2004 Ford Explorer Engine

TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT THE CHECK ENGINE LIGHTS CONTINUED TO ILLUMINATE EVERY TWO MONTHS AFTER THE VEHICLE WAS REPAIRED. EACH TIME THE VEHICLE WAS TAKEN TO THE DEALER, SHE WAS CHARGED A DIAGNOSTIC FEE TO PERFORM THE TEST AND REPAIR A DIFFERENT PROBLEM. THE CONTACT DID NOT KNOW WHAT REPAIRS WERE PERFORMED ON THE VEHICLE. THE MANUFACTURER WAS CALLED WHO STATED THAT THEY WOULD SEND HER INFORMATION ON HOW TO TRADE THE VEHICLE IN FOR ANOTHER VEHICLE, WHICH INCLUDED ADDITIONAL DISCOUNTS; HOWEVER, SHE HAD NOT HEARD FROM THEM. THE FAILURE MILEAGE WAS 59,078.

TL*THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 55 MPH, THE VEHICLE SUDDENLY STALLED AND ALL THE WARNING LIGHTS ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE WAS ABLE TO BE RESTARTED. THE FAILURE OCCURRED THREE DIFFERENT TIMES. THE VEHICLE WAS INSPECTED BY AN AUTHORIZED DEALER WHO COULD NOT DUPLICATE THE FAILURE. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 67,100. UPDATED 02/23/11*LJ UPDATED 05/04/11

TL*THE CONTACT OWNS A 2004 FORD EXPLORER . WHILE DRIVING 55 MPH, THE VEHICLE STALLED AND THE CONTACT HAD TO GET THE BATTERY JUMPED IN ORDER TO DRIVE TO HER RESIDENCE. THE ALTERNATOR FAILED AND WAS REPLACED; HOWEVER, AFTER THE ALTERNATOR WAS REPLACED THE CONTACT WAS UNABLE TO MOVE THE VEHICLE EVEN WHEN THE ACCELERATOR PEDAL WAS ENGAGED. THERE WAS A WRENCH SYMBOL THAT ILLUMINATED ON THE INSTRUMENT PANEL WHERE THE DEALER STATED THAT THE COMPUTER SHIFTED INTO LIMP MODE. THERE HAVE BEEN NO ADDITIONAL REPAIRS TO THE VEHICLE. THE FAILURE AND CURRENT MILEAGES WERE 120,000.

TL* THE CONTACT OWNS A 2004 FORD EXPLORER. WHILE DRIVING 25 MPH, THE VEHICLE BEGAN MAKING AN ABNORMAL SQUEALING NOISE FROM THE FRONT END. THE VEHICLE WAS THEN TAKEN TO AN INDEPENDENT MECHANIC WHERE THE CONTACT WAS ADVISED THAT THE HARMONIC BALANCER FAILED AND CAUSED THE AIR CONDITIONING LINE TO FAIL. HE ALSO STATED THAT THE SERPENTINE BELT WOULD NEED REPLACING. THE MECHANIC REPAIRED ALL COMPONENTS AT THE CONTACT'S EXPENSE. NEITHER THE DEALER NOR THE 'MANUFACTURER WAS CONTACTED TO REPORT THE FAILURE. THE FAILURE MILEAGE WAS 78,350 AND THE CURRENT MILEAGE WAS 78,470.

TL* THE CONTACT OWNS A 2004 FORD EXPLORER. THE CONTACT STATED THE ABS WARNING LIGHT ILLUMINATED AND THE VEHICLE WAS REPAIRED. FOLLOWING REPAIRS, THE CONTACT WAS DRIVING AT AN UNKNOWN SPEED WHEN THE VEHICLE STALLED WITHOUT WARNING. THE DEALER ADVISED THAT THE FAILURE WAS DUE TO THE REAR CASSETTE FRACTURING AND CAUSING THE TIMING CHAIN TO FAIL AND DESTROY THE ENGINE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE AND CURRENT MILEAGES WERE 140,000.

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. *TR

TL* THE CONTACT OWNS A 2004 FORD EXPLORER. HE STATED THAT WHILE DRIVING AT 65 MPH, THE ENGINE STALLED WITHOUT WARNING. THE CONTACT WAS ABLE TO COAST OFF THE ROADWAY WHERE THE VEHICLE WAS TOWED TO THE DEALER. THE DEALER ADVISED THE TIMING BELT HAD BROKEN AND DESTROYED THE ENGINE. THE ENTIRE ENGINE WOULD NEED TO BE REPLACED. THE VEHICLE WAS LEFT WITH THE DEALER WHERE THE CONTACT WAS AWAITING REPAIRS. THE MANUFACTURER WOULD NOT PROVIDE ANY ASSISTANCE. THE FAILURE AND CURRENT MILEAGES WERE 136,000.

SPARK PLUG BLOWOUT WHILE DRIVING HOME FROM WORK . EXPLORER HAS ONLY 50K MILES. *TR

HARMONIC BALANCER WENT BAD MAY 2009, JUST UNDER 19,000 MILES ON MY 2004 ST! LEFT MY FAMILY AND I STRANDED ON I-95 IN PHILADELPHIA. FORD HAS SOLD A LOT OF REPLACEMENTS BUT WON'T ISSUE RECALL OR TSB. THE SERPENTINE JUMPED OFF THE BALANCER PULLEY AND LANDED ON THE RUBBER MOUNT OF THE BALANCER THEN ATE THROUGH THE SENSOR. JAN 21, 2010: STARTED UP THE ST, NO PROBLEM. DROVE ONE BLOCK, STOPPED AT STOP SIGN. MADE RIGHT TURN AND ACCELERATED, THEN THE ST DIED; 22,000 MILES. JUST BEFORE IT LOST ALL POWER IN THE ENGINE, I HEARD WHAT SOUNDED LIKE A TURBINE QUICKLY DECELERATING. NOW I TURN THE KEY, HEAR THE STARTER CLICKING, AND NOTHING HAPPENS WITH THE ENGINE. TOWED TO FORD DEALERSHIP. THERE WAS A RATTLE JUST BEFORE THIS HAPPENED. FORD SERVICE DEPT. REP CALLED ME LATE YESTERDAY AND SAID IT MAY BE ATTRIBUTED TO POOR INSTALLATION OF HARMONIC BALANCER, POSSIBLY NOT TORQUED CORRECTLY; SOUNDED LIKE PASSING THE BUCK. HE NEEDED PERMISSION TO PULL THE FRONT OF THE ENGINE APART TO LOOK INSIDE, I GAVE HIM A GREEN LIGHT TO DO SO. HE JUST CALLED TODAY AND SAID THE "KEY WAY AND SPROCKET" ARE BAD. HE SAID THEY COME IN A KIT WITH A NEW TIMING CHAIN; PARTS AND LABOR AFTER A FRIENDLY DISCOUNT: $925. THE TRUCK IS ALREADY THERE AND APART, SO I GAVE THEM THE GO AHEAD TO FIX IT. NORMAL PRICE WOULD HAVE BEEN ABOUT $1100. STRANGE, THEY HAVE A "REPAIR KIT" TO FIX THIS PARTICULAR ISSUE, BUT FORD SAYS THERE IS NO PROBLEM WITH THE ENGINE! HARMONIC BALANCER GOES BAD, FIX IT WITH NEW AND IMPROVED ONE. THEN THIS HAPPENS, FIX IT WITH NEW AND IMPROVED PARTS FROM A "REPAIR KIT"! FORD SAYS THERE ARE NO KNOWN PROBLEMS WITH THIS ENGINE! *TR

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

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.

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

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

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.

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

2004 FORD EXPLORER XLT FIRE. *TR

STARTED HEARING A SQUEAL LIKE A SLIPPING FAN BELT, CHECKED IT OUT AND FOUND THE CRANKSHAFT PULLEY SEPARATED FROM THE DAMPER, THE BELT CAME OFF THE PULLEY AND WAS RIDING ON THE DAMPER. IT IS NOW COSTING ME $500 TO HAVE THE PULLEY REPLACED, I HAVE NOTICED OTHERS HAVING THIS SAME ISSUE, IT SEAMS THAT THIS IS A DEFECTIVE PART AND FORD SHOULD BE REQUIRED TO FIX THIS AT THEIR COST. IF I HAD CONTINUED TO DRIVE WITHOUT GETTING IT FIXED IT WOULD HAVE BROKEN THE CRANKSHAFT TIMING SENSOR CAUSING ENGINE SHUT DOWN AND MAYBE LOSS OF VEHICLE CONTROL. *TR

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

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.

MY TRUCK BEGAN MAKING LOUD WHINNING NOISES JUNE 2007, THE STEERING WAS VERY TIGHT WHEN USING THE A/C AND CHECK ENGINE LIGHT CAME ON, A/C DID NOT COOL OR GET A TIGHT SEAL FOR AIR FLOW, FRONT TIRE WEAR HAS ACCELERATED CAUSING SHAKY STEERING, POWER STEERING GOT WORSE, ALTHOUGH ALL FLUIDS WERE NEW AND BELTS LOOK WORN OUT AND WITH ALL THIS I ONLY HAD 52,120 MILES. I HAD WRECK IN 07 BECAUSE OF THE STEERING AND REPORTED IT TO MY INSURANCE FOR PAYMENT. WHEN ALL THE PROBLEMS CONTINUED TO PILE UP AND REGULAR MAINTENANCE DIDN'T SOLVE ANYTHING, I TOOK IT TO 3 MECHANICS AND ALL SAID AC COMPRESSOR OR POWER STEERING NEEDED REPLACING AND OTHER COMPONENTS LOOKED PREMATURELY WORN. FINALLY HAD AC COMPRESSOR REPAIRED ON 7/26/08 ONLY TO FIND OUT THAT THE HARMONIC BALANCER WAS THE CAUSE OF ALL MY PROBLEMS AND HAD TO BE REPLACED AS WELL. THE MECHANIC GAVE ME THE PARTS AND SAID IT LOOKED LIKE A WEAK LEGO BLOCK. I HAVE ALL THE OLD PARTS IN MY TRUNK AND EVEN THOUGH MY VEHICLE WAS REPAIRED, IT STILL RUNS BAD, BUT THE MECHANIC STATED THAT THE HARMONIC BALANCER IS THE INITIATOR, DUE TO POOR MANUFACTURING. *TR

TURNED ON THE CRUISE CONTROL AND THE ENGINE CUT OUT - NO POWER. PLACED IN NEUTRAL AND RESTARTED. *TR

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

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

TL*- THE CONTACT STATED THAT WHILE PULLING THE 2004 FORD EXPLORER SPORT TRAK WITHN 30000 FAILURE MILEAGE INTO THE DRIVEWAY THE CONTACT PUT THE VEHICLE INTO PARK AND BEGAN TO HEAR A TAPPING FROM THE FRONT OF THE ENGINE. THE VEHICLE WAS TAKEN TO A DEALER, WHO DETERMINED THAT THE VALVE SPRING WAS WORN. THE VEHICLE HAS NOT BEEN REPAIRED. THE CURRENT MILEAGE WAS 33000.*AKI

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