Vehicle report

2004 FORD EXPEDITION

Service bulletins

90 bulletins

Technical service bulletins are instructions a manufacturer sent its dealers about a known fault. They are not recalls and the work is usually not free, but they are the clearest signal of a problem the manufacturer already knows about.

TSB 24-2188

Service Bulletin/Repair Instructions

This article supersedes TSB 22-2219 to update the Parts List and Service Procedure to clarify applicable steps by vehicle application. Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 (non-Raptor) vehicles equipped with 4WD may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (IWE). To correct this condition, follow the Service Procedure to remove and cap the vacuum supply line or to reprogram the transfer case control module (TCCM) and replace any worn vacuum and/or IWE components.

SSM 51536

Service Bulletin/Repair Instructions

For 2000-2024 Ford and Lincoln vehicles, swapping a module from a vehicle for diagnosis purposes is likely to cause errors and is not recommended. It is also not recommended to order a replacement module using a vehicle identification number (VIN) from a different vehicle. Most modules on these affected vehicles are VIN/vehicle specific and hardware variations between modules do exist. Swapping a module from a vehicle or ordering a module using a different vehicle/VIN can cause ineffective repairs and additional vehicle down time. Make sure all appropriate Workshop Manual (WSM) procedures are followed when diagnosing the condition prior to all module replacements and only order modules using the correct VIN.

TSB 22-2219

Service Bulletin/Repair Instructions

Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 (non-Raptor) vehicles equipped with 4WD may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (IWE). To correct this condition, follow the Service Procedure to remove and cap the vacuum supply line or to reprogram the transfer case control module (TCCM) and replace any worn vacuum and/or IWE components.

TSB 20-2307

Service Bulletin/Repair Instructions

Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 vehicles equipped with TOD transfer cases may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (IWE). To correct this condition, follow the Service Procedure steps to remove and cap the vacuum supply line.

TSB 20-2233

Service Bulletin/Repair Instructions

This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended.

TSB 19-2026

Service Bulletin/Repair Instructions

Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition

SSM 46085

Service Bulletin/Repair Instructions

The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate when reading these PIDs and cannot display quickly enough to validate a concern. The PCM automatically monitors these inputs more accurately and will set diagnostic trouble codes (DTCs) when appropriate. Using these PIDs for diagnostics will lead to inaccurate results and improper ETB replacements. If a concern is intermittent and no DTCs are present, refer to historical DTCs and the PC/ED, Section 3 No DTCs Present Index chart for further information.

TSB-08-19-3

Service Bulletin/Repair Instructions

FORD: SOME VEHICLES MAY EXHIBIT OIL SEPARATION FROM THE INTERNAL LUBE FOUND IN THE UNITIZED CARTRIDGE SEAL. OIL SEPARATION APPEARS TO BE AND IS OFTEN MISDIAGNOSED, AS AN AXLE LUBE LEAK. *PE

07212

Service Bulletin/Repair Instructions

SOME 1997-2008 VEHICLES EQUIPPED WITH A 4.6L 2V, 5.4L 2V, OR 6.8L 2V ENGINE--SPARK PLUG THREAD REPAIR PROCEDURE--NOT COVERED UNDER NEW VEHICLE LIMITED WARRANTY. *NJ THIS INCLUDES F-53 MOTORHOME CHASSIS. UPDATED 2/23/10. *PE

0514

Service Bulletin/Repair Instructions

BRAKE SHUDDER (ROTOR THICKNESS VARIATION) DUE TO THE NEW LOW DUST FRONT BRAKE LINING USED IN PRODUCTION, OR NEW LININGS THAT WERE INSTALLED PER TSB 04-05-02. *TT

06216

Service Bulletin/Repair Instructions

LIMITED SLIP AXLE CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNING MANEUVERS. *TT

06317

Service Bulletin/Repair Instructions

BRAKE SHUDDER. *TT

0637

Service Bulletin/Repair Instructions

LOW TIRE INDICATOR ON - TPMS SYSTEM SENSOR WAKE UP. *TT

041601

Service Bulletin/Repair Instructions

WDS COP KIT DIAGNOSTIC TIP - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING. *TT

0594

Service Bulletin/Repair Instructions

DRIVERS FRONT POWER SEAT WILL NOT MOVE FORWARD OR REARWARD. *TT

05198

Service Bulletin/Repair Instructions

REAR WINDOW WIPER INOPERATIVE. *TT

18815

Service Bulletin/Repair Instructions

A TINY CRACK, OR CRACKS, AROUND THE TRANSFER CASE DRAIN PLUG HOLE. *TT

04105

Service Bulletin/Repair Instructions

AXLE SEAL LEAKS. LEAKS FROM REAR HALFSHAFT AXLE SEAL. SERVICE TIPS. *TT

042421

Service Bulletin/Repair Instructions

SAFETY BELT RETRACTION SPEED. *TT

18478

Service Bulletin/Repair Instructions

AXLE SEAL LEAKS. *EH

031207

Service Bulletin/Repair Instructions

STEERING WHEEL AT 65 MPH (105 KM/H) OR HIGHER. *TT

05618

Service Bulletin/Repair Instructions

REAR AXLE NOISE REPAIR. *TT

0554

Service Bulletin/Repair Instructions

USE OF STAINLESS STEEL EXHAUST STUDS IN SERVICE FOR 5.4L 2V ENGINE. *TT

05411

Service Bulletin/Repair Instructions

NOISE FROM A/C (AIR CONDITIONING) OR INSUFFICIENT A/C COOLING. *TT

05417

Service Bulletin/Repair Instructions

INTERMITTENT ROUGH IDLE - NON-COMMANDED EGR (EXHAUST GAS RECIRCULATION VALVE) FLOW. *TT

18466

Service Bulletin/Repair Instructions

AXLE WHINE HOWL. THIS INCLUDES 1997-05 FORD VEHICLES. *EH

18506

Service Bulletin/Repair Instructions

ALUMINUM ALLOY WHEELS PITTING AND OR PEELING CLEANING PROCEDURES. *EH

05310

Service Bulletin/Repair Instructions

SAFETY BELT WEB STOP BUTTON SERVICE. *EH

18400

Service Bulletin/Repair Instructions

FOUR CORNER LOAD LEVELING AIR SUSPENSION MAY EXHIBIT LEVELING CONCERNS, SUCH AS ONE FRONT CORNER DROPPING. INDIVIDUAL AIR SPRINGS AVAILABLE FOR SERVICE. *TT

18423

Service Bulletin/Repair Instructions

AXLE WHINE HOWL SERVICE WITH INDIVIDUAL PARTS INSTEAD OF AN AXLE ASSEMBLY. *EH

18439

Service Bulletin/Repair Instructions

TINY CRACK OR CRACKS AROUND THE TRANSFER CASE DRAIN PLUG. *EH

050618

Service Bulletin/Repair Instructions

REAR AXLE NOISE REPAIR. *SC

052621

Service Bulletin/Repair Instructions

UNINTENDED BRAKE ASSIST. *TT

052624

Service Bulletin/Repair Instructions

VIBRATION DIAGNOSIS - TIRE/WHEEL RUNOUT. *TT

18384

Service Bulletin/Repair Instructions

POPPING OR QUAVERING FROM RADIO ON THE AM BAND. *TT

040704

Service Bulletin/Repair Instructions

CLIMATE CONTROLLED SEAT DIAGNOSIS - SERVICE TIPS. *TT

041614

Service Bulletin/Repair Instructions

STEERING COLUMN CLUNK, POP OR CREAK. *AR UPDATE. *TT

0471

Service Bulletin/Repair Instructions

WARNING INDICATORS-PARKING AID-REVERSE SENSING SYSTEM (RSS) AND FORWARD SENSING SYSTEM (FSS)-FALSE ACTIVATION OF WARNING TONE-SERVICE TIPS. *MJ UPDATE. *TT

04251

Service Bulletin/Repair Instructions

ALUMINUM CORROSION - SERVICE TIP. *TT

04189

Service Bulletin/Repair Instructions

REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR. *TT

042107

Service Bulletin/Repair Instructions

GENERAL (PCM) POWER TRAIN CONTROL MODULE PROGRAMMING PROCEDURES. *TT

042116

Service Bulletin/Repair Instructions

REVERSE TILT MIRROR SYSTEM DIAGNOSTICS AND REPAIR. *EH

18213

Service Bulletin/Repair Instructions

GRINDING NOISE FROM FRONT AXLE WHEEL HUBS ON ACCELERATION IN 2WD - SERVICE TIP. VARIOUS MODELS INCLUDING 2005 EXPEDITION/NAVIGATOR. *TT

18217

Service Bulletin/Repair Instructions

MULTIPLE VEHICLES - FUEL LEVEL INDICATION CONCERNS - SERVICE TIP. VARIOUS MODELS INCLUDING 2005 SUPER DUTY F-SERIES, EXCURSION, EXPEDITION, EXPLORER, MOUNTAINEER AND AVIATOR. *TT

18228

Service Bulletin/Repair Instructions

TIRE FEATHERING AT LOW MILEAGE. OASIS. VARIOUS MODELS INCLUDING 2005 EXPEDITION. *TT

03198

Service Bulletin/Repair Instructions

CHATTER, SHUDDER, A BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNS ON VEHICLES EQUIPPED WITH THE 9.75 INCH OR 8.8 INCH LIMITED SLIP REAR AXLE. *TT

04174

Service Bulletin/Repair Instructions

MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - SYSTEM LEAN DIAGNOSTIC TROUBLE CODES (DTC'S) - SERVICE TIPS. VARIOUS MODELS INCLUDING 2004 F-SERIES. *TT

18127

Service Bulletin/Repair Instructions

VARIOUS ELECTRIC CONCERNS. INTERIOR ILLUMINATION, QUARTER WINDOWS, MOONROOF FUNCTION, ACCESSORY DELAY, COURTESY LAMPS, ELECTRO CHROMATIC MIRROR, CLIMATE CONTROLLED SEATS, ELECTRONIC PARK BRAKE RELEASE, FLASHER RELAY, AUDIO SYSTEM, ELECTRONIC HIDDEN ANTENNA MODULE (EHAM), POWER LIFT GATE, AND REAR CLIMATE CONTROL. *TT

18172

Service Bulletin/Repair Instructions

REVERSE SENSING SYSTEM DEFAULTING OFF, SETTING DIAGNOSTIC TROUBLE CODES, OR LOSING COMMUNICATION WITH DIAGNOSTIC SCAN TOOL. *TT

031404

Service Bulletin/Repair Instructions

ENGINE MISFIRE OR RUNNING - COIL ON PLUG (COP) IGNITION SYSTEMS - WDS COP KIT DIAGNOSTIC TIPS. TO INCLUDE VARIOUS 2005 MODELS. * AR THIS ARTICLE 04161 SUPERSEDES TSB 03-14-04.

041511

Service Bulletin/Repair Instructions

MISFIRE AT IDLE WITH DIAGNOSTIC TROUBLE CODES P0300-P0308, P0316. *TT

041514

Service Bulletin/Repair Instructions

REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR. *TT

031501

Service Bulletin/Repair Instructions

INOPERATIVE ELECTRIC REAR WINDOW DEFROSTER (HEATED BACKLITE) GRID LINES, INTEGRAL ANTENNA CONCERNS. *TT

17905

Service Bulletin/Repair Instructions

MULTIPLE VEHICLES USING FEHP REAR AXLE FLUID. FLUID USAGE CHANGE. *TT

17881

Service Bulletin/Repair Instructions

RIDE HEIGHT ISSUES ON AUTOMOBILES WITH AIR SUSPENSION. *TT

17693

Service Bulletin/Repair Instructions

DIAGNOSTIC TROUBLE CODE (DTC) P0320 (IGNITION ENGINE SPEED INPUT CIRCUIT MALFUNCTION). *TT

17732

Service Bulletin/Repair Instructions

CHECK AIR SUSPENSION MESSAGE WITH DIAGNOSTIC TROUBLE CODE (DTC) C1724, C1873, AND/OR C1889. *TT

17738

Service Bulletin/Repair Instructions

CHARGING SYSTEM WARNING INDICATOR INTERMITTENTLY ON WITH POSSIBLE DIAGNOSTIC TROUBLE CODE (DTC) P0620. *TT

17755

Service Bulletin/Repair Instructions

AXLE WHINE AT HIGHWAY SPEEDS (40-60 MPH). *TT

0454

Service Bulletin/Repair Instructions

AIR SUSPENSION COMPRESSOR NOISE. *TT

0457

Service Bulletin/Repair Instructions

POP/THUMP NOISE AT END OF WINDOW MOVEMENT AND/OR DRIVER'S WINDOW BOUNCE BACK AND REVERSE TO MID-POSITION. *TT

0459

Service Bulletin/Repair Instructions

INTERMITTENT LOSS OF COOLING OR AIRFLOW FROM A/C SYSTEM AT HIGHWAY DRIVES. *TT

0411

Service Bulletin/Repair Instructions

BRAKE DUST - REVISED BRAKE LININGS - VEHICLES BUILT PRIOR TO 12/18/2003. *TT

17598

Service Bulletin/Repair Instructions

REAR AXLE HALFSHAFT SEAL LEAK. *TT

17630

Service Bulletin/Repair Instructions

REVERSE TILT MIRROR FUNCTION - SERVICE TIP. *TT

17632

Service Bulletin/Repair Instructions

AXLE WHINE AT HIGHWAY SPEEDS (40-60 MPH). *TT

17639

Service Bulletin/Repair Instructions

RIDE HEIGHT ISSUES. *TT

17557

Service Bulletin/Repair Instructions

SAFETY BELT DIFFICULT TO PULL OUT DUE TO WEB STOP BUTTON USED FOR VEHICLE ASSEMBLY. *MJ

17574

Service Bulletin/Repair Instructions

INTERIOR CARPET CURLING NEAR THE EMERGENCY BRAKE. *TT

0397

Service Bulletin/Repair Instructions

CLIMATE CONTROLLED SEAT DIAGNOSIS - SERVICE TIPS. *TT *MJ

04149

Service Bulletin/Repair Instructions

DIAGNOSTIC TROUBLE CODE (DTC) P0320 WITH POSSIBLE DRIVEABILITY CONCERNS AND/OR CHARGING SYSTEM WARNING INDICATOR ON WITH POSSIBLE DTC P0620. *TT

17459

Service Bulletin/Repair Instructions

COURTESY RAIL LAMPS DO NOT OPERATE CORRECTLY OR CAUSE A BATTERY DRAW. *TT

17466

Service Bulletin/Repair Instructions

CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION FROM LIMITED SLIP REAR AXLE DURING LOW SPEED TURNS. *TT

17488

Service Bulletin/Repair Instructions

AXLE WHINE BETWEEN 58-62 MPH. *TT

17524

Service Bulletin/Repair Instructions

TPMS MODULE REPLACEMENT AND CONFIGURATION - SERVICE TIP. *TT

03256

Service Bulletin/Repair Instructions

ENGINE-ROMEO BUILT 4.6L 2V-TICK NOISE FROM ENGINE-ENGINES BUILT BEFORE 9/17/2003. *MJ

17411

Service Bulletin/Repair Instructions

TIRE PRESSURE MONITORING SYSTEM (TPMS) MODULE CONFIGURATION - SERVICE TIP. *MJ

17418

Service Bulletin/Repair Instructions

DIAGNOSTIC TROUBLE CODE (DTC) P0320 WITH DRIVEABILITY SYMPTOMS. *MJ

99263

Service Bulletin/Repair Instructions

CORRECT LUG NUT TORQUE SPECIFICATIONS - INCREASE WHEEL NUT AND STUD SIZE - SERVICE TIP. *TT

17316

Service Bulletin/Repair Instructions

FUEL SIGNAL TO INSTRUMENT CLUSTER SERVICE TIP. *TT

17317

Service Bulletin/Repair Instructions

PARKING AID SYSTEM MESSAGES AND CONTROL FUNCTIONS DO NOT DISPLAY IN THE MESSAGE CENTER. *TT

17320

Service Bulletin/Repair Instructions

BROKEN EXHAUST MANIFOLD STUDS. *TT

17356

Service Bulletin/Repair Instructions

LOSS OF CLIMATE CONTROL COOLING DURING EXTENDED DRIVING. *TT

17247

Service Bulletin/Repair Instructions

ACCUMULATION OF BRAKE DUST ON THE WHEELS UNDER REGULATOR DRIVING CONDITIONS. *TT

17289

Service Bulletin/Repair Instructions

PARKING AID SENSOR READINGS DO NOT DISPLAY ON WDS. *TT

03181

Service Bulletin/Repair Instructions

REMOTE KEYLESS ENTRY (RKE) - SERVICE TIPS. *TT

17135

Service Bulletin/Repair Instructions

MOANING NOISE FROM THE EXHAUST SYSTEM, OR VIBRATION IN THE REAR PASSENGER FLOOR PAN, WHEN DRIVING 45-55 MPH AND 1200-1400 RPM ALL WITHOUT FLEX COUPLING IN THE EXHAUST. *TT

17168

Service Bulletin/Repair Instructions

VEHICLES EQUIPPED WITH ADVANCETRAC STABILITY ASSIST/INTERACTIVE VEHICLE DYNAMICS - IVD) MAY EXHIBIT A DIAGNOSTIC TROUBLE CODE C1998. *TT

17030

Service Bulletin/Repair Instructions

VEHICLES WITH A SILVER VALVE STEM TIRE PRESSURE MONITOR SYSTEM (TPMS) MAY EXHIBIT A WARNING LIGHT/MESSAGE ON. *TT

061510

Service Bulletin/Repair Instructions

AIR SUSPENSION PERFORMANCE - HEIGHT SENSOR LINKAGE ARM DISENGAGING. *KB

Reading this report

Complaint counts are reports filed with NHTSA, not failure rates. A common model collects more of them than a rare one that breaks more often.

2004 Ford Expedition Service Bulletins: 90 bulletins | CarFathom