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

Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!

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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!
    DIY REPAIR SAMPLES > CONTINUE EXPLORING >
    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

    Air Bag System Precautions -> Ford Motor Co. -> Arming -> 1990-91 -> 1990-92 -> 1991-92 -> 1992-93 -> 1992-94 -> 1992-96 -> 1992-98 -> 1993 -> 1993-94 -> 1993-95 -> 1994 -> 1994-95 -> 1994-96 -> 1994-97 -> 1995 -> 1995-2004 -> 1995-96 -> 1995-98 -> 1996-97 -> 1996-99 -> 1997-2000 -> 1997-2001 -> 1997-2004 -> 1997-99 -> 1998 -> 1998-2000 -> 1998-2002 -> 1999-2000 -> 1999-2001 -> 1999-2002 -> 1999-2004 -> 2000 -> 2000-01 -> 2000-04 -> 2001-02 -> 2001-03 -> 2001-04 -> 2002-03 -> 2002-04 -> 2004 -> Aerostar & Bronco -> Aspire -> Aviator -> Blackwood, Expedition & Navigator -> Built After February 2002 -> Built Before March 2002 -> Capri -> Continental -> Contour & Mystique -> Cougar -> Crown Victoria Grand Marquis & Marauder -> Econoline -> Escape -> Escort, Tracer & ZX2 -> Excursion -> Explorer & Mountaineer -> Explorer Sport & Sport Trac -> F Series -> Focus -> Freestar & Monterey -> Light Trucks & Vans -> LS -> Mark VII -> Mark VIII -> Mustang -> Passenger Cars -> Probe -> Ranger -> Sable & Taurus -> Tempo & Topaz -> Thunderbird -> Town Car -> Villager -> Windstar
    Vehicle: 2004 Ford Explorer 4.0 V6 GAS

    Passenger Cars

    Aspire
    • Disconnect battery ground cable.
    • Wait one minute for back-up power supply to deplete stored energy.
    • Remove restraint system diagnostic tool from driver's side air bag module electrical connector.
    • Connect driver's side air bag module electrical connector.
    • Install driver's side air bag module as outlined under "Component Service."
    • Remove restraint system diagnostic tool from passenger's side air bag module electrical connector.
    • Install passenger's side air bag module as outlined under "Component Service."
    • C...

    CLICK HERE TO GET FULL ACCESS TO 2004 Ford Explorer A/C & HEATER SERVICE PROCEDURES

    BRAKE SERVICE PROCEDURES FOR 2004 Ford Explorer AUTOMOBILES

    Drum Brakes -> Expedition, Explorer, E-Series, F-Series, Mountaineer, Navigator & Ranger -> Brake Service -> Heavy Duty -> Installation -> Removal -> Standard Duty
    Vehicle: 2004 Ford Explorer 4.6 V8 GAS

    Drum brakes are available in standard versions or in heavy duty versions. Refer to Figs. and for component locations when performing the following procedures.

    Removal

    Standard Duty
    • Raise and support vehicle, remove rear wheel and tire assemblies.
    • Remove and discard spring nut.
    • If brake drum is rusted to axle shaft pilot diameter, tap center of brake drum between wheel studs.
    • Pull brake drum off of axle.
    • If brake drums will not come off, sing a screwdriver, move brake shoe adjusting lever off of brake adjusting screw, then loosen brake adjuster to allow drum to release.
    • Remove long brake...

    CLICK HERE TO GET FULL ACCESS TO 2004 Ford Explorer BRAKE SERVICE PROCEDURES

    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

    CLICK HERE TO GET FULL ACCESS TO 2004 Ford Explorer FUEL FILTER REPLACEMENT PROCEDURES

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

    DRIVESHAFT, Replace -> Four Wheel Drive (4WD) -> Front -> Rear -> Two Wheel Drive (2WD)
    Vehicle: 2004 Ford Explorer 4.6 V8 GAS

    Front

    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.

    • With vehicle in neutral, raise and support vehicle.
    • Index-mark front axle pinion flange to front driveshaft.
    • Remove transfer case skid plate.
    • Index-mark transfer case pinion flange to front ...

    CLICK HERE TO GET FULL ACCESS TO 2004 Ford Explorer DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES

    TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR 2004 Ford Explorer AUTOMOBILES

    Relearn Procedures -> TPMS Sensor Activation -> TPMS Sensor Training
    Vehicle: 2004 Ford Explorer 4.0 V6 FLEX

    TPMS Sensor Activation

    To conserve battery power, the TPMS sensors will go into a sleep mode after approximately 30 minutes of inactivity. The sensors will not transmit tire pressure information while in sleep mode. The sensors must be activated to transmit the latest tire pressure information.

    • Place the ignition switch in the On position.
    • Position Ford TPMS activation tool, or equivalent, against the LF tire side wall 180° from the valve stem.
    • The TPMS activation tool will flash a green light and sound a beep for each successful response from a TPMS sensor.
    • Press the TPMS activat...

    CLICK HERE TO GET FULL ACCESS TO 2004 Ford Explorer TIRE PRESSURE MONITORING SYSTEM PROCEDURES

    STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2004 Ford Explorer AUTOMOBILES

    Starter, Replace
    Vehicle: 2004 Ford Explorer 4.6 V8 GAS

    • Disconnect battery ground cable.
    • Raise and support vehicle.
    • Remove starter motor solenoid terminal cover.
    • Remove B+ terminal nut and disconnect cable.
    • Remove S terminal nut and disconnect cable.
    • Remove starter mounting bolts and stud b...

    CLICK HERE TO GET FULL ACCESS TO 2004 Ford Explorer STARTER & ALTERNATOR REPLACEMENT PROCEDURES

    MAINTENANCE LAMP RESET PROCEDURES FOR 2004 Ford Explorer AUTOMOBILES

    Ford Motor Co. Trucks -> Anti-Lock Or Rear Anti-Lock Brake System Warning ->
    Vehicle: 2004 Ford Explorer 4.0 V6 GAS

    Red and yellow indicator lamps are used to warn of system faults. The red lamp warns of such faults as low brake fluid level, parking brake On, system pressure differential and other system faults. The red indicator lamp will light for approximately two seconds during engine starting and should go off, unless parking brake is applied or a problem in the brake system exist. The red indicator lamp should reset after repairs to system have ...

    CLICK HERE TO GET FULL ACCESS TO 2004 Ford Explorer MAINTENANCE LAMP RESET PROCEDURES

    RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Ford Explorer AUTOMOBILES

    Heater Hose, Replace -> Bypass -> Inlet -> Outlet
    Vehicle: 2004 Ford Explorer 4.0 V6 GAS

    Inlet

    • Drain cooling system into a suitable container.
    • Reposition heater core inlet hose clamp at heater inlet tube.
    • Remove hose from heater inlet tube.
    • Reposition heater hose inlet clamp at heater core.
    • Remove heater inlet hose from heater core.
    • Remove hose from vehicle.
    • Reverse procedure to install.

    Outlet

    • Drain cooling system into a suitable container.
    • Reposition heater hose outlet clamp at heater core.
    • Disconnect heater out...

    CLICK HERE TO GET FULL ACCESS TO 2004 Ford Explorer RADIATOR & HOSE REPLACEMENT PROCEDURES

    SERPENTINE BELT SERVICE PROCEDURES FOR 2004 Ford Explorer AUTOMOBILES

    Serpentine Drive Belt, Replace
    Vehicle: 2004 Ford Explorer 4.6 V8 GAS

    Always use square drive tool in hole in tensioner to move tensioner. Never pry on tensioner pulley. When releasing drive belt tensioner, never allow tensioner to snap back. Damage to tensioner or pers...

    CLICK HERE TO GET FULL ACCESS TO 2004 Ford Explorer SERPENTINE BELT SERVICE PROCEDURES

    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+.

    Body Component Location Views Diagram for 2004 Ford Explorer  4.6 V8 GASBody Component Location Views Diagram for 2004 Ford Explorer 4.6 V8 GAS

    Components on diagram:
  • Park Lamp
  • Stop Lamp
  • Tail Lamp
  • Connector C-327
  • Connector C-412
  • Engine Compartment Component Location Views Diagram for 2004 Ford Explorer  4.6 V8 GASEngine Compartment Component Location Views Diagram for 2004 Ford Explorer 4.6 V8 GAS

    Components on diagram:
  • Ignition Coil
  • Connector C-1065
  • 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  4.6 V8 GAS Wiring Diagram2004 Ford Explorer 4.6 V8 GAS Wiring Diagram

    Components on diagram:
  • Turbine Shaft Speed (TSS) Sensor
  • Powertrain Control Module (PCM)
  • Output Shaft Speed (OSS) Sensor
  • Intermediate Shaft Speed (ISS) Sensor
  • 2004 Ford Explorer  4.0 V6 FLEX Wiring Diagram2004 Ford Explorer 4.0 V6 FLEX Wiring Diagram

    Components on diagram:
  • Main Light Switch
  • Headlamp Relay
  • Multifunction Switch
  • Vehicle Security Module (VSM)
  • Low Beam Lamp, Left Front
  • 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 details2010 Ford Explorer Mirror, Driver Side.

    Source: Auto Body Parts Store

    $135.48

    Click here to view more details about 2009 Ford Explorer Tail Light Guard2009 Ford Explorer Tail Light Guard, 5/16 in. Solid Rod, 3/4 In Round Tube, Made Of Stainless Steel, Features A Sleek Contoured Design, With Aries Limited Lifetime Warranty.

    Source: Auto Body Parts Store

    $162.33

    Click here to view more details about 2013 Ford Explorer Or  Fog Light, Passenger Side, Driver Side2013 Ford Explorer Or Fog Light, Passenger Side, Driver Side, DRIVER SIDE OR PASSENGER SIDE FOG LIGHT, ROUND STYLE, MUSTANG WITH PONY PACKAGE, RANGER WITH STX PACKAGE, [FO], , .

    Source: Wheels / Rims, Mirrors & Lights Store

    $35.01

    Click here to view more details about 2003 Ford Explorer V6, 4.0 L, 242 CID Rebuilt Engine2003 Ford Explorer V6, 4.0 L, 242 CID Rebuilt Engine, Warranty: 3-Year/100,000 Mile, .

    Source: Rebuilt Engines Store

    $2,328.00

    Click here to view more details2008 Ford Explorer Used Ignition Switch W/Key, (elec switch only), Automatic Transmission, Very Good.

    Source: Used Auto Parts Store

    $61.00

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

    Source: Used Auto Parts Store

    $118.00
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