FordExpedition2004Overview/ford/expedition/2004/base/

2004 Ford Expedition

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2004 Expedition.

Body SUV

The 2004 Ford Expedition is a full-size SUV built on Ford's body-on-frame platform, powered with an engine requiring 7.0 quarts of 5W-20 API-grade motor oil for maintenance. This model year accumulated 296 total owner complaints, with air bags representing the most frequently cited issue among four total recalls issued for the vehicle. Compared to the model's complaint history spanning from 1991 to 2027, where the 1999 model year recorded the highest at 1,007 complaints and the 1991 model year the lowest at just 1, the 2004 falls toward the lower end of the spectrum in terms of recorded owner concerns, suggesting relatively fewer documented issues relative to other years within the Expedition's production run.

Model year202520242023202120202019201820172004

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity7.0 qtOEM · verified
Engine oil type5W-20 APIOEM · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 65 · 650 CCA battery. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 65 · 650 CCAOEM · verified
Tire sizeP265-70R17OEM · verified

OE service part numbers OEM · verified

Spark plugAGSF32PM4

Full specifications

Engine, drivetrain, dimensions and economy.

Dimensions & weight NHTSA vPIC

Overall length203.9 in
Overall width78.7 in
Overall height77.6 in
Wheelbase117.7 in
Curb weight5686 lb
Track (front / rear)66.9 / 66.9 in
Weight distribution (front / rear)50/50

Performance & power Independent road tests

0–60 mph, quarter-mile, horsepower and torque from independent road tests.

Independent road tests for the Expedition of this era, listed by trim and engine — this page spans more than one engine, so no single horsepower figure is shown.

8.6–9.6 sec0–60 mph (tested)quickest 8.60 sec — 2004 XLT
YearTrim / engine0–60¼ mileHPDrivetrain
2004XLT 5.4L V88.60 sec16.50 sec260 hp4x4
2004XLT NBX 5.4L V89.60 sec16.91 sec260 hp4x4
2006King Ranch 5.4L V89.40 sec16.90 sec300 hp4x4

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 7.0 qt of 5W-20 API engine oil, DOT 3 brake fluid. Torque the oil drain plug to 10.0 ft-lbs. The firing order is 1-3-7-2-6-5-4-8. Note the cylinder-head bolts finish on a torque angle (torque-to-yield) — they stretch permanently and should be replaced, not reused, during any head service.

Lubricants & capacities

Automatic Transmission FluidATF
Automatic Transmission Fluid Capacity5
Brake FluidDOT 3
Engine Oil5W-20 · API
Engine Oil Capacity7.0 qt
Power Steering FluidATF
Transfer Case FluidATF
Transfer Case Fluid Capacity4 pints

Engine torques

Camshaft Bearing/Carrier Cap Bolts or Studs7.4 ft-lbs
Camshaft Bearing/Carrier Cap Bolts or Studs6-9 ft-lbs
Engine Flywheel Bolts59 ft-lbs
Engine Flywheel Bolts55-64 ft-lbs
Exhaust Manifold to Cylinder Head Bolts18 ft-lbs
Exhaust Manifold to Cylinder Head Bolts18 ft-lbs
Engine Oil Pan Drain Plug19.0 ft-lbs
Engine Oil Pan Drain Plug10.0 ft-lbs

Chassis torques

Transfer Case Fill Plug11.0 ft-lbs
Transfer Case Drain Plug11.0 ft-lbs
Rear Wheel Hub250 ft-lbs
Front Wheel Hub20 ft-lbs
Rear Wheel Hub250 ft-lbs

Ignition

Cylinder Firing Order1-3-7-2-6-5-4-8
Curb Idle Speed (No Load)755 rpm
Curb Idle Speed Variance (No Load)75 rpm
Curb Idle Speed (No Load)730 rpm
Curb Idle Speed Variance (No Load)30 rpm
Spark Plug ManufacturerMotorcraft
Spark Plug Gap0.052-0.056 in
Spark Plug Torque11.0 ft-lbs

Battery & A/C

RefrigerantR134a
Refrigerant CapacityLess auxiliary A/C, 2.50. With auxiliary A/C, 3.62. lbs
Oil GroupPAG
Oil Type46
Oil CapacityLess auxiliary A/C, 9.00. With auxiliary A/C, 14.00. oz
Standard BCI Group Number65
Standard BCI Cranking Performance650 cca
Standard BCI Group Number65

Service checks

Key ON Engine OFF (KOEO)35-45
RPM28-45 @ Idle rpm
Key ON Engine OFF (KOEO)80-120
Key ON Engine OFF (KOEO)35-45
RPM28-45 @ Idle rpm
Injector Primary Resistance11-18 na ohms
Engine Oil Pressure40-125 psi
Engine Oil Pressure RPM2500 rpm

Brakes

Torque Caliper to Bracket26 ft-lbs / 41 ft-lbs
Torque to Knuckle140 ft-lbs / 148 ft-lbs
Minimum Pad ThicknessFront: 0.059; Rear: 0.039 in
Rotor Max Parallel Variation0.0003 in / 0.0004 in
Rotor Runout Limit0.002 in
Rotor Minimum Machining1.087 in / 0.77 in
Rotor Discard at or Under1.063 in / 0.748 in

Multi-step torque procedures OEM · verified

Connecting Rod (Large End) Bearings — tightening sequence 1 stages
118 ft. lbs., Step 2: 33 degrees, Step 3: 9018 ft. lbs
Connecting Rod (Large End) Bearings — tightening sequence 1 stages
133 ft. lbs., Step 2: 90 degrees, Step 3: 12033 ft. lbs
Crankshaft Pulley and/or Damper Bolts — tightening sequence 1 stages
166 ft. lbs., Step 2: loosen one turn, step 3: 37 ft. lbs., step 4: 9066 ft. lbs
Crankshaft Pulley and/or Damper Bolts — tightening sequence 1 stages
166 ft. lbs., step 2: Loosen one turn., step 3: 37 ft. lbs., step 4: 9066 ft. lbs
Cylinder Head — tightening sequence 3 stages
130 ft. lbs.30 ft. lbs
290 degrees90 degrees
390
Cylinder Head — tightening sequence 3 stages
130 ft. lbs.30 ft. lbs
290 degrees90 degrees
390
Intake Manifold to Engine Bolts — tightening sequence 1 stages
11.5 ft. lbs., Step 2: 181.5 ft. lbs
Intake Manifold to Engine Bolts — tightening sequence 1 stages
13 ft. lbs., step 2: 183 ft. lbs
Main Bearings — tightening sequence 1 stages
17.4 ft. lbs., Step 2: 18 ft. lbs., Step 3: 30 ft. lbs., Step 4: 90 degrees7.4 ft. lbs

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 5,000 mi; spark plugs every 100,000 mi; coolant every 50,000 mi. The big-interval services (every 50,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

Every 5,000 miEngine Oil (drain & refill) · Engine Oil Filter (replace) · Tire & Wheel Assembly (rotate)
Every 15,000 miBrake System (inspect) · Cabin Air Filter (replace) · Engine Coolant System Hoses (inspect) · Steering Linkage (inspect) · Suspension System (inspect) · Transmission Assembly (inspect fluid level)
Every 20,000 miAccessory Drive Belt (inspect)
Every 30,000 miEngine Air Filter Element (replace) · Exhaust System Heat Shield (inspect) · Fuel Filter (replace) · Temperature Controlled Seat Air Filter (replace)
Every 50,000 miEngine Coolant System (drain, flush & refill)
Every 60,000 miWheel Bearing (repack)
At 100,000 miAccessory Drive Belt (inspect) · Engine Coolant System (drain, flush & refill)
Every 100,000 miPCV Valve (replace) · Spark Plugs (replace)
At 150,000 miAccessory Drive Belt (inspect) · Drive Axle Assembly (drain & refill) · Drive Belt (replace) · Transfer Case Assembly (drain & refill) · Transmission Fluid & Filter (replace)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

The 2004 Ford Expedition sits in a notably quieter portion of this generation's federal record after the high-volume complaint years of 1997–2003, when annual complaints ranged from 612 to 1,007 and recalls ran as high as 11 per year. With 296 complaints, 4 recalls, 2 investigations, and 91 TSBs, the 2004 model posts the lowest complaint count of the 2001–2006 window and represents a clear downward inflection from 2003's 655 complaints and 6 recalls. Compared with the immediately following years, 2004 is comparable to 2005 (315 complaints, 5 recalls) and 2006 (299 complaints, 6 recalls), suggesting the model line had moved past its most troubled period. The leading complaint categories for 2004 were air bags (36), hydraulic service brakes (29), and tires/engine cooling (21 each), with 48 crash-related and 15 fire-related complaints, though the data does not specify root causes. Given its position on the declining side of the complaint/recall curve and its substantially lower complaint volume than the surrounding early-2000s model years, a well-maintained 2004 Expedition appears to be a comparatively favorable choice within this generation.

4
Open recalls
NHTSA campaigns
91
Service bulletins
Manufacturer communications
2
ODI investigations
Office of Defects Investigation
296
Owner complaints
48 involved a crash · 15 a fire
NHTSA crash-test rating federal NCAP · out of 5 stars
Rollover★★★★★

Owner complaints filed with NHTSA, by component

All 296 complaints on record, top 8 components.

Air Bags36
Service Brakes, Hydraulic29
Tires21
Engine & Engine Cooling21
Electrical System20
Engine16
Power Train15
Structure15

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 4 campaigns on record for this vehicle.

06E064000Exterior LightingReported 17/07/2006

CERTAIN TRADESONIC COMBINATION LAMPS SOLD AS REPLACEMENT LAMPS FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. COMBINATION LAMPS NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM WITH THE REQUIREMENTS OF FEDERAL… Remedy: TRADESONIC WILL NOTIFY OWNERS AND REPLACE THE LAMPS FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING JULY 2006. OWNERS MAY CONTACT TRADESONIC AT 626-934-8884.

09E012000Exterior LightingReported 07/04/2009

SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE… Remedy: SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON MAY 11, 2009. OWNERS MAY CONTACT SABERSPORT AT…

Technical service bulletins NHTSA · verified

Showing 5 of 91 bulletins on record with NHTSA.

BulletinDateComponentSummary
TSB 24-21882024-07-24WheelsThis article supersedes TSB 22-2219 to update the Parts List and Service Procedure to…
SSM 515362023-04-04StructureFor 2000-2024 Ford and Lincoln vehicles, swapping a module from a vehicle for diagnosis…
TSB 22-22192022-06-21Power TrainSome 2003-2020 Expedition/Navigator and 2006-2020 F-150 (non-Raptor) vehicles equipped…
TSB 20-23072020-10-16Electrical SystemSome 2003-2020 Expedition/Navigator and 2006-2020 F-150 vehicles equipped with TOD…
TSB 20-22332020-07-13StructureThis article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420
Catalyst system efficiency below threshold — Bank 1
P0300
Random / multiple cylinder misfire detected
P0171
System too lean — Bank 1
P0455
Evaporative emission system leak detected — large leak
P0128
Coolant thermostat below regulating temperature
P0442
Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN
Decode a VIN to confirm the transmission and build data for a specific Expedition. OEM
Build data
Plant, GVWR class, engine and body data for any 17-character VIN.
Recalls
Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Reference guides

Cross-vehicle references for the kinds of data on this page.

Frequently asked

How much oil does the 2004 Expedition take?

7.0 qt of 5W-20 API MEETING FORD SPECIFICATION WSS-M2C945-A, per the factory manual.

Does the 2004 Expedition have open recalls?

NHTSA lists 4 recall campaign(s) for this model year. Check your specific vehicle by VIN.