I have an '04 Explorer Eddie Bauer that was exhibiting the same problem. Ford replaced the throttle body assembly and SOLVED the problem. Flashing the PCM did not fix my problem. I had to involve the Eastern Regional Manger to get the dealer to fix the problem. It seems it is a Ford factory known issue with certain Ford vehicles but no TSB has been issued. Here is how to tell if it might be the throttle body issue: accelerate to about 38 MPH and engage cruise control, begin coasting downhill, watch the tachometer, if the tachometer drops below 500 RPMs you may need the throttle body replaced. My RPMs were dropping below 300 then engine would sometimes die. The key issue seems to be the engine RPMs dropping while in 4th gear below 600 while coasting downhill. The problem did not occur in over-drive, only in 4th gear. Since the throttle body replacement engine RPMs never drops below 700.
My repair was made under extended warranty at 78K miles in March, 2008. Ford should fix without warranty as a major safety issue. By shifting into neutral you can immediately restart the engine after the stalling.
Monday, April 21st, 2008 AT 7:20 PM