Target Audience:
Families and owners needing a midsize SUV with available V8 power and towing capability
Market Segment:
Midsize sport utility vehicle
Engine Options:
4.0L V6 or 4.6L V8
Drivetrain:
Rear-wheel drive or Control Trac four-wheel drive
Seating:
5-passenger with optional third-row seating
Towing:
Tow packages available for trailers and boats
Manual Type:
Workshop service repair manual
Page Count:
Comprehensive multi-hundred page factory-level coverage
Delivery Method:
Instant digital download
Compatibility:
Windows, Mac, tablets, and smartphones
Systems Covered:
Engine, transmission, brakes, suspension, electrical, body, and more
Procedures:
Step-by-step repair, removal, installation, and diagnostic procedures
Engine:
4.0L SOHC V6 and 4.6L SOHC V8 mechanical repair
Engine Cooling:
Radiator, thermostat, water pump, and fan clutch service
Fuel System:
Fuel pump, injectors, fuel rail, and tank procedures
Ignition:
Coil-on-plug ignition and spark control diagnostics
Automatic Transmission:
5R55S and 4-speed automatic service and overhaul
Transfer Case:
Control Trac 4WD system service
Axles:
Front and rear differential repair
Suspension:
Front and rear suspension, including independent rear suspension
Steering:
Power steering gear and pump service
Brakes:
Hydraulic system, ABS, and pad/rotor replacement
HVAC:
Heating, ventilation, and air conditioning service
Electrical:
Wiring diagrams, connectors, and component testing
Body and Trim:
Panels, doors, bumpers, and interior components
Restraints:
Airbag and seat belt system procedures
Wheels and Tires:
Specifications and alignment procedures
Diagnostic Procedures:
Symptom charts and fault code diagnostics
Torque Specifications:
Factory torque values for fasteners throughout
Wiring Diagrams:
Complete circuit diagrams included
Special Tools:
Factory special tool references
Exploded Views:
Component illustrations for assembly reference
Part Numbers:
Factory part number references
Fluid Capacities:
Refill capacities for all systems
Lubricants:
Approved fluid specifications
File Format:
PDF (searchable, bookmarked, zoomable)
Compatibility:
Windows, macOS, Linux, iOS, and Android — any device with a PDF reader
Requirements:
A PDF reader application (e.g. Adobe Acrobat Reader, free)
Searchability:
Fully text searchable for fast lookup of any topic
Print Quality:
High-resolution digital pages, printable at full clarity
Binding Type:
N/A — digital download, no physical binding
Paper Type:
N/A — digital download, no physical paper
Base Engine:
4.0L SOHC V6 (Explorer)
Optional Engine:
4.6L SOHC V8
Configuration:
90-degree V, overhead cam
Displacement:
4.0 liters (245 cu in)
Fuel System:
Sequential multi-port fuel injection
Displacement:
4.6 liters (281 cu in)
Fuel System:
Sequential multi-port fuel injection
Application:
Standard on Explorer (2004)
Airbags:
Dual front airbags with front side airbags
Seat Belts:
Three-point belts with pretensioners
Structure:
Safety cage body construction
ABS:
Four-wheel anti-lock brakes
Traction Control:
Available traction assist
Tire Pressure:
Tire pressure monitoring
Crash Test Data:
N/A - refer to NHTSA and IIHS archives for 2004 ratings
Audio System:
AM/FM stereo with CD player; available premium audiophile sound
Optional:
Available in-dash CD changer
Convenience:
Optional electronic automatic temperature control, power adjustable pedals, and remote keyless entry
Assistance Systems:
N/A - modern ADAS features not offered in 2004
Oil Change:
Every 5,000 miles or 6 months (normal service: up to 7,500 miles)
Tire Rotation:
Every 5,000 miles
Air Filter:
Inspect regularly, replace approximately every 30,000 miles
Spark Plugs:
Approximately every 100,000 miles
Coolant:
Replace per factory schedule, typically 100,000 miles initial
Engine Oil:
5W-30 API certified
Automatic Transmission:
Mercon V
Coolant:
Motorcraft Gold extended-life coolant
Known Issues:
Rear suspension and wheel bearing wear on high-mileage units; heater core and intake manifold gasket concerns on the 4.0L V6
Ball Joints:
Front ball joints are a common wear item
Transmission:
5R55S valve body and servo wear can cause shift concerns
Manufacturer:
Ford Motor Company, Dearborn, Michigan, USA
Model Origin:
Explorer introduced in 1991 as Ford's midsize SUV
Third Generation:
Redesigned for 2002 with independent rear suspension and available V8
2004 Changes:
Minor trim and feature updates within the third-generation run
Production Location:
Louisville Assembly Plant, Kentucky, USA
