MercuryMonterey2004Overview/mercury/monterey/2004/base/

2004 Mercury Monterey

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2004 Monterey.

Body VANTransmission Automatic 4-spd

The 2004 Mercury Monterey is a full-size van powered by a 5.0-quart oil capacity engine (requiring 5W-20 API viscosity) and paired with a 4-speed automatic transmission, delivering EPA fuel economy of 15 mpg city, 21 mpg highway, and 17 mpg combined. This model year recorded 283 owner complaints—the highest in the 2004–2007 generation—with the Power Train as the top complaint area and five recalls issued. As the most complaint-heavy year of the Monterey's run, the 2004 represents the low point in the model's reliability history, a stark contrast to the 2007's mere seven complaints.

Model year200720062005200419741973197219711970

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity5.0 qtOEM · verified
Engine oil type5W-20 APIOEM · verified
Lug nut torque100 ft-lbsOEM · verified
EPA fuel economy15/21/17 mpgEPA · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 59 · 540 CCA battery. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 59 · 540 CCAOEM · verified
Tire sizeP235-60R16OEM · verified

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

TransmissionAutomatic 4-spd

Ratings & economy EPA / vPIC

EPA city / highway / combined15 / 21 / 17 mpg
DrivetrainFront-Wheel Drive
Recommended fuelRegular Gasoline

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 5.0 qt of 5W-20 API engine oil, DOT 3 brake fluid. Torque lug nuts to 100 ft-lbs, the oil drain plug to 19.0-29.0 ft-lbs. The firing order is 1-4-2-5-3-6.

Lubricants & capacities

Automatic Transmission FluidATF
Automatic Transmission Fluid Capacity13.5
Brake FluidDOT 3
Engine Oil5W-20 · API
Engine Oil Capacity5.0 qt
Power Steering FluidATF

Engine torques

Crankshaft Pulley and/or Damper Bolts118 ft-lbs
Exhaust Manifold to Cylinder Head Bolts18.0 ft-lbs
Engine Oil Pan Drain Plug19.0-29.0 ft-lbs

Chassis torques

Lug Nuts100 ft-lbs

Ignition

Cylinder Firing Order1-4-2-5-3-6
Curb Idle Speed (No Load)800 rpm
Curb Idle Speed Variance (No Load)50 rpm
Spark Plug ManufacturerMotorcraft
Spark Plug Gap0.052-0.056 in
Spark Plug Torque11.0 ft-lbs
Ignition Timing15-20 Not adjustable degrees
Ignition Timing Reference RPM700-750 rpm

Battery & A/C

RefrigerantR134a
Refrigerant CapacityLess auxiliary A/C, 2.25. With auxiliary A/C, 3.31. lbs
Oil GroupPAG
Oil Type46
Oil CapacityLess auxiliary A/C, 10.00. With auxiliary A/C, 12.00. oz
Standard BCI Group Number59
Standard BCI Cranking Performance540 cca
Optional BCI Group Number65

Service checks

Pressure Test20 psi
Radiator Cap Pressure Relief13-18 psi
Thermostat Opening Temperature188-195 °F
Key ON Engine OFF (KOEO)30-45
Injector Primary Resistance11-18 ohms
Engine Oil Pressure40-125 psi
Engine Oil Pressure RPM2500 rpm
Intake Valve LashHydraulic in

Brakes

Torque Caliper to Bracket26 ft-lbs / 24 ft-lbs
Torque to Knuckle136 ft-lbs / 75 ft-lbs
Minimum Pad ThicknessFront: 0.118; Rear: 0.118 in
Rotor Minimum Machining1.14 in / 0.74 in
Rotor Discard at or Under1.11 in / 0.72 in

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 5,000 mi; spark plugs every 100,000 mi; coolant every 50,000 mi. The big-interval services (every 50,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

Every 5,000 miEngine Oil (drain & refill) · Engine Oil Filter (replace) · Tire & Wheel Assembly (rotate)
Every 15,000 miBrake System (inspect) · Cabin Air Filter (replace) · Engine Coolant System Hoses (inspect) · Steering System (inspect) · Suspension System (inspect) · Transmission Assembly (inspect fluid level)
Every 30,000 miEngine Air Filter Element (replace) · Exhaust System (Complete) (inspect) · Fuel Filter (replace) · Temperature Controlled Seat Air Filter (replace)
Every 50,000 miEngine Coolant System (drain, flush & refill)
At 100,000 miEngine Coolant System (drain, flush & refill)
Every 100,000 miAccessory Drive Belt (inspect) · PCV Valve (replace) · Spark Plugs (replace)
At 150,000 miDrive Belt (replace) · Transmission Fluid & Filter (replace)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

The 2004 Mercury Monterey sits at the highest point of a sharply declining federal record across this generation, registering 283 complaints, 5 recalls, 7 investigations, and 60 TSBs—figures that dramatically exceed every subsequent year and establish 2004 as the peak of reported activity. From 2005 through 2007, complaints fell sequentially to 119, 44, and 7, recalls tapered from 4 down to 2, investigations settled at 3, and TSBs dropped from 41 to 9, confirming a clear downward arc that makes 2004 the generation's most documented year. Power Train dominates the 2004 complaint record at 185 filings, while Structure, Steering, and Seats each generated 7 complaints; the data does not specify a root cause for the Power Train volume. The 2004 model also logged 6 fire complaints and 2 crash complaints, figures consistent with its status as the generation’s highest-complaint year. Because the federal record trends downward across nearly every category after 2004, this is not the strongest year to buy, and shoppers would be better served by the lower-complaint 2006 or 2007 models.

5
Open recalls
NHTSA campaigns
60
Service bulletins
Manufacturer communications
7
ODI investigations
Office of Defects Investigation
283
Owner complaints
2 involved a crash · 6 a fire
NHTSA crash-test rating federal NCAP · out of 5 stars
Rollover★★★★
Owner complaints by model year NHTSA · this generation & adjacent

Owner complaints filed with NHTSA, by component

All 283 complaints on record, top 8 components.

Power Train185
Structure7
Steering7
Seats7
Structure,Seats6
Unknown Or Other4
Vehicle Speed Control4
Suspension4

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 5 campaigns on record for this vehicle.

12V006000Power Train:Automatic TransmissionReported 09/01/2012

FORD IS RECALLING CERTAIN MODEL YEAR 2004 AND 2005 FORD FREESTAR AND MERCURY MONTEREY VEHICLES. THE TORQUE CONVERTER OUTPUT SHAFT MAY FAIL. Remedy: FORD WILL NOTIFY OWNERS, AND DEALERS WILL REPLACE THE TORQUE CONVERTER FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 9, 2012. OWNERS MAY CONTACT THE FORD MOTOR COMPANY…

13V081000SeatsReported 07/03/2013

Ford is recalling certain model year 2004-2007 Freestar and Mercury Monterey vehicles manufactured from March 24, 2003, through November 7, 2006, equipped with a third row seat and originally sold in, or currently… Remedy: Ford will notify owners, and dealers will install new third row seat latch striker mounting brackets, free of charge. The recall began on March 28, 2013. Owners may contact Ford…

Technical service bulletins NHTSA · verified

Showing 5 of 60 bulletins on record with NHTSA.

BulletinDateComponentSummary
SSM 460852016-09-21Engine And Engine CoolingThe Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing…
TSB1600692016-04-21SeatsSafety recall 13S01 - Corrosion on sheet metal that supports 3rd row seat latch strikeers…
16-00692016-04-21SeatsFor 2004-2007 Freestar or Monterey vehicles Safety Recall 13S01 has been issued for…
TSB-14-01662014-09-09SeatsFORD/MERCURY: SAFETY RECALL REGARDING SHEET METAL SUPPORT FOR FOLDING 3RD ROW SEAT LATCH…
TSB-14-01442014-08-11Equipment Adaptive/MobilityFORD/MERCURY: SHEET METAL SUPPORTING FOLDING 3RD ROW SEAT LATCH STRIKERS WILL EXPERIENCE…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420
Catalyst system efficiency below threshold — Bank 1
P0300
Random / multiple cylinder misfire detected
P0171
System too lean — Bank 1
P0455
Evaporative emission system leak detected — large leak
P0128
Coolant thermostat below regulating temperature
P0442
Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN
Decode a VIN to confirm the transmission and build data for a specific Monterey. OEM
Build data
Plant, GVWR class, engine and body data for any 17-character VIN.
Recalls
Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Reference guides

Cross-vehicle references for the kinds of data on this page.

Frequently asked

How much oil does the 2004 Monterey take?

5.0 qt of 5W-20 API, per the factory manual.

Does the 2004 Monterey have open recalls?

NHTSA lists 5 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the Monterey get?

EPA figures are 15 city / 21 highway / 17 combined mpg.