Two problems related to brake disc rotor have been reported for the 2004 Ford Explorer. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2004 Ford Explorer based on all problems reported for the 2004 Explorer.
After only 300 miles on the odometer---discovered the 2 front rotors were warped and the car shook when braking. We asked that they be replaced. Ford area rep would not allow it. . . The dealer, instead, "turned" the rotors by taking off 50% of surface. Ford said this still met their spec for warranty repair. We believe it is unfair!!.
- the contact owns a 2004 Ford Explorer. While driving at 60 mph the contact felt the brake pedal shutter when the brake was depressed. Also, the contact felt the steering wheel vibrate. The dealer stated that the problem was due to the rotors. The dealer resurfaced the rotors at 12,000 miles. Approximately eleven months later the contact experienced the same problem. The dealer stated the rotors needed to be replaced. The dealer replaced the rotors at 24,000 miles. Two months later ,the dealer replaced the rotors again, and the rotor assembly at 26,000 miles. Four months later the contact had the same problem. The dealer resurfaced the front and rear rotors at 30,000 miles. There have been no further occurrences. The vehicle currently has 36000 miles.