Two problems related to engine 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.
On my way to the airport for a business trip, I was driving the vehicle on the interstate when all of a sudden and without any warning, the engine stopped. I had to maneuver onto traffic and stop to try to start the engine without success. I called aaa and they had the vehicle towed to my home. When I came back I sent it to the shop and the mechanic advised me that the timing chain sprocket retainer pin broke, and because of that all valves bent, so I have to replace the engine. For 72900 miles and keeping all maintenance in order I consider this a safety issue and unacceptable in terms of quality. I have spoken to the manufacturer and they refuse to take action because the vehicle is out of warranty.
Auto goes into fail safe mode while being driven. Has happened 5 times since Mar. 10, 2006. I have had it in the shop on Mar. 14, April 22, April 27, may 25, and June 12, all for the same concern. The engine bogs down to 4 cylinders and loses power. The first 3 times it happened while driving at around 35 mph the last two times it has happened while merging into traffic on the highway coming off a feeder road. I'm am afraid I will end up in a serious accident. I put it in the shop on June 12, 2006 and just picked it up yesterday on July 17,2006. It was in the shop for over a month. As I was feeding into traffic yesterday evening of July 17, the engine again downshifted into fail safe mode causing me to bog down. I have lost all faith in this vehicle and do not want it anymore. I have owned Fords for the last 35 years and have never had this kind of problem before with a Ford.