the harness the sending switch is located, if one exists or is it in power steering pump. Call Ford NADA! Call two local Ford dealers. One says dont work on cars 15 years old, other says go to liabary to get diagrams, Ford says obsolete parts in 10 years.Bummer! Husband ordered 8/10/20 New 2021 Bronco. Pushed into 2022 due to supply chain. …
Back windows fell off track and windows fell down, cannot roll them up. AC and Heater broke and won't work at all. Fuel system is too lean. Transmission is going out Timing Chain and tensioners making loud knocking noise. Burning oil.
2004 Ford Explorer traveling 40-45mph on a rural road. Driver lost control of the vehicle at a "s" curve and hit an utility pole with the front end. The pole was snapped in half. Airbags did not deploy. Driver was the only person in the vehicle. 35 lb dog was on the passenger seat. Driver was wearing a seat belt. Driver hit his chest on the steering wheel bruising his lung. Driver also hit his head on the windshield causing a laceration (approximately 1.5") down to his skull. Driver was transferred via ambulance to the nearest hospital and admitted for 48 hours. The canine broke her back and had to be put down the following day.
Tl* the contact owned a 2004 Ford Explorer. The contact heard a loud boom and discovered that his parked vehicle was on fire. The fire department extinguished the flames. The insurance company determined that the vehicle was destroyed. There were no injuries. The manufacturer was not notified of the failure. The VIN was invalid. The approximate failure mileage was 155,000.
I backed SUV out of garage and put in park, got out of vehicle while still running (to close garage door), closed the SUV door, turned around and saw that SUV was moving forward into my garage. I opened the SUV door while it was moving and jumped in the drivers seat, pushed on the brake and SUV did not stop, I was looking down at the floor to see why SUV did not stop, pulled up my foot and placed it back down on the brake. SUV still did not stop. It then made a loud noise like the engine was reeving up and then the SUV took off forward, ran through the back of my garage, ran through my back yard, ran over a tree in the yard, ran through my back yard fence and my neighbor's fence and crashed into the back side of neighbor's house. …
Engine dies when driving with cruise control operating and heading down slight hill at speed of around 35 MPH. Cruise is designed to maintain driving speed going down the hill (up or down hill for that matter). The tachometer indicates a slowing of engine RPM. At higher speeds, the slowing of RPM does not fall too low. However, at the slower speed around 35mph, the RPM drops below 500 RPM and the engine stalls. I lose power steering and breaks. I have a difficult time steering and breaking. This is a safety problem on a curve or if a red light is ahead. I can't steer the car on the curve. I May not be able to stop the car at the traffic light and end up in an intersection and be hit by vehicles with a green light. I May hit a car in front of me that has stopped at a light or stop sign. I May not be able to stop for a pedestrian crossing at the intersection (with the light). …
Tl contact owns a 2004 Ford Explorer. The contact stated that the vehicle would not start. She depressed the accelerator pedal and the vehicle started and began to vibrate. She then placed the vehicle in reverse and heard a loud clunking noise. She smelled a strong gas odor inside the passenger compartment. The contact looked in her rearview mirror and noticed a large amount of smoke coming from the exhaust system. She parked the vehicle and had it towed. She then noticed that all of the radiator fluid leaked out. The mechanic stated that the valve failed and damaged the entire engine. The mechanic also stated that the engine needed to be replaced and appeared to be a manufacturer defect. The current and failure mileages were 63,000. …
I have already put a complaint in about my throttle body issue. This evening I went about a mile and a half, and my wrench light came on and my truck started to not to be able to move. I pulled over, turned it off. Waited a bit and restarted it. This time it took a bit to get it to start up. I then proceeded to go back home because of how it was acting a mile and a half after driving, not often two minutes later it happens again, and the engine started chugging, I couldn't move, and I almost got rear ended again! I then again turned it off and waited and then started the truck up. It took sometime once again to start. I finally made it back home in tears. I was able to get codes off, since I picked a up a code raffia few days prior. I got code p2104, p2111, and p2112. This issue needs to be addressed. I will be calling Ford tomorrow!
Tl* the contact owns a 2004 Ford Explorer. The contact stated that the service engine and the battery warning lights illuminated. The contact also stated that the vehicle jerked and made a loud noise. The vehicle was taken to a dealer who replaced the front driver side hub and wheel bearing, the rear springs, the three passenger gear calipers, four rear driver side calipers, the battery, five rear brake pads, and six rear rotors plus an oil change. Three weeks after the repairs, the vehicle stalled without warning. In addition, the brake pedal hesitated to respond. The vehicle was towed back to the dealer, who diagnosed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 140,817.
I have a 2004 Ford Explorer and when I hit the 84000 mile my car started falling apart starting with the heater A/C vent actuator first time in late 2011 then again in jan 2015 this repair has cost me over $1200 then the engine light has come on and I've been told by Ford repair shop which was $97 just to look at it that it was from different coils that were over $300 a piece which has been replaces a couple of time to the Cadillac converter which was over $3500 to replacing the bearings a couple hundred many times. I'm at the point where I'm not sure to keep this car or junk it these repairs are breaking me! I see that I'm not the only one that is complaining about these problems.... There should be some type of recall....!!!!!!!!!!!
NHTSA investigations
Spark plug ejection from cylinder head
On September 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 Ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or…
Engine complaints in other Explorer years
Frequently asked questions
How common are engine problems on the 2004 Ford Explorer?
NHTSA has 114 complaints about the engine & cooling of the 2004 Ford Explorer, 9% of the model year's 1,304 complaints. The component named most often is engine (19 mentions).
Is there a recall for 2004 Ford Explorer engine problems?
No. NHTSA lists no engine & cooling recall for the 2004 Ford Explorer. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Ford Explorer engine problems start?
Half of the complaints with a recorded mileage happened before about 74,000 miles, and 16% before 25,000 miles.
Is it dangerous?
Owners linked 2 crashes, 5 fires and 3 injuries to engine & cooling problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.