2004 Ford Explorer Service and Repair Manual

This factory service and repair manual for the 2004 Ford Explorer covers the 4.0L V6, single overhead-cam and able to run on gasoline or flex-fuel, and the 4.6L V8, single overhead-cam and gasoline only, both naturally aspirated. Only the 4-door sport utility body is listed, but seven trims are: Eddie Bauer, Limited, NBX, XLS, XLS Sport, XLT and XLT Sport. Procedures, specifications, torque values, wiring diagrams and diagnostics cover each engine and the transmission, driveline, brakes, suspension, steering, body and electrical systems that all seven share.

Engines covered

• 4.0L V6 (245 cu in) — SOHC, naturally aspirated, gasoline or flex-fuel
• 4.6L V8 (281 cu in) — SOHC, naturally aspirated, gasoline

Body styles covered

• 4-door sport utility

Trims covered

• Eddie Bauer
• Limited
• NBX
• XLS
• XLS Sport
• XLT
• XLT Sport

Known issues on the 2004 Explorer. Four recalls are on federal record, and all of them concern parts sold for the truck rather than parts built into it. Three cover aftermarket corner, bumper and headlamp assemblies that lacked amber side reflectors or otherwise failed the lighting standard, and one covers replacement side and rear glass that might not break into small pieces as tempered glass should. Owners have filed 1,408 complaints with NHTSA, led by the power train at 440, structure at 373 and visibility at 93. Transmission diagnostics, body structure and glass replacement procedures are covered in the manual with specifications and torque values.