The 2004 Ford Explorer features a 22.5-gallon fuel tank across all standard models, providing approximately 315-427 miles of driving range depending on engine configuration and driving conditions, with the V6 models offering better fuel economy than V8 variants while maintaining similar tank capacity.
What is the Fuel Tank Capacity of a 2004 Ford Explorer?
The 2004 Ford Explorer has a fuel tank capacity of 22.5 gallons (85.2 liters) across most models and configurations. This uniform capacity applies to both two-wheel drive and four-wheel drive variants, as well as models equipped with either the 4.0L V6 or 4.6L V8 engine. The only exception is the Eddie Bauer trim with specific configurations, which features a slightly larger 26-gallon tank on some models.
Does Fuel Tank Size Vary Between Different 2004 Explorer Trim Levels?
Most 2004 Explorer trim levels—including XLS, XLT, NBX, and Limited—feature the standard 22.5-gallon fuel tank. However, some Eddie Bauer models were equipped with a larger 26-gallon tank, providing approximately 15% more fuel capacity. This variation appears to be configuration-specific rather than standard across all Eddie Bauer models. When purchasing a used Explorer, checking the specific vehicle’s documentation is recommended as some aftermarket modifications might have affected the original fuel capacity.
What is the Driving Range of a 2004 Ford Explorer?
| Engine/Drivetrain | City Range (miles) | Highway Range (miles) | Combined Range (miles) |
|---|---|---|---|
| 4.0L V6 2WD | 315 (14 mpg) | 427.5 (19 mpg) | 360 (16 mpg) |
| 4.0L V6 4WD | 315 (14 mpg) | 427.5 (19 mpg) | 360 (16 mpg) |
| 4.0L V6 FFV 2WD | 315 (14 mpg) | 450 (20 mpg) | 360 (16 mpg) |
| 4.0L V6 FFV 4WD | 315 (14 mpg) | 427.5 (19 mpg) | 360 (16 mpg) |
| 4.6L V8 2WD | 292.5 (13 mpg) | 405 (18 mpg) | 337.5 (15 mpg) |
| 4.6L V8 4WD | 292.5 (13 mpg) | 405 (18 mpg) | 337.5 (15 mpg) |
These ranges are calculated based on EPA fuel economy ratings and assume a full tank. Real-world driving ranges may vary based on driving habits, terrain, vehicle condition, and load. The Distance to Empty feature typically provides a warning when approximately 50 miles of range remains.
How Does the 2004 Explorer’s Fuel Capacity Compare to Other SUVs?
| SUV Model | Fuel Tank Capacity | Highway Range | City Range |
|---|---|---|---|
| 2004 Ford Explorer | 22.5 gallons | 405-450 miles | 292-315 miles |
| 2004 Jeep Grand Cherokee | 20.5 gallons | 389 miles | 287 miles |
| 2004 Chevrolet TrailBlazer | 18.7 gallons | 411 miles | 299 miles |
| 2004 Toyota 4Runner | 23.0 gallons | 483 miles | 345 miles |
| 2004 Nissan Pathfinder | 21.1 gallons | 422 miles | 295 miles |
| 2004 GMC Envoy | 18.7 gallons | 411 miles | 299 miles |
The Explorer’s 22.5-gallon tank was among the larger offerings in its class, providing competitive range despite its somewhat lower fuel economy compared to some rivals. The Toyota 4Runner offered the best combination of tank size and efficiency, resulting in the longest potential range.
What is the Fuel Economy of the 2004 Ford Explorer?
| Engine/Drivetrain Configuration | City MPG | Highway MPG | Combined MPG |
|---|---|---|---|
| 4.0L V6 2WD | 14 | 19 | 16 |
| 4.0L V6 4WD | 14 | 19 | 16 |
| 4.0L V6 FFV 2WD (gasoline) | 14 | 20 | 16 |
| 4.0L V6 FFV 2WD (E85) | 10 | 14 | 12 |
| 4.0L V6 FFV 4WD (gasoline) | 14 | 19 | 16 |
| 4.0L V6 FFV 4WD (E85) | 10 | 14 | 12 |
| 4.6L V8 2WD | 13 | 18 | 15 |
| 4.6L V8 4WD | 13 | 18 | 15 |
V6 vs. V8 Fuel Economy Comparison
The 4.0L V6 engine offers better fuel economy than the 4.6L V8 across all driving conditions. The V6 provides approximately 7% better fuel efficiency in city driving (14 mpg vs. 13 mpg) and 5-10% better efficiency on the highway (19-20 mpg vs. 18 mpg).
While the V8 delivers more power (239 hp vs. 210 hp) and superior towing capacity (up to 7,140 lbs vs. 5,380 lbs), this comes at the cost of increased fuel consumption. Real-world owner reports suggest the difference might be less pronounced in highway driving, with some V8 owners reporting similar highway efficiency to V6 models when cruising at steady speeds. However, in stop-and-go traffic, the V6’s efficiency advantage becomes more significant.
Flex Fuel Vehicle (FFV) variants capable of running on E85 ethanol blend suffer a significant efficiency penalty of approximately 25-30% when using E85 instead of gasoline.
How to Check the Fuel Level in a 2004 Ford Explorer
The 2004 Explorer features a standard analog fuel gauge on the instrument cluster that displays the approximate fuel level. The gauge may not be perfectly linear, typically showing more movement in the upper half of the range than the lower half.
The low fuel warning light typically activates when approximately 2-3 gallons remain in the tank, providing roughly 30-50 miles of remaining range depending on driving conditions. This reserve capacity is designed to give drivers sufficient time to find a gas station.
For more accurate measurement, the Explorer’s trip computer can display an estimated “Distance to Empty” figure based on recent driving patterns. This calculation becomes more conservative as fuel levels decrease, often showing a remaining range of 50 miles when the low fuel warning first appears.
To manually verify fuel level, park on level ground before checking the gauge, as parking on an incline can cause inaccurate readings due to fuel shifting within the tank.
How Much Does it Cost to Fill a 2004 Ford Explorer?
| Fuel Type | Current National Average Price (April 2025) | Cost to Fill 22.5-Gallon Tank | Cost to Fill 26-Gallon Tank (Eddie Bauer) |
|---|---|---|---|
| Regular Unleaded | $3.16 per gallon | $71.10 | $82.16 |
| Premium Unleaded | $3.99 per gallon | $89.78 | $103.74 |
| E85 Ethanol Blend | $2.63 per gallon | $59.18 | $68.38 |
| Diesel (not applicable) | $3.58 per gallon | N/A | N/A |
These costs are based on national average fuel prices as of April 2025. Regional prices may vary significantly, with states like California having prices up to 50% higher than states with the lowest fuel costs. The annual fuel cost for a 2004 Explorer driven 15,000 miles per year ranges from approximately $2,900-$3,600 depending on the engine and driving conditions.
Common Fuel System Issues in the 2004 Ford Explorer
The 2004 Explorer may experience several fuel system issues as it ages:
- Fuel pump failure (typically occurring between 100,000-150,000 miles)
- Fuel pressure regulator malfunction causing rough idle and stalling
- Fuel sending unit problems leading to inaccurate gauge readings
- Fuel Pump Driver Module (FPDM) corrosion causing intermittent fuel delivery
- Clogged fuel filters restricting flow and reducing performance
- Fuel injector clogs or failures causing rough running and poor efficiency
- Inertia switch tripping unnecessarily (located under driver’s side carpet)
- Fuel tank pressure sensor failures triggering check engine lights
- Evaporative emissions system leaks causing fuel odors
- Fuel line corrosion in regions using road salt
Many owners report that the fuel pump is particularly prone to failure in high-mileage vehicles, often with little warning. Preventative replacement around 100,000 miles may be worthwhile for those planning to keep their Explorer long-term.
Were There Any Fuel System Recalls for the 2004 Explorer?
There were no major fuel system-specific recalls issued by Ford for the 2004 Explorer. However, some related issues were addressed in technical service bulletins (TSBs) rather than formal recalls. These included:
- TSB 05-22-12: Addressing potential Fuel Pump Driver Module (FPDM) corrosion issues that could cause stalling or no-start conditions
- TSB 03-16-1: Covering potential fuel pressure regulator leaks causing fuel odor
- TSB 06-5-9: Addressing fuel gauge inaccuracy problems on some models
While not recall-level concerns, these issues were recognized by Ford as requiring attention in some vehicles. Owners experiencing fuel system problems should check if their specific vehicle was covered under any of these service bulletins, as repairs might have been covered by extended warranties in some cases.
How to Improve Fuel Economy in a 2004 Ford Explorer
To maximize fuel efficiency in a 2004 Explorer:
- Maintain proper tire pressure (typically 30-35 PSI)
- Replace air filters regularly (every 15,000-30,000 miles)
- Use the recommended motor oil viscosity
- Remove unnecessary weight from the vehicle
- Avoid excessive idling (over 10 seconds of idling uses more fuel than restarting)
- Drive at moderate speeds (fuel economy drops significantly above 60 mph)
- Accelerate gradually rather than aggressively
- Use cruise control on highways to maintain steady speeds
- Plan trips to combine errands and avoid stop-and-go traffic
- Consider aftermarket modifications like electric cooling fans
- Keep up with regular maintenance including spark plug replacement
- Use fuel injector cleaners periodically to maintain injector efficiency
- Remove roof racks when not in use to reduce aerodynamic drag
- Consider installing an aftermarket engine tuner for improved efficiency
Implementing these strategies can improve real-world fuel economy by 10-15% over typical driving habits.
What Type of Fuel Does a 2004 Ford Explorer Use?
The 2004 Ford Explorer is designed to run on regular unleaded gasoline with a minimum octane rating of 87. Using higher octane premium fuel (91-93 octane) provides no performance or efficiency benefits in standard models and is an unnecessary expense.
Flex Fuel Vehicle (FFV) variants can run on E85 ethanol blend (85% ethanol, 15% gasoline) or regular gasoline. However, using E85 results in approximately 25-30% lower fuel economy compared to gasoline, though it may be more economical depending on the price difference between fuels.
Ford specifically advises against using gasoline containing more than 10% ethanol (E10) in non-FFV models, as higher ethanol concentrations can damage fuel system components not designed for such blends. Diesel fuel should never be used in any 2004 Explorer model as it would cause severe engine damage.
2004 Explorer Fuel Door and Cap: Location and Replacement
The fuel door on the 2004 Explorer is located on the driver’s side rear quarter panel. It does not have a remote release mechanism; instead, it must be manually opened by pressing the edge of the door to release the spring-loaded latch.
The fuel cap is a standard threaded type with a ratcheting mechanism to prevent overtightening. It includes a plastic tether to prevent the cap from being lost during refueling. The cap should be turned counterclockwise to remove and clockwise until it clicks to reinstall.
Replacement caps should meet OEM specifications to ensure proper sealing and evaporative emissions control. Using an incorrect or low-quality cap can trigger check engine lights related to the evaporative emissions system. OEM replacement caps typically cost $15-25, while aftermarket options range from $5-15. The cap requires no tools for replacement and can be easily installed by hand.
People Also Ask:
How many miles can a 2004 Ford Explorer go on a full tank?
A 2004 Ford Explorer can travel approximately 315-450 miles on a full tank depending on the engine, driving conditions, and configuration. V6 models typically achieve 360 miles of combined city/highway driving, while V8 models average about 337 miles per tank.
Did the 2004 Ford Explorer have different gas tank sizes for 4WD vs 2WD models?
No, both 2WD and 4WD versions of the 2004 Ford Explorer feature the same 22.5-gallon fuel tank capacity. The only variation is in certain Eddie Bauer models that came with a larger 26-gallon tank regardless of drive configuration.
What is the fuel pressure specification for a 2004 Ford Explorer?
The 2004 Ford Explorer’s fuel system should maintain approximately 35-45 PSI (pounds per square inch) at idle. The fuel pressure regulator modulates this pressure based on engine load and vacuum conditions to ensure proper fuel delivery across all operating conditions.
How accurate is the fuel gauge on a 2004 Ford Explorer?
The fuel gauge on a 2004 Explorer is moderately accurate but tends to be non-linear. It typically moves more quickly through the top half of the range and more slowly through the bottom half. Many owners report that the last quarter of the gauge represents significantly less than 25% of the actual fuel capacity.
What is the reserve fuel capacity on a 2004 Ford Explorer?
The 2004 Explorer has approximately 2-3 gallons of reserve capacity after the low fuel warning light illuminates. This provides roughly 30-50 miles of additional driving range depending on conditions and driving habits, giving drivers adequate time to find a gas station.