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Bumped into this problem also and also found this thread.
Here is how i solved the problem:
I went in to the secret screen (5x home, 3x fastforward, 2x fastbackward) and learned that the updateserver was set to BETA for some reason. Its for sure it wasnt me who changed that setting! I switched to RELEASE and after that the update worked.
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Re: Update error 004 over and over
I checked, my update server was also set to "Beta". I switched it to "release", I didn't test the update since my S/W is current, after the double manual update.
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Re: Update error 004 over and over
I also showed beta but had already updated as well. Good to know about the “secret screen”.
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Re: Update error 004 over and over
I used your method, and even though I didn't have to change anything, the update worked! No more frustration! Thank you!
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Re: Update error 004 over and over
BLESS YOU! I was at the part where I couldn't surpass the update now and could not get to the home screen. This secret menu option was a lifesaver, thank you!!
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Re: Update error 004 over and over
I'm having the same problem. How do you get to the secret screen? I've never heard of The Secret screen please explain?
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Re: Update error 004 over and over
Secret Reset and Update menu; Press the Home button on your remote 5 times, then press Fast Forward > Fast Forward > Fast Forward > Rewind > Rewind
Once in there look at the left side and find what it says for software update server and it most likely is set as Beta. To change you will go down to the Cycle software update server option and select. This will change from the beta server to standard release server and for there you can exit and your update should work.
https://www.wikihow.com/Roku-Secret-Menu
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Re: Trouble updating roku express get error code 004
This is a issue. Ive got a whole new router. Checked the connection on the roku and its connected. This is another issues besides connectivity
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Re: Trouble updating roku express get error code 004
This sounds like a roku problem. My internet is fine.
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Re: Update error 004 over and over
I checked mine and it's set to RELEASE. I still cannot update.