FordExplorer2004Overview/ford/explorer/2004/base/

2004 Ford Explorer

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

Body SUV

The 2004 Ford Explorer is an SUV with a routine engine-oil specification of 5.0 quarts of 5W-30 API oil. Across the Explorer’s 1990–2025 complaint history, the 2004 model logged 1,408 owner complaints—well under the line’s peak of 3,620 complaints for the 2002 model, but far above the 12 recorded for 1990. Power-train issues head the 2004 complaint list, and the model was subject to five recalls, so researchers should view it as a middle-of-the-road year rather than a high point for reliability.

Model year202620252024202320212020201920182004

Quick specs

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

Engine oil capacity5.0 qtOEM · verified
Engine oil type5W-30 APIOEM · verified
Lug nut torque100 ft-lbsOEM · 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 sizeP245-65R17OEM · verified

Full specifications

Engine, drivetrain, dimensions and economy.

Dimensions & weight NHTSA vPIC

Overall length189.4 in
Overall width72 in
Overall height71.3 in
Wheelbase113.8 in
Curb weight4374 lb
Track (front / rear)61 / 61 in
Weight distribution (front / rear)52/48

Performance & power Independent road tests

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

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

8.2–10.7 sec0–60 mph (tested)quickest 8.20 sec — 2005 XLT
YearTrim / engine0–60¼ mileHPDrivetrain
2005XLT 4.6L V88.20 sec16.40 sec239 hp4x4
2002Limited 4.0L V68.70 sec16.50 sec210 hp4x4
2002Limited 4.0L V68.80 sec16.50 sec210 hp4x4
2002XLT 4.0L V69.00 sec16.90 sec210 hp4x4
2002Eddie Bauer 4.0L V610.70 sec17.90 sec210 hp4x4

Service quick specs OEM factory data

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

This engine holds 5.0 qt of 5W-30 API engine oil, SYNTHETIC · 75W-140 · GL-5 in the differential, DOT 3 brake fluid. Torque lug nuts to 100 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 Capacity12.5-13.0
Brake FluidDOT 3
Differential Gear OilSYNTHETIC · 75W-140 · GL-5
Differential Gear Oil Capacity5.1 Pints, rear
Engine Oil5W-30 · API
Engine Oil Capacity5.0 qt
Power Steering FluidATF

Engine torques

Camshaft Bearing/Carrier Cap Bolts or Studs11-12 ft-lbs
Camshaft Bearing/Carrier Cap Bolts or Studs7.4 ft-lbs
Engine Flywheel Bolts59 ft-lbs
Intake Manifold to Engine Bolts18 ft-lbs
Exhaust Manifold to Cylinder Head Bolts15 ft-lbs
Intake Manifold to Engine Bolts7.4 ft-lbs
Exhaust Manifold to Cylinder Head Bolts16 ft-lbs
Main Bearings67-74 ft-lbs

Chassis torques

Lug Nuts100 ft-lbs
Transfer Case Fill Plug4WD: 18.0, With AWD: 13.0 ft-lbs
Transfer Case Drain Plug4WD: 18.0, With AWD: 13.0 ft-lbs
Rear Wheel Hub203 ft-lbs
Front Wheel Hub184-250 ft-lbs
Rear Wheel Hub203 ft-lbs

Ignition

Cylinder Firing Order1-4-2-5-3-6
Cylinder Firing Order1-3-7-2-6-5-4-8
Curb Idle Speed (No Load)MT: 850, AT: 710 rpm
Curb Idle Speed Variance (No Load)MT: 50, AT: 40 rpm
Curb Idle Speed (No Load)890 rpm
Curb Idle Speed (No Load)755 rpm
Curb Idle Speed Variance (No Load)75 rpm
Spark Plug ManufacturerMotorcraft

Battery & A/C

RefrigerantR134a
Refrigerant CapacityLess auxiliary A/C, 2.00. With auxiliary A/C, 3.50. lbs
Oil GroupPAG
Oil Type46
Oil CapacityLess auxiliary A/C, 9.00. With auxiliary A/C, 13.00. oz
Standard BCI Group Number65
Standard BCI Cranking Performance650 cca
Standard BCI Group Number65

Service checks

Pressure Test13-18 psi
Radiator Cap Pressure Relief13-18 psi
Thermostat Opening Temperature183-190 °F
Pressure Test13-18 psi
Radiator Cap Pressure Relief13-18 psi
Thermostat Opening Temperature183-190 °F
Key ON Engine OFF (KOEO)35-45
RPM28-45 @ Idle rpm

Brakes

Torque Caliper to Bracket24 ft-lbs
Torque to Knuckle100 ft-lbs
Minimum Pad ThicknessFront: 0.060; Rear: 0.030 in
Rotor Minimum Machining0.98 in / 0.45 in
Rotor Discard at or Under0.96 in / 0.43 in

Multi-step torque procedures OEM · verified

Connecting Rod (Large End) Bearings — tightening sequence 1 stages
115 ft. lbs., Step 2: 9015 ft. lbs
Connecting Rod (Large End) Bearings — tightening sequence 1 stages
118 ft. lbs., Step 2: 33 degrees, Step 3: 9018 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
124 ft. lbs.24 ft. lbs
2turn 80 degrees80 degrees
3turn 80
Cylinder Head — tightening sequence 3 stages
126 ft. lbs.26 ft. lbs
290 degrees90 degrees
390 degrees90 degrees
Cylinder Head — tightening sequence 5 stages

Prep Do not reuse old bolts. Coat new bolts with the specified engine oil.

1M12 bolts9 ft. lbs
2M12 bolts18 ft. lbs
3M8 bolts24 ft. lbs
4M12 bolts90 degrees
5M12 bolts90 degrees
Engine Flywheel Bolts — tightening sequence 1 stages
110 ft. lbs., Step 2: 5210 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 Line (inspect) · Brake Linings (inspect) · Brake System (inspect) · CV Joint Boot (inspect) · Cabin Air Filter (replace) · Driveshaft U-Joint (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 miEngine Coolant System (drain, flush & refill)
Every 100,000 miAccessory Drive Belt (inspect) · PCV Valve (replace) · Spark Plugs (replace)
At 150,000 miDrive 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 Explorer recorded 1,408 complaints, 5 recalls, 4 investigations and 126 TSBs, which is slightly higher than the 2003 figures (1,313 complaints, 7 recalls, 3 investigations, 176 TSBs) but markedly lower than the 2002 peak of 3,620 complaints. Compared with the following year, 2005 saw a sharp drop to 568 complaints, 3 recalls, 2 investigations and 60 TSBs, indicating that 2004 sits on the descending limb of a complaint surge that began in the mid‑1990s and peaked in 2002. Recall frequency also fell from the double‑digit levels seen in 2000‑2001 (14‑16 recalls) to just five in 2004, continuing the downward trend thereafter. Investigations followed a similar pattern, decreasing from a high of 18 in 1991 to four in 2004 and then to two or fewer in most subsequent years. Overall, the 2004 model exhibits fewer complaints and recalls than the generation’s worst years and aligns with the improving reliability trend that followed, making it a reasonably sound choice among used Explorers of this era.

5
Open recalls
NHTSA campaigns
126
Service bulletins
Manufacturer communications
4
ODI investigations
Office of Defects Investigation
1,408
Owner complaints
75 involved a crash · 16 a fire
NHTSA crash-test rating federal NCAP · out of 5 stars
Rollover★★★★★

Owner complaints filed with NHTSA, by component

All 1,408 complaints on record, top 8 components.

Power Train385
Structure347
Visibility55
Engine & Engine Cooling53
Vehicle Speed Control50
Air Bags44
Wheels36
Visibility,Structure32

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 4 campaigns on record for this vehicle.

06E049000Exterior LightingReported 24/05/2006

CERTAIN CK MOTORSPORTS COMBINATION HEADLIGHTS, CLEAR CORNER, BUMPER, AND SIDE MARKER LIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON THE PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH… Remedy: CK MOTORSPORT WILL NOTIFY OWNERS AND REPLACE THE NONCOMPLIANT LAMPS FREE OF CHARGE. THE RECALL BEGAN ON JULY 1, 2006. OWNERS MAY CONTACT CK MOTORSPORT AT 1-909-610-7211.

07E104000Visibility:Glass, Side/RearReported 11/12/2007

CERTAIN CURVED TEMPERED REPLACEMENT GLASS MANUFACTURED BY HANGZHOU SAFETY GLASS LTD AND SUPPLIED TO SAFELITE BY AUTO TEMP INC., IDENTIFIED AS DOT-430, AND SOLD FOR USE ON CERTAIN DOMESTIC AND FOREIGN VEHICLES MAY NOT… Remedy: SAFELITE WILL NOTIFY ITS RETAIL CUSTOMERS AND REPLACE THE GLASS FREE OF CHARGE. RETAIL CUSTOMERS CAN CONTACT SAFELITE TOLL FREE AT 1-888-843-2906. SAFELITE WILL NOTIFY ITS…

Technical service bulletins NHTSA · verified

Showing 5 of 126 bulletins on record with NHTSA.

BulletinDateComponentSummary
TSB 19-20262019-02-07StructureSome 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels…
TSB 19-20262019-02-07StructureSome 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels…
SSM 460852016-09-21Engine And Engine CoolingThe Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing…
TSB-12-8-12012-08-01Electrical SystemFORD/LINCOLN/MERCURY: MAY HAVE SLUDGE BUILDUP IN THROTTLE BODY LEADING TO LESS AIRFLOW OR…
TSB-12-7-42012-07-10EngineFORD/LINCOLN/MERCURY: IF BATTERY WAS DISCONNECTED OR DEAD, VEHICLES/TRUCKS MAY EXPERIENCE…

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 Explorer. 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 Explorer take?

5.0 qt of 5W-30 API MEETING FORD SPECIFICATION WSS-M2C946-A, per the factory manual.

Does the 2004 Explorer have open recalls?

NHTSA lists 5 recall campaign(s) for this model year. Check your specific vehicle by VIN.