MercuryMountaineer2004Overview/mercury/mountaineer/2004/base/

2004 Mercury Mountaineer

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

Body SUV

The 2004 Mercury Mountaineer is a body-on-frame SUV requiring 5.0 quarts of 5W-30 API oil, placing it in the traditional truck-based utility segment. With 210 total owner complaints and a single recall, its reliability record falls between the model’s highest complaint year (2002, with 390) and its lowest (1996, with just 3), while the top complaint area—Structure—highlights a consistent concern across the generation. This positions the 2004 as a middle-ground entry in the Mountaineer’s long-term dependability history.

Model year201020092008200720062005200420032002

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 sizeP245-70R16OEM · verified

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 oil drain plug to 19.0 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 Capacity12.4
Brake FluidDOT 3
Differential Gear OilSYNTHETIC · 75W-140 · GL-5
Differential Gear Oil Capacity3.6 Pints, Rear
Engine CoolantUSE FORD PREMIUM GOLD COOLANT
Engine Oil5W-30 · API
Engine Oil Capacity5.0 qt

Engine torques

Camshaft Bearing/Carrier Cap Bolts or Studs11-12 ft-lbs
Intake Manifold to Engine Bolts7.4 ft-lbs
Exhaust Manifold to Cylinder Head Bolts16.0 ft-lbs
Intake Manifold to Engine Bolts18.0 ft-lbs
Exhaust Manifold to Cylinder Head Bolts15.0 ft-lbs
Main Bearings67-74 ft-lbs
Engine Oil Pan Drain Plug17.0-22.0 ft-lbs
Engine Oil Pan Drain Plug19.0 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

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
Spark Plug ManufacturerMotorcraft
Spark Plug Gap0.052-0.056 in
Spark Plug Torque13.0 ft-lbs

Battery & A/C

RefrigerantR134a
Refrigerant CapacityLess auxiliary A/C, 2.50. 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
Key ON Engine OFF (KOEO)35-45
Key ON Engine OFF (KOEO)35-45
RPM28-45 @ Idle rpm
Engine Oil Pressure15 psi
Engine Oil Pressure RPM2000 rpm

Brakes

Torque Caliper to Bracket24 ft-lbs
Torque to Knuckle100 ft-lbs
Minimum Pad ThicknessFront: 0.118; Rear: 0.118 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
Crankshaft Pulley and/or Damper Bolts — tightening sequence 1 stages
137 ft. lbs., 9037 ft. lbs
Cylinder Head — tightening sequence 3 stages

Prep Do not reuse old bolts. Coat bolt threads with clean engine oil.

126.0 ft. lbs.26 ft. lbs
290 degrees90 degrees
390 degrees90 degrees
Engine Flywheel Bolts — tightening sequence 1 stages
110 ft. lbs., Step 2: 5210 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 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)
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 Mercury Mountaineer generated 210 complaints, 1 recall, 3 investigations, and 103 TSBs, exceeding the 2003 figures of 152 complaints, 1 recall, and 2 investigations while falling well short of the 2002 peak of 390 complaints and 5 investigations. Across the generation, federal filings show an early cycle of high activity from 1997 through 2000, a sharp spike in 2002, and a subsequent general downward trajectory; 2004 interrupts that decline with a rebound in complaints before volumes drop to 82 in 2005 and largely remain lower through 2010. In this arc, 2004 sits as a mid-generation outlier with elevated owner reports relative to its immediate neighbors, though it shares their low recall count of just one campaign. The top 2004 complaint areas were Structure with 65 filings and Power Train with 48, with 11 crash-related and 2 fire-related complaints recorded, but the data does not specify root causes. For a buyer, this makes 2004 a moderate-risk choice—better than the 2002 model with its generation-high complaint volume but notably weaker than the lower-complaint 2005 and later years—suggesting a later model year would be the safer purchase.

1
Open recalls
NHTSA campaigns
103
Service bulletins
Manufacturer communications
3
ODI investigations
Office of Defects Investigation
210
Owner complaints
11 involved a crash · 2 a fire
NHTSA crash-test rating federal NCAP · out of 5 stars
Rollover★★★★★
Owner complaints by model year NHTSA · this generation & adjacent

Owner complaints filed with NHTSA, by component

All 210 complaints on record, top 8 components.

Structure65
Power Train48
Vehicle Speed Control13
Air Bags10
Electrical System8
Engine & Engine Cooling7
Unknown Or Other5
Suspension3

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 1 of 1 campaigns on record for this vehicle.

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 103 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-12-7-42012-07-10EngineFORD/LINCOLN/MERCURY: IF BATTERY WAS DISCONNECTED OR DEAD, VEHICLES/TRUCKS MAY EXPERIENCE…
TSB-08-19-32009-05-01Power TrainFORD: SOME VEHICLES MAY EXHIBIT OIL SEPARATION FROM THE INTERNAL LUBE FOUND IN THE…

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 Mountaineer. 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 Mountaineer take?

5.0 qt of 5W-30 API, per the factory manual.

Does the 2004 Mountaineer have open recalls?

NHTSA lists 1 recall campaign(s) for this model year. Check your specific vehicle by VIN.