What is the 2002-2005 Ford Explorer 4.6L 2-Valve Triton V8 Spark Plug Ejection / Stripped Head Threads (TSB 07-21-2)?

The optional 4.6L 2-valve modular V8 (shared with the Mercury Mountaineer) has aluminum heads that engage only a few spark-plug threads (~0.25 in). Under thermal cycling the plug can strip the threads and eject from the head, sometimes blowing out the coil boot with it. Ford ackn… Repairs typically run $150-$1,500. Severity: high.

What is the 2000-2010 Ford Explorer Cruise Control Deactivation Switch Brake Fluid Leak and Underhood Fire Risk?

Many Ford vehicles of this era, including the Explorer, were subject to recalls for the speed control deactivation switch mounted on the brake master cylinder. The switch can leak brake fluid internally, overheat, and in some cases cause an underhood fire even when the vehicle is… Repairs typically run $0-$250. Severity: high.

What is the 2002-2005 Ford Explorer Liftgate Applique Panel Cracking and Liftgate Glass Hinge Corrosion/Separation?

Third-generation Explorers are well known for cracking in the rear liftgate applique panel beneath the glass, often around the Ford emblem area, and for corrosion at the liftgate glass hinges. Owners report visible cracks, rattles, water intrusion, and in more serious cases separ… Repairs typically run $300-$1,200. Severity: medium.

What is the 2002-2005 Ford Explorer Instrument Cluster / Gauge Failure Causing Erratic or Dead Speedometer and Gauges?

The 2002-2005 Explorer/Mountaineer instrument panel cluster (IPC) suffers internal failures that cause fluttering, sticking or dead gauges — speedometer, tachometer, fuel and temperature — plus dim/dead odometer segments. Ford issued a Special Service Message noting some 2002-200… Repairs typically run $150-$600. Severity: medium.

What is the 2002-2010 Ford Explorer Front Upper Ball Joint Wear Causing Clunk, Steering Wander and Uneven Tire Wear?

The independent front suspension on the 2002-2010 Explorer/Mountaineer uses upper control arms with pressed-in ball joints that wear out relatively early. Worn upper (and lower) ball joints produce a clunk over bumps, vague/loose steering, and cupped or inner-edge tire wear. On t… Repairs typically run $250-$750. Severity: medium.

What is the 2002-2010 Ford Explorer Rear Wheel Bearing and Hub Failure Causing Growling Noise and ABS Concerns?

Rear wheel bearing and hub assemblies are a frequent wear/failure item on independent rear suspension Explorers from this period. Owners commonly report a humming or growling noise that increases with road speed and can be mistaken for tire noise or differential problems. In some… Repairs typically run $250-$700. Severity: medium.

What is the 1997-2005 Ford Explorer 4.0L SOHC Camshaft Position Sensor and Synchronizer Failure Causing P0340 Misfire and Stalling?

The 4.0L V6 uses a camshaft synchronizer (a gear-driven cylindrical housing that also drives the oil pump intermediate shaft) with the camshaft position sensor mounted on top. The plastic vane/'flag' on the synchronizer and the sensor's internal magnet wear or come apart, manglin… Repairs typically run $150-$500. Severity: medium.

What is the 2002-2010 Ford Explorer Interior and Exterior Door Handle Breakage Causing Doors That Won't Open?

The 2002-2010 Explorer/Mountaineer/Sport Trac door handles use brittle plastic pivot pieces in the latch/handle mechanism. The exterior handle typically cracks first and jams the linkage, then the interior handle snaps when forced. Owners are eventually left with doors that won't… Repairs typically run $40-$300. Severity: low.

What is the 1995-2010 Ford Explorer Power Window Regulator Cable/Clip Failure Causing Window to Fall Into the Door?

The cable-drive window regulators on the Explorer/Mountaineer/Sport Trac fail as their plastic cable guides crack and the steel lift cable frays or jumps off the drum. The window then binds, drops crooked, or falls down inside the door — the motor often still runs. The front door… Repairs typically run $120-$400. Severity: low.

What is the 1997-2005 Ford Explorer DPFE Sensor / EGR Failure Setting P0401 and Companion P0171/P0174 Lean Codes?

The Differential Pressure Feedback EGR (DPFE) sensor on the 4.0L/4.6L Explorer has a very high failure rate past ~60k miles. Internal corrosion makes it under-report EGR flow, so the PCM sets P0401 (insufficient EGR flow) and can hold the EGR valve open too long, producing a lean… Repairs typically run $80-$350. Severity: low.

Ford · Known Issues

2004 Ford Explorer Problems: 14 Issues Every Owner Should Know

2004 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated July 2026

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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Ford Explorer has 14 documented known issues, with 6 rated critical. The most serious are Timing Chain Cassette and Guide Failure on 4.0L SOHC V6 ($1,800-$4,500 repair), 5R55W/5R55S Transmission Servo Bore Wear Causing Flare, Slip, and Delayed Reverse ($900-$3,500 repair), Rear Coil Spring Rust and Fracture Causing Sudden Ride-Height Drop and Tire Puncture Risk ($250-$750 repair), 4.6L 2-Valve Triton V8 Spark Plug Ejection / Stripped Head Threads (TSB 07-21-2) ($150-$1,500 repair), Internal Radiator Transmission Cooler Rupture Causing Coolant/ATF Cross-Contamination ('Pink Milkshake') ($400-$3,500 repair) and Cruise Control Deactivation Switch Brake Fluid Leak and Underhood Fire Risk ($0-$250 repair). Across all issues with published estimates, repair costs range from $40 to $4,500. DIY maintenance guides at au7o.io.

Frequently Asked Questions

What are the most common Ford Explorer problems?

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Ford Explorer has 14 documented issues. The most frequently reported are: Timing Chain Cassette and Guide Failure on 4.0L SOHC V6, 5R55W/5R55S Transmission Servo Bore Wear Causing Flare, Slip, and Delayed Reverse, Rear Coil Spring Rust and Fracture Causing Sudden Ride-Height Drop and Tire Puncture Risk. Of these, 6 are rated critical and should be addressed promptly.

Is the Ford Explorer reliable?

The 2004 Ford Explorer has 14 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 6 issues are rated critical: Timing Chain Cassette and Guide Failure on 4.0L SOHC V6 and 5R55W/5R55S Transmission Servo Bore Wear Causing Flare, Slip, and Delayed Reverse and Rear Coil Spring Rust and Fracture Causing Sudden Ride-Height Drop and Tire Puncture Risk and 4.6L 2-Valve Triton V8 Spark Plug Ejection / Stripped Head Threads (TSB 07-21-2) and Internal Radiator Transmission Cooler Rupture Causing Coolant/ATF Cross-Contamination ('Pink Milkshake') and Cruise Control Deactivation Switch Brake Fluid Leak and Underhood Fire Risk. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Ford Explorer problems?

Repair costs for known Ford Explorer issues range from $0 to $4,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Timing Chain Cassette and Guide Failure on 4.0L SOHC V6, typically costs $1,800-$4,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 2000-2010 Ford Explorer Timing Chain Cassette and Guide Failure on 4.0L SOHC V6?

The 4.0L SOHC Cologne V6 is notorious for timing chain guide and cassette failures, especially the rear cassette that is difficult to access with the engine installed. Plastic guide material breaks down over time, causing startup rattle, persistent chain noise, cam timing errors,… Repairs typically run $1,800-$4,500. Severity: high.

All 14 Known Issues

Other Ford Models

Frequently Asked Questions

What are the most common Ford Explorer problems?

Is the Ford Explorer reliable?

How much does it cost to fix common Ford Explorer problems?

What is the 2000-2010 Ford Explorer Timing Chain Cassette and Guide Failure on 4.0L SOHC V6?

When Issues Typically Appear

2000-2010 Ford Explorer: Timing Chain Cassette and Guide Failure on 4.0L SOHC V6#

2002-2005 Ford Explorer: 4.6L 2-Valve Triton V8 Spark Plug Ejection / Stripped Head Threads (TSB 07-21-2)#

1997-2005 Ford Explorer: 4.0L SOHC Camshaft Position Sensor and Synchronizer Failure Causing P0340 Misfire and Stalling#

2002-2005 Ford Explorer: Rear Coil Spring Rust and Fracture Causing Sudden Ride-Height Drop and Tire Puncture Risk#

2002-2010 Ford Explorer: Front Upper Ball Joint Wear Causing Clunk, Steering Wander and Uneven Tire Wear#

2002-2010 Ford Explorer: 5R55W/5R55S Transmission Servo Bore Wear Causing Flare, Slip, and Delayed Reverse#

2002-2006 Ford Explorer: Internal Radiator Transmission Cooler Rupture Causing Coolant/ATF Cross-Contamination ('Pink Milkshake')#

2000-2010 Ford Explorer: Cruise Control Deactivation Switch Brake Fluid Leak and Underhood Fire Risk#

2002-2005 Ford Explorer: Instrument Cluster / Gauge Failure Causing Erratic or Dead Speedometer and Gauges#

1995-2010 Ford Explorer: Power Window Regulator Cable/Clip Failure Causing Window to Fall Into the Door#

2002-2005 Ford Explorer: Liftgate Applique Panel Cracking and Liftgate Glass Hinge Corrosion/Separation#

2002-2010 Ford Explorer: Rear Wheel Bearing and Hub Failure Causing Growling Noise and ABS Concerns#

2002-2010 Ford Explorer: Interior and Exterior Door Handle Breakage Causing Doors That Won't Open#

1997-2005 Ford Explorer: DPFE Sensor / EGR Failure Setting P0401 and Companion P0171/P0174 Lean Codes#

What is the 2002-2010 Ford Explorer 5R55W/5R55S Transmission Servo Bore Wear Causing Flare, Slip, and Delayed Reverse?

What is the 2002-2005 Ford Explorer Rear Coil Spring Rust and Fracture Causing Sudden Ride-Height Drop and Tire Puncture Risk?