2004 Ford Explorer REPAIR MANUAL -- HOW TO FIX YOUR CAR OR TRUCK

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2004 Ford Explorer CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Ford REPAIR SHOPS DON'T WANT YOU TO KNOW

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Get Full Access Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2004 Ford Explorer car and truck repair procedures including Ford engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up & drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix your Ford Explorer automobile. Try the Automotix DIY solution today!
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Using the Automotix DIY repair procedures will save you hundreds and even thousands of dollars! In addition, it will save you hours of touring the city searching for Ford mechanics you can trust. The Automotix DIY solution is particularly affordable. A full access to the entire DIY repair procedures and diagrams for your 2004 Ford Explorer vehicle will cost less than a single gallon of gas. Here are some of the DIY repair tips and procedures you will find here:

A/C & HEATER SERVICE PROCEDURES FOR 2004 Ford Explorer AUTOMOBILES

Component Replacement & Adjustment -> Explorer & Mountaineer -> Thermostatic Expansion Valve (Fixed Orifice Tube), Replace -> Auxiliary -> Front
Vehicle: 2004 Ford Explorer 4.0 V6 GAS

Front

  • Recover refrigerant as outlined under .
  • Remove tube clamp and disconnect auxiliary line fitting.
  • Disconnect condenser to evaporator line from evaporator core using suitable spring lock coupling tool
  • Remove orifice using guide fixed orifice tool No. 412-034, or equivalent. If orifice is broken, use removal tool No. 412-035, or equivalent.
  • Reverse procedure to ...

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BRAKE SERVICE PROCEDURES FOR 2004 Ford Explorer AUTOMOBILES

Disc Brakes -> Adjustments -> E-250 w/Tension Limiter -> E-450 & E-550 -> E-Super Duty -> Expedition, Explorer, F-Super Duty, Mountaineer & Navigator -> Freestar & Monterey -> Parking Brake -> Rear Disc
Vehicle: 2004 Ford Explorer 4.0 V6 FLEX

Parking Brake

Expedition, Explorer, F-Super Duty, Mountaineer & Navigator
Rear Disc
  • Remove rear disc brake rotor as outlined in .
  • Measure inside diameter of parking brake drum using brake adjustment gauge tool No. D81L-1103-A, or equivalent, Fig. .
  • Adjust parking brake shoe to .020 inch (.508 mm) less than drum measurement, Fig. .
  • Reverse procedure to install.
E-Super Duty
E-250 w/Tension Limiter
  • Loosen tension limiter nut to end of tension limiter threads.
  • Depress brake pedal to last detent position (17 clicks).
  • Measure and record exposed length of cinch strap, Fig. .
  • Tighten tension limiter n...

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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Ford Explorer AUTOMOBILES

Ford Motor Co. Light Trucks, SUVs & Vans -> Fuel Shutoff Switch Location -> 1999-06 Explorer, Explorer Sport & Sport Trac & Mountaineer
Vehicle: 2004 Ford Explorer 4.0 V6 GAS

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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2004 Ford Explorer AUTOMOBILES

CV AXLE SHAFT, Replace
Vehicle: 2004 Ford Explorer 4.0 V6 FLEX

The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.

  • Raise and support vehicle.
  • Remove wheel and tire assembly.
  • Remove wheel hub retainer nut and washer assembly. Discard wheel hub retainer nut and washer assembly. It is a torque prevailing des...

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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR 2004 Ford Explorer AUTOMOBILES

Component Locations
Vehicle: 2004 Ford Explorer 4.0 V6 GAS

Refer to F...

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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2004 Ford Explorer AUTOMOBILES

Alternator, Replace
Vehicle: 2004 Ford Explorer 4.0 V6 GAS

  • Disconnect battery ground cable:
  • Disconnect alternator drive belt.
  • Position protective cover aside, remove and discard generator B+ terminal nut.
  • Disconnect alternator B+ terminal and electrical connectors.
  • Remove alternator mounting bolts.
  • Remov...

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MAINTENANCE LAMP RESET PROCEDURES FOR 2004 Ford Explorer AUTOMOBILES

Ford Motor Co. Trucks -> Electronic Throttle Control ->
Vehicle: 2004 Ford Explorer 4.6 V8 GAS

Electronic throttle displays when the system has malfunctioned and the engine has defaulted to a limp-home operation. On vehicles equipped with ...

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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Ford Explorer AUTOMOBILES

Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2004 Ford Explorer 4.6 V8 GAS

Lower

  • Drain cooling system into a suitable container.
  • Reposition hose clamp from radiator.
  • Remove radiator outlet hose from radiator.
  • Reposition hose clamp from water pump.
  • Remove radiator outlet hose from water pump and from vehicle.
  • Reverse procedure to in...

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SERPENTINE BELT SERVICE PROCEDURES FOR 2004 Ford Explorer AUTOMOBILES

Serpentine Drive Belt, Replace
Vehicle: 2004 Ford Explorer 4.0 V6 GAS

  • Raise tensioner by turning counterclockwise, then remove belt.
  • Install new be...

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COMPONENT LOCATION DIAGRAMS FOR 2004 Ford Explorer AUTOMOBILES

Component location diagrams for most 2004 Ford Explorer cars and light trucks sold in the U.S. from 1990+.

Engine Bulkhead Diagram for 2004 Ford Explorer  4.0 V6 GASEngine Bulkhead Diagram for 2004 Ford Explorer 4.0 V6 GAS

Components on diagram:
  • Connector C-148
  • Connector C-124
  • Connector C-1195
  • Brake Fluid Level Switch
  • Vapor Management Valve
  • In Roof Panel Diagram for 2004 Ford Explorer  4.0 V6 FLEXIn Roof Panel Diagram for 2004 Ford Explorer 4.0 V6 FLEX

    Components on diagram:
  • Connector C-340
  • Connector C-940b
  • Map Lamp Connector Cargo Lamp
  • Connector C-927
  • Interior Lamp Connector
  • CLICK HERE TO GET FULL ACCESS TO 2004 Ford Explorer PARTS/COMPONENTS LOCATION DIAGRAMS!

    WIRING DIAGRAMS FOR 2004 Ford Explorer AUTOMOBILES

    OEM drawn wiring diagrams for most 2004 Ford Explorer cars and light trucks sold in the U.S.

    2004 Ford Explorer  4.0 V6 GAS Wiring Diagram2004 Ford Explorer 4.0 V6 GAS Wiring Diagram

    Components on diagram:
  • PCM Power Relay
  • Accelerator Pedal Position Sensor
  • Evaporative Emission (EVAP) Canister Vent Valve
  • Powertrain Control Module (PCM)
  • 2004 Ford Explorer  4.0 V6 FLEX Wiring Diagram2004 Ford Explorer 4.0 V6 FLEX Wiring Diagram

    Components on diagram:
  • Audio Unit
  • CLICK HERE TO GET FULL ACCESS TO 2004 Ford Explorer WIRING DIAGRAMS!

    TECHNICAL SERVICE BULLETINS FOR 2004 Ford Explorer AUTOMOBILES

    OEM TSB listings for most 2004 Ford Explorer cars and light trucks sold in the U.S. from 1985+.

    Document: DTC P0505 / P0506 / HESITATION / LOSS OF RPM / DIFFICULTY STARTING / LOW IDLE RPM
    Vehicle: 2004 Ford Explorer 4.0 V6 GAS

    Symptoms:
  • Driveability
  • Starting Problems
  • Auto Systems:
  • Fuel Sys, Driveability, Filters (Air & Fuel)
  • Document: 4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON ACCELERATION / DECELERATION OR BINDING ON SLOW TURNS
    Vehicle: 2004 Ford Explorer 4.6 V8 GAS

    Symptoms:
  • Sticking, Binding
  • Vibration
  • Auto Systems:
  • Drive Axles, Shafts, U-Joints, CV-Joints
  • CLICK HERE TO GET FULL ACCESS TO 2004 Ford Explorer TECHNICAL SERVICE BULLETINS!

    COMPONENT/PARTS SPECIFICATIONS FOR 2004 Ford Explorer AUTOMOBILES

    BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2004 Ford Explorer cars and light trucks sold in the U.S. and Canada from 1970+.

    • Brake caliper mounting bolt torque
    • Brake drum runout, machining, & discard specs
    • Minimum brake lining thickness.
    • Brake rotor runout, parallelism, machining, discard, & finish specs

    A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2004 Ford Explorer cars and light trucks sold in the U.S. and Canada from 1980+.

    • Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap

    COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.

    PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules

    QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2004 Ford Explorer cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.

    • Automatic transmission/transaxles capacities, lubricant recommendations
    • Differential/final drive capacities, lube recommendations, grades, & viscosities
    • Final drive fill & drain plug torques
    • Number of lubrication fittings & plugs
    • Power steering, brake, & clutch fluid recommendations
    • Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
    • Number of lubrication fittings & plugs
    • Power steering, brake, & clutch fluid recommendations
    • Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
    • Severe service maintenance & interval recommendations
    • Tire sizes, wheel nut/bolt torque, pressures & rim sizes
    • Transfer case capacities, lube recommendations, grades, & viscosities

    TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2004 Ford Explorer cars and light trucks sold in the U.S. and Canada from 1980+

    • Airflow sensor electrical specifications
    • Tensioning specifications for systems with automatic tensioners
    • Barometric pressure sensor specs
    • Battery group number and cranking performance
    • Crankshaft & camshaft position sensor resistance
    • Engine compression pressures
    • Coolant temperature sensor specs
    • Computer advance.
    • Diesel fuel temperature sensor resistance.
    • Distributor advance specifications
    • Ignition pickup coil resistance
    • Exhaust gas recirculation temperature sensor resistance
    • Engine fastener torque values
    • Firing order diagrams
    • Fuel system pressures
    • Generator (alternator) specs
    • Intake air temperature sensor specs
    • Ignition coil specifications
    • Fuel injector resistance
    • Engine idle speeds
    • Knock sensor resistance
    • Manifold absolute pressure sensor specs
    • Mixture control solenoid resistance
    • Voltage regulator specs
    • Spark plug applications & gaps
    • Starter motor electrical specs.
    • Tensioning specifications for systems without automatic tensioners
    • Throttle body temperature sensor resistance
    • Ignition timing in degrees at rpm
    • Transmission oil temperature sensor resistance
    • Throttle position sensor specs
    • Vacuum sensor valve specs

    CLICK HERE TO GET FULL ACCESS TO 2004 Ford Explorer SPECIFICATIONS DATA!

    Shop online for auto body parts, engines, wheels, lights...

    Click here to view more details2003 Ford Explorer Bumper Cover, Rear.

    Source: Auto Body Parts Store

    $264.60

    Click here to view more details1999 Ford Explorer Bumper Bracket, Front, Passenger Side, A high quality, OE replacement bumper bracket; With 1-year limited TruckEFX warranty..

    Source: Auto Body Parts Store

    $13.40

    Click here to view more details2013 Ford Explorer 17" Aftermarket Wheel Covers, Aftermarket Wheel Covers; 17 Inch; Chrome Finish; ABS; 5 Spoke; Push-On Lug HUG Style Retention, , .

    Source: Wheels / Rims, Mirrors & Lights Store

    $60.50

    Click here to view more details about 1996 Ford Explorer V6, 4 L, 245 CID Rebuilt Engine1996 Ford Explorer V6, 4 L, 245 CID Rebuilt Engine, Explorer/Ranger All & Manual trans Aerostar Van, Block # 95TM-AB, Head # 95TM. Supplied with new head casting., Warranty: 3-Year/100,000 Mile, .

    Source: Rebuilt Engines Store

    $2,105.00

    Click here to view more details2000 Ford Explorer Used A/C Compressor, 4.0, AUTO, RWD 2 Dr (Sport), Very Good.

    Source: Used Auto Parts Store

    $87.00

    Click here to view more details2007 Ford Explorer Used Cargo Cover, Storage Box Lid, Good.

    Source: Used Auto Parts Store

    $85.00
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