Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety.

CarComplaints.com Notes: The 2004 Ford Explorer one of our worst vehicles on record. "Avoid like the plague" is putting it lightly.

The 2002-2005 Explorer has a very well-established record of expensive transmission failure at under 100k miles. The Explorer has an enclosed transmission which is typically replaced with a rebuilt transmission at a cost of almost $3,000.

Another common problem for the 2002-2005 Explorer is wheel bearing failure at around 90k miles, with a typical repair bill of $500 to $1000 depending on how many wheel bearings failed.

Adding insult to injury, the 2002-2005 Explorer also has a massive problem with the rear panel cracking. While it's a minor annoyance compared to transmission failure, ironically the crack usually goes right through the Ford logo.

8.0

pretty bad
Typical Repair Cost:
$581.00
Average Mileage:
93,682 miles
Total Complaints:
43 complaints

Most Common Solutions:

  1. not sure (15 reports)
  2. fix blend door motor is slipping or blend door is broken (11 reports)
  3. replace blend door actuator (10 reports)
  4. replace blend door (7 reports)
2004 Ford Explorer AC / heater problems

AC / heater problem

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2004 Ford Explorer Owner Comments (Page 2 of 3)

« Read the previous 20 complaints

problem #23

Nov 302011

Explorer LS 4.0L V6

  • Automatic transmission
  • 72,650 miles

A D V E R T I S E M E N T S

will blow cold air no heat I hear part does not cost much it is the Labor that cost so much. Just Like all the other problems with the explorer ford will not fix. i am a ford retiree & my children have fords. we suppose to be a family of fine vehicles. but that is not true. thank you. thompson 5.

Update from Dec 10, 2011: Sorry it was not the blend door motor mechanic friend fixed it.part 42.00 with his discount at koi auto parts.thankyou for your interest.

- , Paris, KY, USA

problem #22

May 092011

Explorer

  • Manual transmission
  • 56,000 miles

HAVE A 2004 FORD EXPLORER WHICH I TAKE CARE OF...IN MAY OF THIS YEAR TURNED ON THE AIR AND THIS VERY,VERY LOUD CLICKING NOISE STARTED...I TURNED IT OFF AND TURNED THE A/C BACK ON....NO A/C!!!!! CHECKED THE HEAT....NO HEAT!!!! CONTACTED FORD AFTER I LOOKED UP THE PROBLEM ONLINE AND SAW THE THOUSANDS OF COMPLAINTS THAT ARE ON THERE...COULD NOT BELIEVE THAT FORD HAS NOT RECALLED THIS PART!!!!! COULD THIS NOT BE A FIRE HAZARD???? NOT ONLY THAT, BUT THOSE OF US WITH CHILDREN DO NOT LIKE DRIVING AROUND WITH NO A/C OR HEAT!!!!! SUPPOSEDLY THIS IS A PLASTIC PIECE AND MELTS??? HOW DOES FORD THINK THIS IS NOT AN ISSUE THEY NEED TO ADDRESS???? PERSONALLY....I'M SO TICKED OFF, I WANT TO CALL MY LOCAL NEWS STATION, POST THIS ON FACEBOOK AND CALL THE NEWSPAPER WHILE I'M AT IT......THIS IS RIDICULOUS AND I'LL NEVER BUY ANOTHER FORD!!!!!

- , Indianapolis, IN, USA

problem #21

May 252011

Explorer

  • Automatic transmission
  • 120,000 miles

ok I BOUGHT my 2004 explorer new June 2004. No miles. The AC didnt work, so i drove right back and returned it and got another new one. paid a$1000 more because they didnt have the same one i wanted. NOW 2010 the cold a/c doesn't work and i have to keep recharging the a/c every 5 months to get cold air. Now as of 5/1/2011, the heater when turned on is starting to make a loud clicking sound. i have to turn it off then turn it on again on low or high which ever one makes it stop

- , Whittier, CA, USA

problem #20

May 022011

Explorer V6

  • Automatic transmission
  • 130,000 miles

A D V E R T I S E M E N T S

sad to say that I have had this vehicle 1 yr....we always thought there was something wrong with the vent doors....a few weeks ago suv started clicking whe you turned the blue to red control for heat....it had gotten quite warm out...then it got cold again...when I discovered I had no heat for 2 weeks when it had gotten down to low 40s in may in GA

- , Woodstock, GA, USA

problem #19

Oct 052010

Explorer V8

  • Automatic transmission
  • 128,239 miles

The unit makes a knock, knock, knocking -- it seems to make the noise until the car has "warmed up' but by then , i am usually to my destination. Typically, if it is not turned up to full power, it won't make the noise, however, there are those days where it is fickle and is noisy just the same.

- , Dallas, GA, USA

problem #18

May 012011

Explorer

  • Automatic transmission
  • 103,000 miles

No heat. Blend door. Also crack in the window trim in the back.

- , Greensboro, IN, USA

problem #17

Feb 102011

Explorer 4.0L

  • Automatic transmission
  • 104,875 miles

A D V E R T I S E M E N T S

I think ford should have put out a recall or TSB if sooo many people have had this issue. The worst part is all the cost was from Labor and put in a really bad spot.

- , Nashua, NH, USA

problem #16

Mar 032011

Explorer XLT V6

  • Automatic transmission
  • 100,090 miles

It is cold outside and cold in my vehicle and the clicking started which was almost unbearable, but at least the heat worked, and now, no clicking but also no effing heat! I'm really unhappy with ford and they should at least offer to fix this because it is a major problem! My explorer also has the cracked rear window trim that everyone is also complaining about. Come on ford, step up and fix the problems with your vehicles... or you're gonna lose a lot more money due to people switching brands because they don't feel confident driving your products anymore, I know I don't! I will be trading this vehicle in for something else very soon!

- , Terre Haute, IN, USA

problem #15

Dec 272010

Explorer LX V6

  • Automatic transmission
  • 60,000 miles

Dead in the Chicago winter, the Heat stop working.

- , Chicago, IL, USA

problem #14

Sep 132010

Explorer XLS V6

  • Automatic transmission
  • 82,000 miles

I own a 2004 Ford Explorer and take good care of my vehicle. The problem with the clicking noise behind the dash with the AC/heater drives me totally insane. Also I freeze to death in my car in the winter and in the summer I burn up. Ford needs to step up to the plate and fix this problem as a recall or free of charge. FORD ------STAND BEHIND YOUR PRODUCT!!!!!!!!

- , Montpelier, VA, USA

problem #13

Jan 132011

Explorer V6

  • Automatic transmission
  • 100,000 miles

A D V E R T I S E M E N T S

Has anyone Notice if you Google blend door problem 90% of the results say Ford? That is Horrible! I hope Ford don't Blame me for going back to only Foreign Cars and trucks.

- , Geismar, LA, USA

problem #12

Sep 052007

Explorer XLT V6

  • Automatic transmission
  • 65,343 miles

This is the first of two incidents on the same 2004 Ford Explorer. The first was at 3 years old and the second, surprise, surprise was at 6 years old. I should have gotten rid of the piece of trash after the first. Bought the vehicle brand new in late 2004, frustrated that in just 3 years that the problem cropped up and not covered by Ford. Obviously we had high mileage, but this part/issue has nothing to do with miles driven, the vehicle was only 3 years old. I failed to do any research at the time that would have shown that this is a recurring problem since 2002. Ford refuses to recognize it and step up (and the government will not pressure for a recall) because it is not safety related. It is obvious that Ford knew/knows that this is an issue but they chose to continue their business as usual (turn a blind eye) and stick it to the consumer. The biggest cost of this repair comes in the form of labor due to having to remove the entire dash to get to the blend door and the motor. Ford should have turned on their "lightbuld" and designed a way to access the area which would have made the cost of this repair affordable.

As I stated above, three years later and $495.97 poorer, I had to again have the blend door motor replaced. I am trying to share information that might help establish that it is a recurring issue and show that the "new improved Ford Motor Company" is not any better than it used to be and that they still refuse to be a "stand-up" company and take responsibility for what is obviously a quality/design flaw. I am sick and tired of big companies pretending that they are customer service oriented, yet when it comes down to it, they leave the customer hanging with no recourse, heck you can't even get in contact with anyone from the regional service office. All Ford service issues are routed to a third party company that doesn't have a vested interest in Ford, only the money that they are paid. Imagine a company the size of Ford hiding behind a third party company. That should tell you all you need to know about their integrity.

One last point.....this "rant" comes from the son of a retired Ford assembly plant worker. Someone who always bought and defended Ford products. I can no longer buy or defend Ford. I will buy from the competition.....but in Ford's eye, that's ok because "there is a sucker born every minute" and that is the motto that they truly rely on....not customer service.

- , Lakeville, MN, USA

problem #11

Jan 152011

Explorer XLT V6

  • Automatic transmission
  • 153,834 miles

Well, this is the second time that I have experience this issue on the same car. The first time was at 3 years old, this time at 6 years old.....I think I see a pattern. The pattern though is that this is a recurring issue with 2002 thru 2008 Explorer's. Ford, however, continues to choose to ignore it even when the exact same thing happens to the same customer with the same vehicle three years later. I returned it to the dealership where I originally bought it, and had the first repair done. I told them that there is a documented history to this problem, and that I didn't think that neither I or they should have to incur any cost to repair. The dealership was great....they agreed and said they would contact Ford and present the issue to the Ford Regional Service rep for consideration. After 4 days of following up with the regional guy, the dealer called to say that because the vehicle was over 100,000 miles that Ford would not help. I countered that this issue had nothing to do with mileage. Mileage had no effect on the part or the failure, only a poor design and a well documented, fact that this was an ongoing issue in 2002 thru 2008 Explorers. The regional guy decided that he wanted to hide behind the mileage being over 100,000. This is the "new" Ford?......seems like they are still the "old" Ford, building crap and not standing up for the customer when they should.

I am the son of a retired Ford assembly plant worker. We always bought Ford.....after this treatment, I am only too happy to buy from antone other than Ford. This however will not hurt Ford, because as they say "there is a sucker born every minute" and that is what Ford is banking on, bringing in new suckers to be stuck with their poor customer service standards.

- , Lakeville, MN, USA

problem #10

Dec 012010

Explorer

  • Automatic transmission
  • 64,500 miles

Blend door broke like most other Explorers out there. Quote was $1500 to replace it. Apparently the whole dash has to come off. The back lid has cracked near the Ford emblem, the transmission is slipping, the rear axle sounds like it's going to drop out any second, then this. And I still have a year and half to pay it off. Never again will I buy a Ford, cause from what I am reading now, these are all common problems with this substandard model that Ford will not address.

- , Vineland, NJ, USA

problem #9

Jun 232010

Explorer

  • Automatic transmission
  • 123,000 miles

Had this start early spring the clacking and noises, when turned on the ac/ from heat... used ac all summer and then got to use the heat and wammmyyy freezing cold...would not mind if I did not have to bring my young daughter to school every morning and drive to work 40 miles each way. to repair it is 1,100, without labor!!! OK well my husband has been out of work the last three winters and I am always playing "catch up" with the bills and mortgage!Really use to like my fords, but apparently this is an issue and they have never acknowledged it!!???? May have to start to look at another brand that will stand behind their mistakes and OWN up and fix this problem..... Has nothing to do with up keep of the car, just a PROBLEM they seem to not care about!! ...how sad..

- , Roxbury, CT, USA

problem #8

Nov 102010

Explorer XLT 3.0 V6

  • Automatic transmission
  • 76,000 miles

This problem is easily fix if u are the type of guy who can take apart and put back together an old alarm clock or similar. MEDIUM SKILL LEVEL Go to ur ford dealer and buy the motor for the temperature door, part # YH-1744 1L2Z-19E616-CA the cost is about $78 + tax. It took me about 4 hours to do it, including 45 minutes to go to home depot to buy an elbow for my socket set. IT DOES NOT REQUIRE TO TAKE DE DASH APART HOW THE MECHANIC SAY. THEY JUST WANT UR $$$ And if u want to give it to them that is fine. All you will need to remove is: center console (look out for tricky screws under cup holder), trim piece around a/c controls (just pry it out), and plastic panel under steering wheel for access. This motor is located to the left of the main heater door system or whatever the name is is, white in color and is attached just by 3 little screws. Hey I'm not a mechanic and I did it. My thought was: Well if I can't do it them I'll take it to the blood sucker mechanic to do it for me. U have nothing to loose just by trying. GOOD LUCK!!!

- , Woodbridge, VA, USA

problem #7

Nov 232009

Explorer XL 4.0

  • Automatic transmission
  • 65,000 miles

What kind of manufacturer does not have a default heating system for defrost????? This is a safety issue!!!!!!!!!!

- , Abbeville, SC, USA

problem #6

Sep 012009

Explorer NBX 4.6L V8

  • Automatic transmission
  • 93,000 miles

I got in my car one chilly September morning only to hear this loud "knocking" or banging noise coming from the front dash. I thought it was my motor so I went and pulled my boyfriend out of bed only to find out he didn't know what it was. He is a gearhead so I was pretty surprised. After doing some research online I realized it was my blend door that was broken. I was able to get it stuck so it only blows hot air and then this summer I got it stuck on the other side so it blew cold air. After calling around to several shops I found out the repair is going to cost me $600 - NOT worth it!! Can't wait to trade this truck in.

- , Elizabeth, CO, USA

problem #5

Oct 032010

Explorer XLT 6.0

  • Automatic transmission
  • 98,000 miles

same prob. as most people, no heat and clicking noise

- , Foxboro, MA, USA

problem #4

Apr 142010

Explorer XLT 4.0V6

  • Automatic transmission
  • 91,356 miles

im a ford man from a ford family we own 3 of em but these explorers are junk this is our second and last one the first a 97 xlt 4x4 blew up @ 112000 miles. we replaced it with a new 2004 explorer xlt 4x4 now that its paid for the mother fn heater is clicking an the ford dealer says its around a 600 dollar do it your self fix its only got 90000 on it.don't buy a used silver explorer in southern Indiana it could b this pile of sh*t

- , Campbellsburg, IN, USA

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