One problem related to universal joint has 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.
Engaging the transmission in "reverse" it hesitates, slips then surges. Loud banging/clunking noises heard, sounds like universal joint. Dealer states parts on order. Apparently this is a known defect to Ford, dealer blames it on a defective servo, synchro or solinoid. Awaiting nationwide back ordered parts from the same manufacture, what makes me think that this same part won't again fail. What is Ford's responsibility regarding warranty extension for the transmission which still is encountering the same problems as I await the repair parts? sounds like a safety problem to me.