2004 Nissan Armada Problems: 2 Issues Every Owner Should Know
2004 model year · 0+ owner reports · Updated April 2026
According to Au7o's analysis of 0+ owner reports, the 2004 Nissan Armada has 2 documented known issues. No issues are rated critical, indicating generally reliable ownership. Across all issues, repair costs range from $300 to $1,500. DIY maintenance guides at au7o.io.
All 2 Known Issues
On the 2004-2015 Nissan Armada 5.6L VK56DE V8, the VK56DE V8 in the first-gen Armada is notorious for cracked exhaust manifolds. Both driver and passenger side manifolds develop cracks from thermal cycling, causing an exhaust leak that sounds like a ticking noise on cold start. The cracks worsen over time and can cause check engine lights from O2 sensor readings being affected by the leak. The catalytic converters can also be damaged by unmetered air entering the exhaust stream.
Common Symptoms
- Ticking or tapping noise on cold start that fades when warm
- Exhaust smell in cabin
- Check engine light
- Reduced fuel economy
- Failed emissions test
How to Fix
Replace cracked exhaust manifolds. OEM replacements are $400-$600 each, but aftermarket headers are a popular upgrade ($500-$900 for a set) that are stronger and flow better. Replace all exhaust manifold studs and nuts during the repair — they commonly break during removal. Apply anti-seize to new studs. Both sides should be inspected even if only one is symptomatic.
What Owners Are Using
Parts and tips from 0+ owners who fixed this issue
- TipDon't try to weld the manifold — it'll crack again within months. If you're going through the labor, upgrade to Doug Thorley headers. Better flow, better sound, and they won't crack.
- UpgradeWalker catalytic converter — EPA-compliant direct fit (Walker Catalytic Converter)
- UpgradeMagnaFlow catalytic converter — high-flow performance option (MagnaFlow Catalytic Converter)
- UpgradeDorman exhaust manifold — solves cracking issues on many models (Dorman Exhaust Manifold)
- UpgradeDorman exhaust manifold bolt and stud kit (Dorman Exhaust Manifold Hardware Kit)
On the 2004-2015 Nissan Armada, first-generation Armadas equipped with the rear auto-leveling air suspension suffer from compressor burnout and air spring bag leaks. The compressor runs excessively to compensate for leaking airbags, eventually overheating and failing. Once the system fails, the rear sags significantly, especially when loaded or towing. The air lines also develop cracks at their fittings.
Common Symptoms
- Rear end sags overnight or when parked
- Compressor runs constantly when vehicle starts
- Rear suspension bottoms out over bumps
- Air suspension warning light on dashboard
- Hissing sound from rear when car is off
How to Fix
Replace leaking rear air springs ($200-$400 per side) and the compressor if burnt out ($300-$500). Many owners convert to conventional coil springs using a conversion kit ($300-$500) from Strutmasters or Arnott, which eliminates the expensive air system entirely. The conversion includes rear coil springs, mounting hardware, and an electronic bypass module to eliminate the warning light.
What Owners Are Using
Parts and tips from 0+ owners who fixed this issue
- TipConvert to coil springs and never look back. The Strutmasters kit is $350 installed in 2 hours and rides nearly identical. The air system will just keep failing and costing you money.
- UpgradeReplacement air spring to restore proper ride height and comfort (Arnott Air Spring Assembly)
- UpgradeAir-to-coil spring conversion kit as a permanent fix for air suspension failures (Strutmasters Air Suspension Conversion Kit)