2004 Ford Explorer Ford Explorer 2004

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2004 Ford Explorer repairs by problem area

Engine (20%)

Transmission and Drivetrain (25%)

Brakes and Traction Control (9%)

Suspension and Steering (24%)

Electrical and Air Conditioning (19%)

Paint, Rust, Leaks, Rattles, and Trim (0%)

Other (3%)

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Chart based on 111 repairs.

2004 Ford Explorer repair cost distribution

$2500+ (10%)

$1000 - $2499 (20%)

$500 - $999 (31%)

$100 - $499 (27%)

< $100 (12%)

Chart based on 51 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.
Non-members can see only ten 2004 Ford Explorer repair histories. Log in or join us to see them all.

2004 Ford Explorer

Engine not specified

Ford Explorer in Michigan, United States
Dec 2013 - Dec 2014
Dec 2014

192000 mi
Loud rhythmic whirring sound coming from the rear end of the truck. 
Ford in Ontario, Canada
May 2009 - Mar 2010
Jun 2009

64480 mi

C $230
Air conditioning was recharged. 
Ford Explorer in Indiana, United States
Mar 2014 - Mar 2014
Mar 2014

106000 mi

US $30
EGR value was bad and had to be replaced 
Ford Explorer in South Carolina, United States
Apr 2014 - Apr 2014
Apr 2014

219000 mi

US $40000
The transmission went out. The car will not shift in reverse or go out of first gear. 
Ford Explorer in Nebraska, United States
Dec 2013 - Jan 2015
Dec 2014

147000 mi

US $1500
These 5R55S transmissions are junk. It keeps grinding lots of shavings into the pan and the o/d comes on flashing on & off. Then it doesn't want to stay in o/d. It's a sealed trans w/ no dipstick. Wish I could find a rplcmnt unit that came w a dipstick. 
Jan 2015

147000 mi

US $800
5R55S sealed-up transmissions are a bunch of junk! 
Ford Explorer in Alabama, United States
Dec 2010 - Jul 2013
Dec 2011

89000 mi
The right rear main axle seal on the Ford explorer xls is leaking oil. Not yet fixed. 
Jul 2012

92000 mi

US $25
From previous rear axel leak, I changed the rear axel oil with w-mart 85-140 synthetic, added 4 ounces tranny stop leak and the LS additive. Rear end has stopped leaking and is much quieter. 92,000 miles 

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2004 Ford Explorer 4dr SUV

239-horsepower 4.6L V8 5-speed automatic RWD

Ford Explorer in Arizona, United States
Mar 2014 - Jan 2015
Jan 2015

118000 mi

US $2200
Oil filter adapter gasket leaking. Manifold hose leak, and actuator door broken. 
Ford Explorer in Virginia, United States
- Dec 2007
Dec 2007

30000 mi
I had a problem with the limited slip differential package. The vehicle was still under warranty so it cost me nothing. 

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2004 Ford Explorer 4dr SUV

239-horsepower 4.6L V8 5-speed automatic AWD

Ford Explorer in Michigan, United States
Nov 2008 - Jun 2016
Jan 2008

14000 mi
ABS sensor 
Aug 2014

109700 mi

US $800
Defroster vent 

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2004 Ford Explorer 4dr SUV

239-horsepower 4.6L V8 5-speed automatic 4WD w/low range

Ford Explorer in North Carolina, United States
Apr 2011 - Jun 2016
May 2011

35000 mi
Pump seal on the transmission replaced under dealer warranty. 
Ford Explorer in Michigan, United States
Sep 2008 - Jun 2015
Mar 2014

93000 mi

US $500
Front sway bar links Cat back exhaust 
Ford Explorer in California, United States
Sep 2012 - Mar 2014
Aug 2012

94600 mi

US $3040
A belt in the transmission broke, which required a complete rebuild. 
Mar 2014

105000 mi

US $1600
Starter failed, and the flywheel had to be replaced as well. 
Ford Explorer in Missouri, United States
Jan 2013 - Jun 2015
Jun 2013

184000 mi

US $40
Recharge 
Dec 2014

184000 mi

US $1500
Changed CV joint Repaired transmission 
Apr 2015

184300 mi

US $600
Charged ac There was also a new front end tie rod and ball joint installed. 
Ford Explorer in Ontario, Canada
- May 2009
May 2009

88040 mi

C $718
Short in wire harness leading to fuel pump. Harness cost $28 CDN. Remaining cost, diagnoses and labour. 

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2004 Ford Explorer 4dr SUV

210-horsepower 4.0L V6 5-speed automatic RWD

Ford Explorer in Georgia, United States
Jan 2013 - Oct 2014
Aug 2013

76500 mi

US $100
Alternator died. Replaced. 
Oct 2013

79300 mi

US $270
Dirty Solenoids Remove clutch pieces from resevoir Replace Fluid 
Feb 2014

85300 mi

US $150
Thermostat housing cracked. Replace housing. 
May 2014

87300 mi
Battery died 
Oct 2014

93000 mi

US $20
Fuel Pump Relay had to be replaced. 
Ford Explorer in Wisconsin, United States
Aug 2010 - Jun 2011
Sep 2010

95000 mi

US $5300
The car was shaking at idle. 
Ford Explorer in Florida, United States
Aug 2010 - Jun 2016
Sep 2011

70000 mi

US $200
THERMOSTAT HOUSING LEAKED  
Feb 2013

76500 mi
radio volume broke 
Jul 2014

82000 mi

US $230
tie ends for sway bars 
Oct 2014

82300 mi

US $750
upper and lower ball joints 
Ford Explorer in Oklahoma, United States
May 2014 - Sep 2015
Dec 2014

151000 mi

US $287
Front drivers side wheel bearing went out. Seems to be a common failure.  Also discovered the ball joints are bad. Will get them replaced next month. 
Feb 2015

152300 mi

US $458
Passenger side wheel bearing 
Aug 2015

162700 mi

US $100
Alternator went bad 
Sep 2015

164000 mi

US $160
Overheating. Replaced water pump and thermostat. 
Ford Explorer in Alabama, United States
Dec 2010 - Jan 2011
Jan 2011

104000 mi

US $400
replaced right rear wheel bearing 

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2004 Ford Explorer 4dr SUV

210-horsepower 4.0L V6 5-speed automatic AWD

Ford Explorer in Connecticut, United States
Jun 2009 - Jun 2011
Apr 2009

71000 mi

US $800
Replaced rear axle (limited slip) for the second time under warranty. ALso replaced radio subwoofer, and front wheel bearing.  
Jul 2009

80000 mi

US $4300
Replaced transmission. I had reported hard shifting and other transmission problemds to Ford since the vehicle was new but they did not fix it. After the factory extended warranty (75K miles) ran out, the transmission failed entirely. 
Aug 2010

107000 mi

US $200
The rear limited-slip differential started chattering again on slight turns. It has done this repeatedly since delivery. The temporary "fix" is to replace the rear lube with new 140W synthetic lube and add the special XL3 friction modifier. 
Nov 2010

108000 mi

US $50
Replaced bad tire pressure warning sensor inside the tire/wheel assy. They have a long life (5 yr) battery, but that wasn't the problem. Road Salt had corroded the metal cap that screws on to the metal stem to add air to the tire. Junk.  
Ford Explorer in Washington, United States
Nov 2010 - Jun 2011
Jun 2011

64000 mi
First, backup sensors stopped working. Then engine idle was very rough, diagnosed as failure of manifold gaskets, common for this year of truck. 
Ford Explorer in West Virginia, United States
Dec 2009 - Jun 2011
Jan 2010

61400 mi

US $200
replaced intake manifold twice under warranty with $100 per visit 
Ford Explorer in Iowa, United States
Oct 2008 - Jun 2014
May 2011

108000 mi
All 4 wheel bearings were replaced along with back brake pads 
Ford Explorer in Maryland, United States
Sep 2013 - Mar 2014
Nov 2013

127000 mi

US $1200
Replaced all 4 disks and pads. Replaced the The ball joints. 
Feb 2014

128000 mi

US $400
The backup warning system was not working. wiring and speaker replaced. 

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2004 Ford Explorer 4dr SUV

210-horsepower 4.0L V6 5-speed automatic 4WD w/low range

Ford Explorer in California, United States
Jun 2013 - Sep 2014
Sep 2014

140000 mi

US $180
Radiator leaked and had to replace. 
Ford Explorer in Indiana, United States
Oct 2013 - Oct 2014
Aug 2014

83300 mi

US $900
The front wheel bearings were replaced, but the vibration persists. The technician was unable to successfully find the problem. 
Ford Explorer in North Carolina, United States
Jan 2016 - Mar 2016
Feb 2016

133500 mi

US $200
Had to replace starter 
Ford Explorer in Ecuador
Jan 2014 - Jul 2015
Aug 2014

80600 mi

US $324
Fuel sensor wasn't working, it had to be changed. 
Ford Explorer in Pennsylvania, United States
Mar 2011 - Jun 2016
Oct 2013

58700 mi

US $200
abs warning light on abs sensor bad.... 
Sep 2014

65000 mi

US $190
A/C recharge previously taken to another garage who did not repair it. replace blend door replaced plugs replaced upper radiator hose...it was swelled in two places. 
Jan 2015

67000 mi

US $45
Front differential seal leaking. Added grease will replace when warmer In line Heater valve not opening fully. Some heat but not much. Replace heater valve, flush out heater core, top off anti freeze. 
Feb 2016

79000 mi
New brake pads and rotors. Cost $110, bought on line installed myself. 
Ford Explorer in Wisconsin, United States
Nov 2010 - Mar 2016
Sep 2011

97000 mi

US $678
Bad bearings Heater Blend motor broken, had to disassemble dash to access it 
Apr 2013

120300 mi

US $605
Front axle seal and rear bearing rear hatch hinges replaced 
Apr 2014

137700 mi

US $600
bearing with sensor built in replaced 
May 2015

156000 mi

US $1050
Differential carrier bearing failed. Replaced all bearings and seals in differential 
Oct 2015

159700 mi

US $68
Thermostat housing was leaking and ultimately was replaced 
Ford Explorer in Indiana, United States
Dec 2008 - Dec 2010
Oct 2010

131000 mi

US $1000
Gear (or sprocket?) at the head of the drive shaft was severely damaged requiring immediate replacement. 
Ford Explorer in Maryland, United States
Jan 2007 - May 2011
Aug 2007

10000 mi
Transmission slipping. Warranty repair. 
Jan 2009

110000 mi

US $375
Gas level sensor replaced. Had to drop the tank. 
Jan 2010

125000 mi
First oily leak ever. It's the CV boot. Mechanic said to let it get worse before repairing. Mechanic could hear front left and right rear bearings starting to make rrrhing noise but decided to let them get worse before replacing. 
Feb 2010

128000 mi

US $552
Replace heater hose, flush radiator fluid and replace. Hose rubbing up against AC unit for 6 years finally rubbed a hole in it. Used dealer shop. 
Oct 2010

138000 mi

US $1500
Replaced left front wheel bearing. Also got new Fireston Destination Tires and new brakes. Car now makes a road whirring sound from 35 mph to 45 mph. Had differentials and transfer case drained and refilled including friction modifier. 
Dec 2010

138000 mi

US $845
Replaced alternator and emergency brake shoes. 
Feb 2011

138000 mi

US $2300
Replace rear differential 
Ford Explorer in Kentucky, United States
Sep 2009 - Jun 2016
May 2010

80000 mi

US $180
Front Pinion Seal Replaced (Leaking). Also had Rear differential oil replaced (Maintenance) 
Oct 2010

86000 mi

US $700
Rear wheel bearings howling - New bearings installed, TSB. Rear Differential Seals Leaking - New Seals installed, TSB. 
Jun 2011

92000 mi

US $20
"creaking" sound when going over speed bumps. Replaced front sway bar bushings with aftermarket ones that could be lubricated via grease gun 
Jul 2012

107000 mi

US $250
Rt wheel bearing found loose during brake pad replacement Found upper ball joint boot cracker on RT side 
Jan 2013

110000 mi

US $150
Car would not turn over when attempting to start 
Jun 2013

114000 mi

US $60
Rough idle and hesitation. Replaced ignition wires 
Oct 2013

114500 mi

US $50
Replaced left upper ball joint 
Dec 2013

120000 mi

US $115
Replaced serpentine belt, idler pulley and belt tensioner. 
Feb 2014

122000 mi

US $250
Left front wheel bearing making noise. Replaced wheel bearing assembly. Left upper ball joint boot split. Replaced left upper control arm (with ball joint) Clicking noise from underneath dash when temp control moved out of Cold position. Replaced blend door actuator 
Aug 2014

133000 mi

US $50
Power steering pump leaking 
Oct 2014

136000 mi

US $200
Replaced upper control arm and lower ball joint and had four wheel alignment 
Aug 2015

153300 mi

US $200
RT front brake caliper siezed. Replaced both calipers, disks and pads 
Ford Explorer in Wisconsin, United States
Jun 2011 - Jun 2012
Nov 2011

98700 mi

US $3200
Transmission completely inoperable. Sway bar connecting links broken, repaired by owner 
Ford Explorer in New York, United States
Jul 2012 - Sep 2012
Aug 2012

80000 mi

US $110
Rear U-Joint replacement. Only lessened shudder / chatter from rear end. Shop said probably also needed a new differential, though outright failure could be years away. 
Sep 2012

80000 mi
Shudder / chatter from rear. Needed a new exhaust system (or at least some new pipes/clamps). 
Ford Explorer in North Carolina, United States
May 2012 - Jun 2016
Jun 2014

80000 mi

US $100
Oxygen sensor at the back of the catalytic converter had to be replaced 
Oct 2014

84000 mi

US $514
Replaced alternator and battery 
Jun 2015

89000 mi

US $900
Worn rear wheel bearings have been causing roaring noise for about 1 year. Shop assured me there was no rush to get this done. Decided it was time to fix. New wheel bearings and one new axle because heat generated seized hub to axle. 
Ford Explorer in New York, United States
Jan 2014 - Feb 2015
Mar 2014

109000 mi

US $20
front pinion seal was found leaking, removed and replaced seal and refilled with oil 
Aug 2014

122300 mi

US $100
freeplay in right rear trailing arm removed and replaced 
Ford Explorer in North Carolina, United States
Mar 2013 - Jun 2014
Apr 2013

87000 mi
Emission system was causing rough transmission shifting. system cleaned and trouble went away. 
Ford Explorer in Quebec, Canada
Jun 2013 - Jun 2014
Jun 2014

172980 mi

C $100
Leake from the rear axel oil seal i have change the oil seal 

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2004 Ford Explorer 4-door

6-cylinder automatic 2WD

Ford Explorer in Florida, United States
Feb 2012 - Oct 2013
Oct 2012

82000 mi

US $870
Brake repair, specifics not known. 
Jul 2013

94300 mi

US $1255
Replace front wheel bearings and ball joints Replace all brake pads New front rotors and brake fluid 

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2004 Ford Explorer Repair Histories

See our lemon odds and nada odds page to see vehicles with no repairs or vehicles with more than three repairs. To see how frequently 2004 Ford Explorer problems occur, check out our car reliability stats.