Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||||
| 041601 | 11/14/2005 | 05228 | 10018745 | Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running. *tt | 01/12/2006 |
| 051016 | 06/07/2005 | 10017931 | No start/hard start on cold soak - 4.0l engine. *tt | 12/07/2005 | |
| 18573 | 04/01/2005 | 10017882 | No start/hard start on cold soak. *tt | 12/06/2005 | |
| 042112 | 11/01/2004 | 10013383 | Rough idle in drive. *eh | 04/18/2005 | |
| 04225 | 12/31/2004 | 042620 | 10013399 | Throttle pedal response on tip in vehicles built before 10/4/2004 equipped with a 4.0l engine. *eh | 04/18/2005 |
| 0539 | 02/21/2005 | 10012953 | Mil on and/ or runs rough/misfire dtcs p0300-p0308 p0316 and or p0171/p0174 4.6l engine. *eh | 04/05/2005 | |
| ENGINE AND ENGINE COOLING - ENGINE | |||||
| 07212 | 10/01/2007 | 10023943 | Some 1997-2008 vehicles equipped with a 4.6l 2v, 5.4l 2v, or 6.8l 2v engine--spark plug thread repair procedure--not covered under new vehicle limited warranty. *nj this includes f-53 motorhome chassis. updated 2/23/10. *pe | 02/20/2008 | |
| 0531 | 02/21/2005 | 10012947 | Maf diagnostic service tip - vehicles equipped with egr system module (esm). *tt | 04/05/2005 | |
| 031404 | 08/23/2004 | 04161 | 10011162 | Engine misfire or running - coil on plug (cop) ignition systems - wds cop kit diagnostic tips. to include various 2005 models. * ar this article 04161 supersedes tsb 03-14-04. | 01/06/2005 |
| 041910 | 10/04/2004 | 10010719 | Oil leak from oil filter adapter - 4.0l sohc engine built before 4/1/2004. *tt | 12/07/2004 | |
| 03256 | 12/22/2003 | 10008278 | Engine-romeo built 4.6l 2v-tick noise from engine-engines built before 9/17/2003. *mj | 07/26/2004 | |
| 17326 | 11/01/2003 | 10008171 | Engine auxiliary oil cooler line and the right side motor mount squeaking noise from front exterior while driving over bumps. *tt | 07/22/2004 | |
| 17544 | 02/01/2004 | 10008115 | Generator noise in cold ambient temperatures. *mj | 07/22/2004 | |
| 17664 | 03/01/2004 | 10007422 | Intermittent hard start, long crank time or multiple crank attempts before starting. *tt | 06/22/2004 | |
| 17666 | 03/01/2004 | 10007423 | Diagnostic trouble code (dtc) u0300 (internal control module software incompatibility) stored in the pcm with no other dtc's present. *tt | 06/22/2004 | |
| 03144 | 07/21/2003 | 10003744 | Engine misfire or rough running condition with coil on plug (cop) ignition systems may be more accurately diagnosed using the optional worldwide diagnostic system (wds) coil on plug (cop) kit. 2003 super duty f series included. *tt | 10/29/2003 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL | |||||
| 03L17 | 12/01/2003 | 10008284 | Demonstration/delivery hold - special field action 03l17. revised smog emissions information. *tt | 07/26/2004 | |
Investigations
| NHTSA ID | Manufacturer | Date open | Date close | Subject | Recall campaign | |
|---|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK PLUG EJECTION FROM CYLINDER HEAD | ||
| On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi | ||||||
| ENGINE AND ENGINE COOLING - ENGINE | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK PLUG EJECTION FROM CYLINDER HEAD | ||
| On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi | ||||||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK PLUG EJECTION FROM CYLINDER HEAD | ||
| On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi | ||||||
Consumer Complaints
| Fail date | miles | occurences | Purchase date |
|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||
| 08/15/2012 | 71000 | 1 | |
| First issue was with the solenoids now the issue is with 1-2 shift ratio. shifting into neutral. *tr | |||
| 11/11/2010 | 97000 | ||
| Bought the car used with about 85,000 miles on it. after one year of average use (no towing or off-roading) the transmission failed (about 97,000 miles). had it rebuilt and now 2 years and four months later it is failing again (at 122,000 miles). | |||
| 03/06/2012 | 100000 | ||
| Tl-the contact owns a 2004 ford explorer. the contact stated that the engine transitioned into safe mode and stalled. the vehicle was taken to an authorized dealer, where the pcm, throttle, jack shaft chain, and bearings were replaced. the failure continued. both the dealer and manufacturer stated that the failure could not be diagnosed. they recommended attempting various trial and error remedies. the contact stated that the pcm and throttle again needed to be replaced. the failures continued. the failure mileage was 100,000 and the current mileage was 118,861. sm. | |||
| 03/06/2012 | 100000 | ||
| Tl- the contact owns a 2004 ford explorer. the contact stated the engine went into safe mode and stalled. the contact has taken the vehicle to the dealer and had the pcm, throttle, jack shaft chain and bearings replaced on the vehicle in the past two months and the vehicle is still stalling. the dealer and manufacturer said the failure cannot be diagnosed and all that can be done is to continue to try fixes to see if it works. the contact stated that the vehicle now needs the throttle body and pcm replaced again. the contact stated the vehicle continues to get a pip code that causes it to go into safe mode and stalls out the vehicle. the failure mileage was 100,000 and the current mileage was 118,861.rl | |||
| 02/29/2012 | 60200 | ||
| Transmission failure, slips between gears, replacement required. | |||
| 10/01/2011 | 100000 | ||
| Tl* the contact owns a 2004 ford explorer. the contact stated that when driving anywhere from 30-50 mph with the cruise control activated, the vehicle would stall. the vehicle would have to be placed in neutral in order to be restarted. the vehicle was taken to an independent mechanic where they advised the contact that they were unable to diagnose the failure. the manufacturer was contacted and they offered no assistance. the failure mileage was approximately 100,000. the vin was unavailable. | |||
| 10/01/2011 | 100000 | ||
| Tl-the contact owns a 2004 ford explorer. the contact stated that when driving anywhere from 30-50 mph with the cruise control activated, the vehicle would stall. the vehicle would have to be placed in neutral in order to be restarted. the vehicle was taken to an independent mechanic where they advised the contact that they were unable to diagnose the failure. the manufacturer was contacted and they offered no assistance. the failure mileage was approximately 100,000. the vin was unavailable. kmj | |||
| 10/01/2011 | 100000 | ||
| Tl-the contact owns a 2004 ford explorer. the contact stated that while driving approximately 30 to 50 mph with the cruise control activated the vehicle would stall. the vehicle would have to be placed in neutral in order to restart. the vehicle was taken to an independent mechanic and they advised him that they were unable to diagnose the failure. the manufacturer was contacted and they offered no assistance. the failure mileage was approximately 100,000. the vin was unavailable. tb | |||
| 04/18/2011 | 130000 | ||
| Tl*the contact owns a owns a 2004 ford explorer. while driving approximately 35 mph the contact heard a loud pop noise followed by banging noises coming from under the hood. the vehicle was pulled over and the contact noticed exhaust fumes were coming from the engine. the vehicle was taken to an independent repair shop where the contact was told one of the spark plugs broke. the vehicle was in the process of being repaired. the failure and current mileages were 130,000. | |||
| 04/18/2011 | 130000 | ||
| Tl-the contact owns a owns a 2004 ford explorer. while driving approximately 35 mph the contact heard a loud pop noise followed by banging noises coming from under the hood. the vehicle was pulled over and the contact noticed exhaust fumes were coming from the engine. the vehicle was taken to an independent repair shop where the contact was told one of the spark plugs broke. the vehicle was in the process of being repaired. the failure and current mileages were 130,000. sm. | |||
| 02/01/2011 | 40000 | ||
| Tl-the contact owns a 2004 ford explorer xls. the contact stated that while driving at various speeds she experienced a violent shake. the vehicle was taken to the dealer and they advised her that she needed a new engine due to the timing belt. the vehicle has not been repaired due to the engine that she has in her vehicle isn't being produced anymore. the failure and current mileages were approximately 40,000. tb | |||
| 01/29/2011 | 53000 | ||
| 2004 ford explorer: engine seized for no apparant or obvious reason at 53,000 miles. not repairable. also, rear plastic panel beneath window cracked. just read that this is a very common occurance. | |||
| 10/31/2010 | 67800 | ||
| Tl-the contact owns a 2004 ford explorer. while driving approximately 35 mph he heard a noise and the vehicle stalled. the vehicle was towed to an authorized dealer. he was advised by the dealer that the number 3 piston broke and ceased the engine. the vehicle had not been repaired. the vin was unavailable. he called the manufacture for assistance and he was advised that the vehicle was no longer under warranty. the approximate failure and current mileage were 67,800. vwb | |||
| 08/01/2010 | 67100 | ||
| Tl-the contact owns a 2004 ford explorer xlt. the contact stated that while driving approximately 55 mph the vehicle suddenly stalled and all the warning lights illuminated on the instrumental panel. the vehicle was able to restart. this failure has occurred on a intermittent basis. the vehicle was inspected by a dealer who informed the contact that they were unable to diagnose the failure. the vehicle has not been repaired. the failure mileage was approximately 67,100. tb | |||
| 11/26/2010 | 91031 | ||
| I backed suv out of garage and put in park, got out of vehicle while still running (to close garage door), closed the suv door, turned around and saw that suv was moving forward into my garage. i opened the suv door while it was moving and jumped in the drivers seat, pushed on the brake and suv did not stop, i was looking down at the floor to see why suv did not stop, pulled up my foot and placed it back down on the brake. suv still did not stop. it then made a loud noise like the engine was reeving up and then the suv took off forward, ran through the back of my garage, ran through my back yard, ran over a tree in the yard, ran through my back yard fence and my neighbor's fence and crashed into the back side of neighbor's house. all while this was occurring, i was inside of the vehicle with my left leg sticking out of the car (since i jumped in the suv in a hurry, i didn't realize that my leg was still out of the suv), i continually attempted to step on the brakes (each time lifting my foot up so that i could place it directly on the brake), the engine reeved up again while going through the yard. the only thing that stopped the suv was the tall concrete foundation of my neighbor's house that it ran into. i jumped out of the suv, fell to the ground and laid there for a few seconds before i realized that my suv was still running, then i jumped back into the suv and turned the ignition off. | |||
| 05/22/2010 | 68000 | ||
| Tl-the contact owns a ford 2004 ford explorer. while the contact was driving approximately between 55-60 mph, the engine completely stalled and the instrument panel warning indicators illuminate. the vehicle restarted and resumed without the illumination of the warning indicators. the failure occurred on numerous occasions and became progressively worse. the vehicle was not diagnosed or repaired. the failure mileage was 68,000. js | |||
| 08/18/2010 | 78350 | ||
| Tl- the contact owns a 2004 ford explorer . while driving at 25mph , the vehicle started to make a loud squealing noise coming from the front end of the vehicle. the vehicle was then taken to a mechanic and he diagnosed it stating that the harmonic balancer went bad and took out the air conditioning line . he also stated that the serpentine belt needed to be replaced. all the parts were replaced under the owners expense. the dealer was not contacted due to no warranty to the vehicle. the failure mileage was 78350 and the current mileage was 78470.cv | |||
| 08/08/2010 | 140000 | ||
| Tl- the contact owns a 2004 ford explorer. the contact had the vehicle repaired after the abs brakes came on and inspected. right after that the vehicle stalled. the dealer stated that the rear cassette broke and in turn broke the timing chain and killed the engine. there was no warning after the rear cassette broke and the timing belt broke. the failure mileage and current mileage was 140000.rl | |||
| 11/12/2009 | 10500 | ||
| I own a 2004 ford explorer that has experienced two overheating incidents, the second resulted in replacing the engine. the first incident was caused by a stuck thermostat and the second by a leaking hose between the thermostat housing and the engine. in both incidents when the engine temperature warning activated, the temperature was buried in the hot end of the gauge. in both incidents, i immediately decelerated and pulled off the road but in the second incident, the engine was already ruined. an article in the april 2010 issue of design news (made by monkeys, pg 10) about a similar incident with a mazda led me to believe mine was not an isolated occurrence but a result of increased use of aluminum and better cooling systems. in the mazda incident, the engine had been replaced once and was saved from a second replacement only because the driver was looking at the gauge when it suddenly pegged into the hot end. the problem is there in no warning of low coolant until the level drops below the water pump which results in a sudden and often catastrophic rise in engine temperature. the explorer is the most heavily instrumented automobile i have ever owned yet the cooling system warning is stuck in 60s when cars had cast iron blocks, overheated gradually and were forgiving of overtemps. | |||
| 06/11/2010 | 50000 | ||
| Spark plug blowout while driving home from work . explorer has only 50k miles | |||
| 12/04/2009 | 101000 | 1 | |
| When driving vehicle the vehicle stalls when braking. this failure occurs only when the vehicle is at 1/4 tank of gas or less. vehicle has been to ford for repair on 3 occasions. the have replaced the abs sensor, throttle body and a fuel injection cleaning was performed. none of this has fixed the problem. dec 4 2009 was the first occurrence and has occurred several times with the last being today 2-24-2010. *tr | |||
| 10/06/2009 | 79000 | 1 | |
| 2004 ford explorer xlt fire. *tr | |||
| 06/15/2009 | 75200 | 1 | 10/23/2006 |
| Tl*the contact owns a 2004 ford explorer. while driving at various speeds, the accelerator pedal would stick and cause the vehicle to lurch forward and sometimes stall. a technician stated that the throttle sensor assembly was the cause of the failure. he further stated that there were only four parts in the united states that were available for the repair. the vehicle has not been repaired. the failure mileage was 75,000 and current mileage was 75,200. updated 0/01/09 *cn the consumer stated the vehicle has since been repaired, however it took a total of 7 weeks, due to issues with parts. also the vehicle would stall at times. updated 09/09/09*jb | |||
| 02/11/2009 | 39500 | ||
| Tl*the contact owns a 2004 ford explorer. while driving between 10-30 mph, the vehicle stalled. when the contact turns off and restarts the vehicle, it resumes normal operation. the vehicle has shut off a total of four times. he took the vehicle to the dealer for a diagnostic, but they could not locate a failure code. the dealer cleaned the throttle, fuel injector, and reset the power module. the failure mileage was 39,500 and current mileage was 39,600. | |||
| 02/27/2009 | 1 | ||
| Sparkplug blow out of its socket, tearing the threats off, this seams to be a continuous problem with alot of ford's engine, i do have a maintainence program off checking all of the standard point on my explorer, my mechanic checks liquids, oils grease, filters, tires, sparkplugs etc. i believe that after so many complains and a well documented manufactures defect a recall should be issue, because i investigated this issue and it very possible to occur again, this repair cost me 2,154.97 canadian dollars, and it could cost me the same if it happens again. *tr | |||
| 11/02/2008 | 45000 | ||
| Tl*the contact owns a 2004 ford explorer. in 2007, the contact stated that the instrumental panel lights constantly flashed and lost power. the dealer replaced a hose, which corrected the failure for approximately ten months. on november 2, 2008, the vehicle lost power and shut off. the contact had to wait several minutes to restart the vehicle. the dealer was unable to diagnose the failure. the vehicle has not been repaired. the failure mileage was 45,000 and current mileage was 55,000. | |||
| 05/04/2008 | 59000 | 1 | |
| Turned on the cruise control and the engine cut out - no power. placed in neutral and restarted. *tr | |||
| 04/14/2008 | 34706 | 1 | |
| Failure of auxiliary suction line leading to rear ac in vehicle. paid for replacement at ford dealership. part should be expected to function for the life of the vehicle. ford refuses to accept there was an issue with the piping and reimburse for repair. *tr | |||
| 09/21/2007 | 63000 | 1 | 08/01/2004 |
| Tl*the contact owns a 2004 ford explorer. the contact stated that the vehicle would not start. she depressed the accelerator pedal and the vehicle started and began to vibrate. she then placed the vehicle in reverse and heard a loud clunking noise. she smelled a strong gas odor inside the passenger compartment. the contact looked in her rearview mirror and noticed a large amount of smoke coming from the exhaust system. she parked the vehicle and had it towed. she then noticed that all of the radiator fluid leaked out. the mechanic stated that the valve failed and damaged the entire engine. the mechanic also stated that the engine needed to be replaced and appeared to be a manufacturer defect. the current and failure mileages were 63,000. the consumer also stated had problems prior to incident with sun visor falling off, gear shaft would not shift into park, engine sluggish, and while using cruise control vehicle would just shut off. updated 10/22/07 *tr | |||
| 07/24/2007 | 1 | ||
| Multiple problems with my explorer. when shifting into reverse car jolts with a clunking noise. abs light is on and 4x4 high light flashes. service engine light on but no hose leaks can be found. wrench light comes on even after tps replacement suggested by obd-ii. very unhappy with this vehicle. i have owned 7 fords, this is the worst i have owned. *tr | |||
| 02/01/2005 | 1 | ||
| Ford motor company regarding dissatisfaction with lack of performance, reliability and quality of 2004 ford explorer xlt**cc consumer states has had multiple problems with 2004 ford explorer such as very hard shifting gears from a parked position, the vehicle shut down on i95 highway twice and pedals became inoperable, vehicle also slams into gear at high speed and wants to reimbursed for the multiple problems of his 3 year old truck. *tr | |||
| 12/30/2006 | 30150 | 3 | 05/16/2006 |
| On three separate occasions, my explorer would turn over but refuse to start. the third time it took 2 days for it to finally start. on the way to the service appointment at the dealer, the suv stalled in the middle of a very busy intersection. the dealer said that they couldn't pin-point any particular cause but they did have a service bulletin that called for updating of some software. *nm | |||
| 11/21/2006 | 80458 | 1 | 07/01/2005 |
| Dt*: the contact stated while driving various speeds, the engine stalled without warning. afterwards, the engine was restarted after several attempts. the vehicle was inspected by a dealer who was unable to duplicate the problem. the manufacturer was not alerted. | |||
| 08/05/2006 | 18300 | 1 | 07/31/2006 |
| Dt*: the contact stated the automatic transmission was slipping between gears and made clunking noises. the vehicle also made humming sounds from the engine while accelerated over 55 mph. the vehicle has not been to a service dealer. | |||
| 07/15/2005 | 29000 | 20 | 06/13/2005 |
| 2004 explorer has stalled several times without any warning. restarts fine. seems to be with cruise on and going down hill at speeds between 30 and 40. has been to dealership 3 times and they say they can't duplicate. have called ford they say take to dealershp. see several of same complaints on your site. very dangerous. has happened numerous times don't know what to put for incident date. *jb | |||
| 10/05/2004 | 14974 | 10 | 10/29/2003 |
| Dt: 2004 ford explorer. the vehicle stalled while driving, this happened at different speeds. when this occurred the vehicle had to be rolled off of the road. the vehicle completely shut down. the vehicle had to be turned off in order for it comes back on. the vehicle has been to the dealership, and they could not find the cause of the problem. also, could not duplicate it. *ak | |||
| 05/01/2005 | 1 | ||
| 2004 ford explorer engine shuts off and there is difficulty shifting gears.***no answer required***. *mr both of theses malfunctions present a danger and a hazard and are very serious defects. *bf *nm | |||
| 12/14/2004 | 4 | ||
| While driving vehicle stalled. consumer was unable to restart vehicle, and had it towed to the dealer. mechanic informed consumer that the problem could not be duplicated. *ak | |||
| 06/23/2004 | 3 | ||
| While driving smoke began coming from the engine compartment, the engine bogged down and the engine stalled. *nm the engine ran roughly and smoke emitted from the vehicle. since the repair the consumer noticed a hissing noise coming from the air conditioner'; return true; onmouseout=window.status=''; return true;>air conditioner'; return true; onmouseout=window.status=''; return true;>air conditioner. air coming through the windshield was the reason for the noise coming from the air conditioner. the winshield was removed and resealed. *tc *jb | |||
| 07/15/2004 | 14000 | 1 | |
| While driving vehicle stalled. consumer pulled over and restarted the vehicle. dealership was notified, but did not resolve the problem. *ak | |||
| 08/20/2004 | 3000 | 3 | |
| While driving at any speed vehicle lost power. *ak | |||
| 07/19/2004 | 140 | 3 | 07/19/2004 |
| Vehicle stalled on 3 separate occasions when driving down hills. vehicle was taken to the dealer, and they were unable to duplicate the problem. *ak | |||
| 06/11/2004 | 6500 | 3 | |
| The consumer stated that the engine fuse blew. the consumer managed to pull over and had the vehicle towed. determined. please provide more information. *jb | |||
| 06/08/2004 | 11000 | 4 | 11/01/2003 |
| Loud pop from rear-end. abs light,wrench,and check engine light came on. found to be a bad speed sensor and defective rear-end. suv has been in the shop for 2 weeks and no rear-end in sight. *ak | |||
| ENGINE AND ENGINE COOLING - COOLING SYSTEM | |||
| 02/02/2008 | 56000 | 2 | 02/02/2008 |
| Tl*the contact owns a 2004 ford explorer. the contact stated that the air pressure hose that connects to the air compressor failed. as a result, the air conditioning system became inoperative. the dealer stated that a new hose would cost at least $400. the vehicle has not been repaired. the contact is in the process of notifying the manufacturer. the failure mileage was 56,000 and current mileage was 60,080. updated 09/17/08. *lj the air conditioners high pressure hose failed twice. one form the hose on the drivers side going to the radiator. updated 09/25/08. *jb | |||
| 04/04/2005 | 40000 | 15 | 11/05/2004 |
| While driving down the road the engine will stall. has happened several times, replaced mass air flow sensor told this would fix it, but it did not. all but once the car has started back up immediatly. | |||
| ENGINE AND ENGINE COOLING - COOLING SYSTEM - RADIATOR ASSEMBLY | |||
| 09/21/2007 | 63000 | 1 | 08/01/2004 |
| Tl*the contact owns a 2004 ford explorer. the contact stated that the vehicle would not start. she depressed the accelerator pedal and the vehicle started and began to vibrate. she then placed the vehicle in reverse and heard a loud clunking noise. she smelled a strong gas odor inside the passenger compartment. the contact looked in her rearview mirror and noticed a large amount of smoke coming from the exhaust system. she parked the vehicle and had it towed. she then noticed that all of the radiator fluid leaked out. the mechanic stated that the valve failed and damaged the entire engine. the mechanic also stated that the engine needed to be replaced and appeared to be a manufacturer defect. the current and failure mileages were 63,000. the consumer also stated had problems prior to incident with sun visor falling off, gear shaft would not shift into park, engine sluggish, and while using cruise control vehicle would just shut off. updated 10/22/07 *tr | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 01/01/2011 | |||
| Rattling noise and shaking has been coming from engine area for some time now. could not find the cause until recently, and when looking for information online i found it is a very common problem. the harmonic balancer / crankshaft pulley goes bad. the inner ring breaks, causing the sensor to eventually wear down and also need replacement. this repair on average costs people more than $350. to replace. | |||
| 12/16/2009 | 59078 | ||
| Tl-the contact owns a 2004 ford explorer. the check engine lights continues to illuminates every two months after the vehicle has been repaired. each time the vehicle goes into the dealership she was charged a diagnostic fee to run test and repair yet a new problem. the contact did not know what repair was done with the vehicle. the manufacturer was call and stated they would send her information on how to trade the vehicle in for another vehicle and other discounts but she have not heard from them. the failure mileage was 59,078....mw | |||
| 08/21/2010 | 70000 | ||
| Tl- the contact owns a 2004 ford explorer. while driving at 65mph the vehicle stalled without warning. the contact was able to move over unto the side of the road. the vehicle was towed to the dealer diagnosed located the failure at the motor timing chain. the vehicle will be repaired. the manufacturer took a report 1644590504, but didn't offer to assist with the repair, because the motor wasn't covered by warranty. the current and the failure mileage were 70,000. li | |||
| 08/26/2010 | 120000 | ||
| Tl-the contact owns a 2004 ford explorer . while driving at 55 mph , the vehicle stalled and the contact had to get the battery jumped and drove it home. the contact stated that it was the alternator and went out and purchased another alternator. after the alternator was replaced the contact could not be able to move the vehicle even when the accelerator pedal was pressed all the way down to the floor. there was a wrench symbol that illuminated on the instrumental panel where the dealer stated that the computer went into limp mode. there have been no additional repairs to the vehicle. the failure and the current mileage was 120000.cv | |||
| 10/12/2009 | 112000 | 1 | |
| Driving my 2004 ford explorer with the 4.6l engine on the highway at 60 mph the vehicle blow it rear drivers side spark plug. the engine started shaking violently and there was a strong smell of fuel in the passenger compartment. the original factory installed plugs were still installed. the threads in the cylinder heads were striped. the repair was the installation of a heli-coil in to the cylinder head at a cost of $600. *tr | |||
| 08/25/2009 | 75000 | ||
| Tl*the contact owns a 2004 ford explorer xlt. the contact stated that minutes after starting the vehicle it unwarrantly stalled. spontaneous engine failure while driving increases the risk of vehicle crash. she towed the vehicle to a dealer but the technician could not identify the cause of the failure.however he speculated that the spark plugs may be the cause of the failure,but no repairs were made. the failure mileage was 75,000.the current mileage was unknown. | |||
| 06/11/2009 | 36323 | 1 | 08/24/2004 |
| Tl*the contact owns a 2004 ford explorer. while driving approximately 30 mph, the vehicle vibrated violently and stalled without warning. the driver waited a few moments before restarting the engine. the vehicle resumed normal operation, but there was a low power response during acceleration. the vehicle was towed to an independent mechanic for inspection and it was discovered that a valve spring failed. the mechanic suggested that the engine be replaced at the estimated cost of $5,000. the vehicle has not been repaired. the manufacturer was notified of the malfunctions. the failure and current mileages were 36,323. updated 07/08/09 *bf updated 07/08/09.*jb | |||
| 05/16/2009 | 55000 | 1 | |
| My 2004 ford explorer xlt 4.0 will stall intermittently when slowing to a stop or exiting a freeway. the explorer will start right up afterwards. it can be very dangerous to lose all power without warning. right before the stall the rpm's seem to drop below 400 and the power steering starts to go out. it happens at varying times and temperatures and with plenty of gas. *tr | |||
| 08/25/2008 | 76000 | 2 | 06/01/2004 |
| Tl*the contact owns a 2004 ford explorer. the contact stated that the vehicle jerks at any speed and then stalls. the vehicle must be parked on the side of the road in order to restart. he took the vehicle to the dealer approximately eight times and they were able to duplicate the failure; however, the diagnostic is not providing a proper dtc on what needs to be repaired and reprogrammed. the computer indicated what parts needed to be replaced, but all repairs was unsuccessful. the contact stated that the failure was a big safety hazard. the failure mileage was 76,000 and current mileage was 81,000. updated 2/23/09 *cn the consumer stated he lost power on the vehicle. the consumer no longer owns the vehicle. updated 02/25/09. *jb | |||
| 08/24/2008 | 72900 | 1 | |
| On my way to the airport for a business trip, i was driving the vehicle on the interstate when all of a sudden and without any warning, the engine stopped. i had to maneuver onto traffic and stop to try to start the engine without success. i called aaa and they had the vehicle towed to my home. when i came back i sent it to the shop and the mechanic advised me that the timing chain sprocket retainer pin broke, and because of that all valves bent, so i have to replace the engine. for 72900 miles and keeping all maintenance in order i consider this a safety issue and unacceptable in terms of quality. i have spoken to the manufacturer and they refuse to take action because the vehicle is out of warranty. *tr | |||
| 09/02/2008 | 21000 | ||
| Tl*the contact owns a 2004 ford explorer. while driving various speeds, the vehicle vibrated excessively. the dealer stated that the crankshaft pulley failed and needed to be replaced at the cost of $410.79. the failure and current mileages were 21,000. | |||
| 09/18/2006 | 1 | 09/19/2004 | |
| Started of being an engine vibration, 2 month later crankshaft pulley failure. just made it to the dealership, they fixed it but my concerns about the pulley coming off on the highway worry me. *nm | |||
| 03/10/2006 | 34348 | 5 | 10/23/2003 |
| Auto goes into fail safe mode while being driven. has happened 5 times since mar. 10, 2006. i have had it in the shop on mar. 14, april 22, april 27, may 25, and june 12, all for the same concern. the engine bogs down to 4 cylinders and loses power. the first 3 times it happened while driving at around 35 mph the last two times it has happened while merging into traffic on the highway coming off a feeder road. i'm am afraid i will end up in a serious accident. i put it in the shop on june 12, 2006 and just picked it up yesterday on july 17,2006. it was in the shop for over a month. as i was feeding into traffic yesterday evening of july 17, the engine again downshifted into fail safe mode causing me to bog down. i have lost all faith in this vehicle and do not want it anymore. i have owned fords for the last 35 years and have never had this kind of problem before with a ford. *nm | |||
| 05/02/2006 | 30000 | 5 | 08/01/2004 |
| I have two issues with a 2004 ford explorer. first issue the system that notifies tire pressure has failed multiple times. the indicator lights go on or off when the tires are properly inflated or not properly inflated. vehicle is still under original warranty. dealership will not fix or check the sensors associated with this area they can not recreate the issue. i have documentation from passengers and another tire company of the issue happening. second issue. 2004 ford explorer stalled while turning braking and steering locked up. identical reaction as to the problem stated in the failure of the camshaft position sensor in other vehicles from ford that is being investigated. *nm | |||
| 05/04/2005 | 24082 | 1 | 06/03/2003 |
| The consumer was making a left hand turn and the vehicle just shut off, couldn't steer, and couldn't pull off. the vehicle was in the middle of the road and the consumer restarted the vehicle about a minute down the road, when it happened again. the battery light came on and brake light came on, but felt like they were still working.*ak *sb *nm | |||
| 11/08/2004 | 17901 | 4 | 02/06/2004 |
| '04 explorer engine shuts off and steering wheel locks up while driving, car jerks when put in reverse, false fuel reading took truck back to dealership, they do not think any thing is wrong with the truck, this has happen four times. *jb | |||
| 01/10/2005 | 20000 | 3 | 11/03/2003 |
| Car transmission was not responding correctly. after several trips to the dealer to have it checked out, the replaced the solenoid pack several weeks later warning light came on with a battery symbol and said hi temp low oil. engine died when going to park and then again at stop light the next day. dealer could not replicate problem. two weeks later, engine again died with a wrench symbol and said engine failsafe mode. dealer has had it a week and cannot replicate problem. did find a problem with and replaced abs in computer system. *nm | |||
| 10/23/2004 | 70 | 1 | 10/05/2004 |
| I bought a 2004 ford explorer xlt at darcars toyota in silver spring md. it had only 28,000 miles. the plastic valve cover was found to have a crack where one pours the oil in. there was an oil leak around this area. apple ford in columbia, md. said this would not be covered by ford warranty. i thought ford's warranty covers to 3 years or 36,000 miles. this valve cover was over $400.00. why shouldn't this be covered. i signed a paper that states that the ford warranty should still be in effect to 36,000 miles. i don't know how or when this crack occurred, but i have only had the vehicle for 3 weeks. i think this should be covered by ford warranty. *jb | |||
| 07/26/2003 | 5251 | 100 | 03/29/2003 |
| This is intermittent stalls, poor throttle, no start. *jb | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||
| 02/23/2008 | 55300 | 1 | 08/28/2004 |
| I own a 2004 ford explorer, purchased in august. the truck sat for 16 months while i was deployed to iraq. while driving on a 3 hour trip, i heard a metallic clatter noise from my vehicle. i took it to the dealer and was informed that the #2 wrist pin had failed., requiring replacement of the engine. total cost would be $5500. this seemed excessive for such a young vehicle, considering that is was driven infrequently for over a year, and most of the mileage was highway. mileage at failure: 55,300. *tr | |||
| 03/19/2007 | 46000 | 1 | 05/21/2006 |
| We have a 2004 ford explorer eddie bauer, originally purchased in may 20'06 with approximately 30,000 miles . at approximately 36,000 miles in august 2006 we were told that the harmonic balancer needed to be replaced. that was about $500. my husband drove it to work on 3-19-07 and everything was fine. he took it to lunch, everything was still fine, and when he came out, he tried to start the vehiclem and it would not start. there were no check engine lights, no noises, nothing out-of-the-ordinary at all. we had it towed to a ford dealership, who ran some tests, and initially could not figure it out. they ran more tests, and came to the conclusion that the cams are not working. they told us that the engine needs to be replaced. $5,600.00 to replace the engine with 46,000 miles. ford is not offering us any help. they refuse to stand behind their product. they said if we had the extended warranty it would be covered. but the point is that it has 46,000 miles. i need someone to help me before i explode! *ak | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS | |||
| 05/12/2012 | 44489 | 1 | |
| 2004 ford explorer. consumer writes in regards to crankshaft pulley failure *tgw the consumer stated he was unable to move the vehicle from the road and had it towed to a repair shop, but was unable to make the repairs, due to other damage to one of the components. the vehicle was then towed to the dealer, where they informed the consumer the crankshaft pulley had failed, broke the v-belt, which in turn hit and damaged the crankshaft position sensor. *jb | |||