Problems · by component
2004 Ford Explorer engine and engine cooling problems
78 owner complaints to NHTSA about the 2004 Ford Explorer cite engine and engine cooling, 6% of all 1,408 complaints for this model year.
Complaints
78
6% of all complaints
Crashes
1
Reported by owners
Fires
4
Reported by owners
Injuries
1
Reported by owners
What owners say about the engine and engine cooling
Verbatim from NHTSA complaints, newest first
“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”
“I WAS DRIVING DOWN THE STREET AND HEARD A NOISE. WE TURNED AROUND AND THE LIFTGATE HAD FALLEN OFF ITS ON HINGES AND WAS HANGING LOOSE ON BOTH SIDES. WE HAD TO HOLD IT ON AND DRIVE THE CAR BACK HOME. THE CAR HAS NOT BEEN DRIVEN SINCE THAT DATE IN 2010. FORD NEEDS TO BE RESPONSIBLE FOR THE 2004 MODEL AND ALL OF ITS DEFECTIVE PRODUCTS. THIS IS THE SECOND COMPLAINT THAT I HAVE FILED AGAINST FORD CONCERNING THIS CAR. THE FIRST WAS A #2 VALVE FALLING IN THE ENGINE AND CAUSING THE ENGINE TO BLOW UP. NHTSA PLEASE DO SOMETHING ABOUT FORD. SOMEONE HAS TO MAKE CAR MANUFACTURERS RESPONSIBLE TO THE CONSUMER. EVERY TIME THAT NHTSA IS CONTACTED NOTHING IS DONE UNTIL MILLIONS ARE NEGATIVELY AFFECTED. *TR”
“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). *TR”
“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.”
“ON 1/17/12 DRIVING ON HIGHWAY AND NOTICED A BURNING SMELL. IT WAS A STRONG SMELL. NOTICED A GLOW UNDER THE DASHBOARD AND PULLED INTO A EMPTY PARKING LOT. THE TRUCK WENT UP IN FLAMES. CALLED FORD AND THEY SAID PROVE WHAT HAPPENED. NOT SURE BUT THE VEHICLE WAS IN VERY GOOD CONDITION WITH NO PROBLEMS THAT I KNEW OF BEFORE THIS FIRE. NO ONE WAS HURT. *TR”
“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.”
Showing 6 of 78 reports. Read every report on NHTSA.gov.
Data from NHTSA Complaints API (owner reports, unverified) · synced Nov 7, 2026NHTSA vehicle page
Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.