LincolnAviator2004Overview/lincoln/aviator/2004/base/

2004 Lincoln Aviator

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

Body SUVTransmission Automatic 5-spd

The 2004 Lincoln Aviator is an SUV equipped with a five-speed automatic transmission and an engine requiring 6.0 quarts of 5W-20 API oil, delivering EPA fuel economy of 12 city, 17 highway, and 14 combined mpg. Although the powertrain represents the top complaint area among the 81 total owner grievances filed for this year, the vehicle carries zero recalls and shows a notable drop in complaints from the model's 2003 peak of 111. Consequently, the 2004 model sits as an early downward shift in the Aviator's 2003–2027 reliability history, indicating to researchers that while powertrain issues persisted, overall reported problems were beginning to decline.

Model year202520242023202220212020200520042003

Quick specs

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

Engine oil capacity6.0 qtOEM · verified
Engine oil type5W-20 APIOEM · verified
Lug nut torque100 ft-lbsOEM · verified
EPA fuel economy12/17/14 mpgEPA · 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.

Engine & drivetrain NHTSA vPIC

TransmissionAutomatic 5-spd

Dimensions & weight NHTSA vPIC

Overall length192.9 in
Overall width76 in
Overall height71.3 in
Wheelbase113.8 in
Curb weight5002 lb
Track (front / rear)61.4 / 61 in
Weight distribution (front / rear)52/48

Ratings & economy EPA / vPIC

EPA city / highway / combined12 / 17 / 14 mpg
DrivetrainRear-Wheel Drive
Recommended fuelPremium Gasoline

Performance & power Independent road tests

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

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

6.9–7.6 sec0–60 mph (tested)quickest 6.90 sec — 2003 Premium
YearTrim / engine0–60¼ mileHPDrivetrain
2003Premium 4.6L V86.90 sec15.40 sec302 hpAWD
2003Premium 4.6L V87.40 sec15.90 sec302 hpAWD
2003Premium 4.6L V87.60 sec16.20 sec302 hpAWD

Service quick specs OEM factory data

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

This engine holds 6.0 qt of 5W-20 API engine oil, SYNTHETIC · 75W-140 · GL-5 in the differential, DOT 3 brake fluid. Torque lug nuts to 100 ft-lbs, the oil drain plug to 18.0 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
Differential Gear OilSYNTHETIC · 75W-140 · GL-5
Differential Gear Oil Capacity3.6 Pints, Rear
Engine Oil5W-20 · API
Engine Oil Capacity6.0 qt
Power Steering FluidATF

Engine torques

Intake Manifold to Engine Bolts7.4 ft-lbs
Exhaust Manifold to Cylinder Head Bolts15.0 ft-lbs
Engine Oil Pan Drain Plug18.0 ft-lbs

Chassis torques

Lug Nuts100 ft-lbs
Transfer Case Fill Plug11.0 ft-lbs
Transfer Case Drain Plug11.0 ft-lbs
Front Wheel Hub184 ft-lbs
Rear Wheel Hub203 ft-lbs

Ignition

Cylinder Firing Order1-3-7-2-6-5-4-8
Spark Plug ManufacturerMotorcraft
Spark Plug Gap0.052-0.056 in
Spark Plug Torque11.0 ft-lbs
Ignition Timing10, Not adjustable degrees
Ignition Timing Acceptable Variance2 degrees
Ignition Timing Reference RPMIdle rpm

Battery & A/C

RefrigerantR134a
Refrigerant Capacity2.88 lbs
Oil GroupPAG
Oil Type46
Oil Capacity14.00 oz
Standard BCI Group Number65
Standard BCI Cranking Performance650 cca

Service checks

Pressure Test13-18 psi
Radiator Cap Pressure Relief13-18 psi
Thermostat Opening Temperature188-195 °F
Key ON Engine OFF (KOEO)35-45
RPM28-45 @ Idle rpm
Key ON Engine OFF (KOEO)35-45
RPM28-45 @ Idle rpm
Engine Oil Pressure75 psi

Brakes

Torque Caliper to Bracket32 ft-lbs / 24 ft-lbs
Torque to Knuckle155 ft-lbs
Minimum Pad ThicknessFront: 0.118; Rear: 0.118 in
Rotor Minimum Machining1.06 in / 0.45 in
Rotor Discard at or Under1.04 in / 0.43 in

Multi-step torque procedures OEM · verified

Crankshaft Pulley and/or Damper Bolts — tightening sequence 1 stages
137 ft. lbs., 9037 ft. lbs
Cylinder Head — tightening sequence 6 stages
130 ft. lbs.30 ft. lbs
290 degrees90 degrees
3loosen all bolts 1 turn
430 ft. lbs.30 ft. lbs
590 degrees90 degrees
690

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 System (inspect) · Suspension System (inspect) · Transmission Assembly (inspect fluid level)
Every 30,000 miEngine Air Filter Element (replace) · Exhaust System (Complete) (inspect) · Fuel Filter (replace) · Temperature Controlled Seat Air Filter (replace)
Every 50,000 miEngine Coolant System (drain, flush & refill)
Every 60,000 miTransfer Case Assembly (drain & refill) · Wheel 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) · 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 Lincoln Aviator sits between 2003 and 2005 on a declining federal-profile arc, with 81 complaints representing a drop from 111 the year before and 51 the year after. Unlike 2003, which carried one recall, the 2004 model logged zero recalls while investigations held steady at two and technical service bulletins fell from 73 to 56, continuing a downward trend that brought TSBs to 29 by 2005. Leading complaint areas for 2004 centered on Power Train, Structure, and Engine & Engine Cooling, accompanied by two crash-related and one fire-related complaint, though the data does not specify root causes. Relative to 2003, 2004 eliminates recalls entirely while posting markedly lower complaint and service volumes. That profile makes it a solid year to buy, combining the absence of recalls with a complaint count that has already fallen substantially from the prior model year.

0
Open recalls
NHTSA campaigns
56
Service bulletins
Manufacturer communications
2
ODI investigations
Office of Defects Investigation
81
Owner complaints
2 involved a crash · 1 a fire
Owner complaints by model year NHTSA · this generation & adjacent

Owner complaints filed with NHTSA, by component

All 81 complaints on record, top 8 components.

Power Train12
Structure11
Engine & Engine Cooling8
Visibility6
Air Bags5
Unknown Or Other4
Electrical System4
Exterior Lighting2

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

No recall campaigns on record with NHTSA for this vehicle as of the last data refresh.

Technical service bulletins NHTSA · verified

Showing 5 of 56 bulletins on record with NHTSA.

BulletinDateComponentSummary
SSM 460852016-09-21Engine And Engine CoolingThe Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing…
TSB-08-19-32009-05-01Power TrainFORD: SOME VEHICLES MAY EXHIBIT OIL SEPARATION FROM THE INTERNAL LUBE FOUND IN THE…
07062007-05-21Unknown Or OtherEXTENDED WARRANTY COVERAGE ON IGNITION COIL ASSEMBLIES. *KB
052132006-01-01Fuel System, OtherMALFUNCTION INDICATOR LAMP ON WITH PCM DIAGNOSTIC TROUBLE CODE P0463 AND/OR IC DIAGNOSTIC…
06372006-01-01TiresLOW TIRE INDICATOR ON - TPMS SYSTEM SENSOR WAKE UP. *TT

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 Aviator. 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 Aviator take?

6.0 qt of 5W-20 API, per the factory manual.

Does the 2004 Aviator have open recalls?

NHTSA lists 0 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the Aviator get?

EPA figures are 12 city / 17 highway / 14 combined mpg.