2004 Ford Explorer Service & Repair Manual

About This Manual Printable View (8 KB) Introduction To make it easier to locate information, we have consolidated several small sections into a single section. Those sections are: 204-00 — Suspension System (now includes front suspension, rear suspension and wheels and tires). 205-00 — Driveline System (now includes driveshaft, axle and halfshafts). 206-00 — Brake System (now includes front brakes, rear brakes, caliper, brake booster and parking brake). 211-00 — Steering System (now includes steering gear, pump, linkage, column and column switches). 303-01 Engine (now includes accessory drive and emission controls). 303-04 Intake Air, Fuel Charging and Engine Electronics (now includes intake air, fuel charging, starting system and electronic engine controls). 307-01 — Automatic Transmission/Transaxle (now includes cooling and external controls). 310-00 — Fuel System (now includes tanks, lines, pump, filter, pedal and linkage and evaporative emissions). 412-00 — Climate Control System (now includes air distribution, heating, air conditioning, auxiliary climate control and control components). 413-00 — Information, Gauge and Warning Devices (now includes illumination, cluster, horn, clock, message center, warning devices, and parking aid). 414-00 — Battery and Charging System (now includes battery and generator). 415-00 — Entertainment System (now includes all video and audio components). 418-00 — Module Communications Network (now includes all module diagnostics and configuration). 419-02 — Electronic Features (now includes remote convenience, telematics, cell phone, navigation and compass). 501-00 — Body System — Exterior (now includes body panels, exterior trim, mirrors, glass, bumpers and wiper system). 501-01 — Body System — Interior (now includes interior trim, instrument panel and console and roof opening panel). SECTION 100-00: General Information 2004 Explorer/Mountaineer Workshop Manual DESCRIPTION AND OPERATION Procedure revision date: 11/11/2003 22.12.2002 file://C:\TSO\tsocache\SUPER10-45B629E_1712\S4N~us~en~file=S4N00001.htm~g...

Important Safety Instructions Printable View (10 KB) Appropriate service methods and correct repair procedures are essential for the safe, reliable operation of all motor vehicles as well as the personal safety of the individual carrying out the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Anyone who departs from the instructions provided in this manual must first establish that they compromise neither their personal safety nor the vehicle integrity by their choice of methods, tools or parts. Warnings, Cautions and Notes WARNING: Warnings are used to indicate that failure to follow a procedure correctly can result in personal injury. CAUTION: Cautions are used to indicate that failure to follow a procedure correctly can result in damage to the vehicle or equipment being used. NOTE: Notes are used to provide additional essential information required to carry out a complete and satisfactory repair. As you read through this manual, you will come across WARNINGS, CAUTIONS and NOTES. A warning, caution or note is placed at the beginning of a series of steps if it applies to multiple steps. If the warning, caution or note only applies to one step, it is placed at the beginning of the specific step (after the step number). SECTION 100-00: General Information 2004 Explorer/Mountaineer Workshop Manual DESCRIPTION AND OPERATION Procedure revision date: 07/01/2003 22.12.2002 file://C:\TSO\tsocache\SUPER10-45B629E_1712\S4N~us~en~file=S4N00002.htm~g...

How To Use This Manual Printable View (20 KB) Icons There are ten symbols indicating oil, grease, sealant, visual inspection, use of special service tools and removal and installation details. These symbols show the points of inspecting, applying or using such materials during service. SECTION 100-00: General Information 2004 Explorer/Mountaineer Workshop Manual DESCRIPTION AND OPERATION Procedure revision date: 07/01/2003 Symbol Meaning Apply petroleum jelly Apply oil Apply fluid Apply grease Apply sealant Inspect 22.12.2002 file://C:\TSO\tsocache\SUPER10-45B629E_1712\S4N~us~en~file=S4N00003.htm~g...

General Standards All left- and right-hand references to the vehicle are taken from a position sitting in the driver seat looking forward. All left- and right-hand references to the engine are taken from a position at the flywheel looking toward the front camshaft pulley. Where appropriate, instructions will be given for the use of Worldwide Diagnostic System (WDS), Ford Diagnostic System (FDS) 2000 or New Generation STAR (NGS) Tester diagnostic equipment. Install new Use special tool Installation/assembly Removal/disassembly 22.12.2002 file://C:\TSO\tsocache\SUPER10-45B629E_1712\S4N~us~en~file=S4N00003.htm~g...

Identification Codes Printable View (466 KB) Vehicle Identification Number Vehicle Identification Number (VIN) Tag Locator The vehicle identification number (VIN) is a seventeen-digit combination of letters and numbers. The VIN is stamped on a metal tab riveted on the instrument panel, top upper left of the dash. The VIN is also found on the vehicle certification (VC) label. SECTION 100-00: General Information 2004 Explorer/Mountaineer Workshop Manual DESCRIPTION AND OPERATION Procedure revision date: 07/01/2003 Item Description 1 World manufacturer identifier 2 Brake type and gross vehicle weight rating (GVWR) 3 Vehicle line, series, body type 22.12.2002 file://C:\TSO\tsocache\SUPER10-45B629E_1712\S4N~us~en~file=S4N00004.htm~g...

World Manufacturer Identifier The first three vehicle identification number (VIN) positions are the world manufacturer identifier. 1FM — Ford Motor Company, USA, multi-purpose vehicle 4M2 — Ford Motor Company (Mercury), USA, multi-purpose vehicle Brake Type and Gross Vehicle Weight Rating (GVWR) The fourth VIN position is the vehicle brake type and gross vehicle weight rating (GVWR) code, all vehicles use hydraulic brakes. This code may also identify the vehicle safety restraint system. Z — 5,001-6,000 pounds GVWR with driver and front passenger air bags D — 5,001-6,000 pounds GVWR with driver and front passenger air bags and side impact air canopies Line, Series and Body Type 4 Engine type 5 Check digit 6 Model year 7 Assembly plant 8 Production sequence number 22.12.2002 file://C:\TSO\tsocache\SUPER10-45B629E_1712\S4N~us~en~file=S4N00004.htm~g...

VIN positions five through seven indicate the vehicle line, series and body type. U62 — Explorer, 4x2, XLS, multi-purpose vehicle U63 — Explorer, 4x2, XLT, multi-purpose vehicle U64 — Explorer, 4x2, Eddie Bauer, multi-purpose vehicle U65 — Explorer, 4x2, Limited, multi-purpose vehicle U66 — Mountaineer, 4x2, multi-purpose vehicle U72 — Explorer, 4x4, XLS, multi-purpose vehicle U73 — Explorer, 4x4, XLT, multi-purpose vehicle U74 — Explorer, 4x4, Eddie Bauer, multi-purpose vehicle U75 — Explorer, 4x2, Limited, multi-purpose vehicle U82 — Explorer, XLS, all-wheel drive (AWD), multi-purpose vehicle U83 — Explorer, XLT, all-wheel drive (AWD), multi-purpose vehicle U84 — Explorer, Eddie Bauer, all-wheel drive (AWD), multi-purpose vehicle U85 — Explorer, Limited, all-wheel drive (AWD), multi-purpose vehicle U86 — Mountaineer, all-wheel drive (AWD), multi-purpose vehicle Engine Type The eighth VIN position is the engine type (displacement and number of cylinders). E — 4.0L, SOHC, V6, EFI K — 4.0L, SOHC, V6, EFI, flex-fuel W — 4.6L, SOHC, V8, EFI Check Digit 22.12.2002 file://C:\TSO\tsocache\SUPER10-45B629E_1712\S4N~us~en~file=S4N00004.htm~g...

The ninth VIN position is a government assigned, computer-generated check digit. Model year The tenth VIN position is the model year code. 4 — 2004 Assembly Plant The eleventh VIN position is the assembly plant code. U — Louisville, Kentucky Z — St. Louis (Hazelwood) Missouri Build Sequence 22.12.2002 file://C:\TSO\tsocache\SUPER10-45B629E_1712\S4N~us~en~file=S4N00004.htm~g...

VIN positions 12 through 17 are an alphanumeric code for the vehicle build sequence. This is also the vehicle serial and warranty number. A00001-E99999 — Ford J00001-L99999 — Mercury Vehicle Certification (VC) Codes Vehicle Certification (VC) Label Locator 22.12.2002 file://C:\TSO\tsocache\SUPER10-45B629E_1712\S4N~us~en~file=S4N00004.htm~g...

The vehicle (VC) label contains information on the manufacturer name, the month and year of manufacture, the certification statement and the VIN. This label also includes gross vehicle weight (GVWR) information. Exterior Paint Item Description 1 Exterior paint code 2 Region code 3 Domestic special order 4 Wheelbase code 5 Brake code 6 Interior trim code 7 Tape/paint stripe code 8 Radio code 9 Axle code 10 Transmission code 11 Spring code 12 Powertrain calibration information 22.12.2002 file://C:\TSO\tsocache\SUPER10-45B629E_1712\S4N~us~en~file=S4N00004.htm~g...

2004 Ford Explorer Service & Repair Manual

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