Vehicle report

2004 FORD EXPLORER

Service bulletins

108 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 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-12-8-1

Service Bulletin/Repair Instructions

FORD/LINCOLN/MERCURY: MAY HAVE SLUDGE BUILDUP IN THROTTLE BODY LEADING TO LESS AIRFLOW OR ENGINE IDLING RPM FLUCTUATION AND HARD STARTS OR BATTERY DISCONNECT OR DEAD BATTERY AFTER KEEP ALIVE MEMORY (KAM) CLEAR. MODELS 2003-05 THUNDERBIRD, 05-06 MUSTANG, 06-08 FUSION, 04-05 EXPLORER, 05-06 EXPEDITION, 05-07 F-150; 2003-06 LS, 06 ZEPHYR, 05-06 NAVIGATOR; 06-08 MILAN. *PE

TSB-12-7-4

Service Bulletin/Repair Instructions

FORD/LINCOLN/MERCURY: IF BATTERY WAS DISCONNECTED OR DEAD, VEHICLES/TRUCKS MAY EXPERIENCE HARD STARTS AND ENGINE IDLE RPM FLUCTUATION AND EXHIBIT DIAGNOSTIC TROUBLE CODES (DTCS) P0505, P0506, P2111 AND P2112. *PE

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

05213

Service Bulletin/Repair Instructions

MALFUNCTION INDICATOR LAMP ON WITH PCM DIAGNOSTIC TROUBLE CODE P0463 AND/OR IC DIAGNOSTIC TROUBLE CODE B1201 - FUEL GAUGE DROPS TO EMPTY OR SLOW TO UPDATE AFTER REFUELING. *TT

05252

Service Bulletin/Repair Instructions

NEUTRAL TOW CAPABILITY -- SERVICE KIT REQUIREMENTS. *TT

06216

Service Bulletin/Repair Instructions

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

0637

Service Bulletin/Repair Instructions

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

0645

Service Bulletin/Repair Instructions

NEUTRAL TOW CAPABILITY - SERVICE KIT REQUIREMENTS. *TT

041601

Service Bulletin/Repair Instructions

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

042115

Service Bulletin/Repair Instructions

FUEL GAUGE SLOW TO UPDATE AFTER REFUELING. *EH

051710

Service Bulletin/Repair Instructions

NOISE FROM REAR WHEEL HUB BEARINGS. *TT

18719

Service Bulletin/Repair Instructions

MALFUNCTION INDICATOR LAMP COMING ON WITH DIAGNOSTIC TROUBLE CODES (DTCS) P0171, P0172, P0174 AND/OR P0175 (FUEL SYSTEM TOO RICH OR LEAN). *TT

04105

Service Bulletin/Repair Instructions

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

04219

Service Bulletin/Repair Instructions

MALFUNCTION INDICATOR LAMP (MIL) AND ELECTRONIC THROTTLE CONTROL (ETC) LAMPS ON WITH BOTH DIAGNOSTIC TROUBLE CODE (DTC) P2106 AND P2135. *TT

042421

Service Bulletin/Repair Instructions

SAFETY BELT RETRACTION SPEED. *TT

051016

Service Bulletin/Repair Instructions

NO START/HARD START ON COLD SOAK - 4.0L ENGINE. *TT

0537

Service Bulletin/Repair Instructions

DRIVELINE 1ST ORDER VIBRATION/BOOM/DRONE. *TT

04B22

Service Bulletin/Repair Instructions

IMPROPERLY FORMULATED TRANSMISSION FLUID THAT, OVER TIME, MAY CAUSE DELAYED/HARSH REVERSE ENGAGEMENTS. CUSTOMER SATISFACTION PROGRAM 04B22. 5R55S/E & 5R44E TRANSMISSION FLUID ADDITIVE. *TT SUPPLEMENT #1. *TT SUPPLEMENT #2. *TT SUPPLEMENT #3. *TT

18478

Service Bulletin/Repair Instructions

AXLE SEAL LEAKS. *EH

0561

Service Bulletin/Repair Instructions

WRENCH LAMP ON AND NO DIAGNOSTIC TROUBLE CODE (DTC) STORED. *TT

05612

Service Bulletin/Repair Instructions

DELAYED OR HARSH REVERSE ENGAGEMENTS - 5R55S TRANSMISSION - VEHICLES BUILT PRIOR TO 09/23/2004. *TT

05618

Service Bulletin/Repair Instructions

REAR AXLE NOISE REPAIR. *TT

18573

Service Bulletin/Repair Instructions

NO START/HARD START ON COLD SOAK. *TT

05416

Service Bulletin/Repair Instructions

FRONT SEAT(S) SLIGHT MOVEMENT WHEN ACCELERATING AND/OR DECELERATING. *TT

18466

Service Bulletin/Repair Instructions

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

0531

Service Bulletin/Repair Instructions

MAF DIAGNOSTIC SERVICE TIP - VEHICLES EQUIPPED WITH EGR SYSTEM MODULE (ESM). *TT

0538

Service Bulletin/Repair Instructions

INCREASED TURNING EFFORT DURING LOW SPEED SHARP TURNS FALSE 4X4 ENGAGEMENT. *EH

0539

Service Bulletin/Repair Instructions

MIL ON AND/ OR RUNS ROUGH/MISFIRE DTCS P0300-P0308 P0316 AND OR P0171/P0174 4.6L ENGINE. *EH

0527

Service Bulletin/Repair Instructions

5R55S TRANSMISSION FLUID LEAKS FROM CONVERTER HOUSING AREA. DIAGNOSTIC TROUBLE CODE P1783 ON VEHICLES BUILT PRIOR TO 12/12/2004. *TT

18423

Service Bulletin/Repair Instructions

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

04259

Service Bulletin/Repair Instructions

REAR POWER WINDOW(S) INOPERATIVE. *TT

0485

Service Bulletin/Repair Instructions

LIFTGATE GLASS APPLIQUE DAMAGED/CRACKED. SERVICE PROCEDURE. *TT

050618

Service Bulletin/Repair Instructions

REAR AXLE NOISE REPAIR. *SC

05136

Service Bulletin/Repair Instructions

BACKGLASS DIFFICULT TO CLOSE AND AN INTERMITTENT DOOR AJAR LAMP. *TT

05262

Service Bulletin/Repair Instructions

MIL ON WITH DTC P0191 WITH OR WITHOUT VARIOUS DRIVABILITY SYMPTOMS AND/OR ADDITIONAL DTCS. *TT

052624

Service Bulletin/Repair Instructions

VIBRATION DIAGNOSIS - TIRE/WHEEL RUNOUT. *TT

18381

Service Bulletin/Repair Instructions

OPEN FUSE F2.20 (5 AMP) AND/OR F2.1 (30 AMP) WHICH MAY RESULT IN LOSS OF FUNCTION OF SEVERAL SYSTEMS INCLUDING POWER SEATS, ADJUSTABLE PEDALS AND POWER DOOR LOCKS. *TT

04225

Service Bulletin/Repair Instructions

THROTTLE PEDAL RESPONSE ON TIP IN VEHICLES BUILT BEFORE 10/4/2004 EQUIPPED WITH A 4.0L ENGINE. *EH

04268

Service Bulletin/Repair Instructions

INCREASED EFFORT DURING LOW SPEED SHARP TURNS ON 4X4 VEHICLES. *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

04197

Service Bulletin/Repair Instructions

MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DIAGNOSTIC TROUBLE CODES (DTC'S) P0172 AND/OR P0175. *TT

042212

Service Bulletin/Repair Instructions

GEAR SELECTOR LEVER - INCREASED EFFORT TO SHIFT FROM DRIVE TO PARK. *TT

042112

Service Bulletin/Repair Instructions

ROUGH IDLE IN DRIVE. *EH

041910

Service Bulletin/Repair Instructions

OIL LEAK FROM OIL FILTER ADAPTER - 4.0L SOHC ENGINE BUILT BEFORE 4/1/2004. *TT

04195

Service Bulletin/Repair Instructions

FRONT WINDOW CLUNK NOISE. *TT

18202

Service Bulletin/Repair Instructions

UNINTENDED 4X4 ENGAGEMENT DURING LOW SPEED PARKING LOT TURNS. VARIOUS MODELS INCLUDING THE 2005 EXPLORER AND MOUNTAINEER. *TT

18215

Service Bulletin/Repair Instructions

BROKEN REAR CARGO STORAGE DOOR LIFT HANDLE. VARIOUS MODELS INCLUDING 2005 EXPLORER/MOUNTAINEER. *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

18221

Service Bulletin/Repair Instructions

REAR AXLE NOISE. OASIS. VARIOUS MODELS INCLUDING 2005 EXPLORER, MOUNTAINEER AND AVIATOR. *TT

18254

Service Bulletin/Repair Instructions

SPEED CONTROL INOPERATIVE OR NOT HOLDING THE SET SPEED. OASIS. VARIOUS MODELS INCLUDING 2005 EXPLORER, SPORT TRAC, MOUNTAINEER AND AVIATOR. *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

041715

Service Bulletin/Repair Instructions

FRONT AXLE TUBE LEAK. *EH

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

18121

Service Bulletin/Repair Instructions

FUEL GAUGE SLOW TO UPDATE. *TT

18171

Service Bulletin/Repair Instructions

NO CRANK/NO START CONDITION WHEN VEHICLE TEMPERATURE IS BELOW FREEZING (32F/0C). *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.

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

04B17

Service Bulletin/Repair Instructions

SOME OF THE VEHICLES WERE BUILT WITH INSTRUMENT CLUSTERS THAT WERE NOT CONFIGURED PROPERLY FOR USE WITH A REVISED TPMS MODULE. THE TIRE PRESSURE MODULE SYSTEM (TPMS) IS FULLY FUNCTIONAL, BUT THERE IS NO VISUAL INDICATION TO A DRIVER IF THE TIRE PRESSURE MODULE SYSTEM (TPMS) IS ACTIVATED. *MJ

17905

Service Bulletin/Repair Instructions

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

17883

Service Bulletin/Repair Instructions

DELAYED/HARSH REVERSE ENGAGEMENT. *TT

04B15

Service Bulletin/Repair Instructions

REAR AXLE DATE CODE INSPECTION AND SERVICE. VEHICLES MAY HAVE BEEN BUILT WITH AN IMPROPER MIX OF REAR AXLE LUBRICANT AND FRICTION MODIFIER ADDITIVE. IF SO, THE CUSTOMER MAY EXPERIENCE NOISE AND VIBRATION WHILE DRIVING. *TT *MJ

17717

Service Bulletin/Repair Instructions

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

17728

Service Bulletin/Repair Instructions

ANTI-LOCK BRAKE SYSTEM (ABS) LIGHT ON WITH DIAGNOSTIC TROUBLE CODE (DTC) B2900, U1900 AND C1805. *TT

17736

Service Bulletin/Repair Instructions

REAR AXLE NOISE. *TT

17592

Service Bulletin/Repair Instructions

AN INTERMITTENT NO START AND/OR MALFUNCTION INDICATOR LAMP (MIL) ON WITH DIAGNOSTIC TROUBLE CODES (DTC'S) P1233, P1234, P1235, P1236, P1237 OR P1238. *TT

17626

Service Bulletin/Repair Instructions

STANDARD ABS (NOT ADVANCE TRAC/IVD) BUILT PRIOR TO 2/9/2004 MAY EXHIBIT AN INTERMITTENT AMBER ABS LIGHT ON WITH DIAGNOSTIC TROUBLE CODE (DTC'S) B2900, U1900 AND POSSIBLY C1805 STORED IN MEMORY. *TT

17640

Service Bulletin/Repair Instructions

POOR FIT BETWEEN DRIVER AIR BAG AND STEERING WHEEL. *TT

17641

Service Bulletin/Repair Instructions

REAR 3.55 AXLE NOISE. CERTIFIED REAR AXLE OR IMPROVED GEAR SET AVAILABLE. *TT

17664

Service Bulletin/Repair Instructions

INTERMITTENT HARD START, LONG CRANK TIME OR MULTIPLE CRANK ATTEMPTS BEFORE STARTING. *TT

17666

Service Bulletin/Repair Instructions

DIAGNOSTIC TROUBLE CODE (DTC) U0300 (INTERNAL CONTROL MODULE SOFTWARE INCOMPATIBILITY) STORED IN THE PCM WITH NO OTHER DTC'S PRESENT. *TT

17670

Service Bulletin/Repair Instructions

MALFUNCTION INDICATOR (DTC) LAMP ON WITH DIAGNOSTIC TROUBLE CODE (DTC) P2106. *TT

17680

Service Bulletin/Repair Instructions

REAR LIFTGATE RATTLE / LIGHT POPPING NOISE. *TT

17544

Service Bulletin/Repair Instructions

GENERATOR NOISE IN COLD AMBIENT TEMPERATURES. *MJ

17555

Service Bulletin/Repair Instructions

CERTIFIED REAR AXLE AVAILABLE. *MJ

17558

Service Bulletin/Repair Instructions

INTERMITTENT AIR BAG WARNING LAMP ON, MEMORY SEAT, AND/OR ADJUSTABLE PEDAL CONCERNS. *MJ

17560

Service Bulletin/Repair Instructions

REAR AXLE NOISE. ALSO INCLUDES LINCOLN AVIATOR 2002. *MJ

17561

Service Bulletin/Repair Instructions

DELAYED CRANK WITH NO START, DIAGNOSTIC TROUBLE CODES (DTC) U0300/P0606/P2105/P2107, MALFUNCTION INDICATOR MODULE (MIL) AND WRENCH LIGHT ON. *MJ

04142

Service Bulletin/Repair Instructions

NO CRANK WITH DIAGNOSTIC TROUBLE CODE B1601 AND/OR B1213. PATS SECURITY ACCESS ISSUES WITH 4.0L ENGINE. *TT

17479

Service Bulletin/Repair Instructions

MALFUNCTION INDICATOR LAMP (MIL) ON WITH IGNITION COIL RELATED DIAGNOSTIC TROUBLE CODES (P035X). *TT

17494

Service Bulletin/Repair Instructions

DISTANCE TO EMPTY NOT DISPLAYED. *TT

03256

Service Bulletin/Repair Instructions

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

03L17

Service Bulletin/Repair Instructions

DEMONSTRATION/DELIVERY HOLD - SPECIAL FIELD ACTION 03L17. REVISED SMOG EMISSIONS INFORMATION. *TT

17411

Service Bulletin/Repair Instructions

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

17422

Service Bulletin/Repair Instructions

MULTIPLE ELECTRICAL CONCERNS - FUSE 2.17 OPEN. *MJ

17455

Service Bulletin/Repair Instructions

4X4 INOPERATIVE AND/OR INDICATORS BLINKING. *TT

17316

Service Bulletin/Repair Instructions

FUEL SIGNAL TO INSTRUMENT CLUSTER SERVICE TIP. *TT

17326

Service Bulletin/Repair Instructions

ENGINE AUXILIARY OIL COOLER LINE AND THE RIGHT SIDE MOTOR MOUNT SQUEAKING NOISE FROM FRONT EXTERIOR WHILE DRIVING OVER BUMPS. *TT

17276

Service Bulletin/Repair Instructions

A POPPING OR CREAKING NOISE THAT APPEARS TO BE COMING FROM THE FRONT EXTERIOR OF THE VEHICLE. *TT

17285

Service Bulletin/Repair Instructions

MALFUNCTION INDICATOR LAMP/ETC LAMP LIT WITH P0606 AND ONE OR SEVERAL P21XX-SERIES DIAGNOSTIC TROUBLE CODES AT LOW TIME IN SERVICE. *TT

17311

Service Bulletin/Repair Instructions

MALFUNCTION INDICATOR LAMP ON AND/OR ELECTRONIC THROTTLE CONTROL LAMP (ETC) ON WITH DIAGNOSTIC TROUBLE CODE (DTC) P2106. *TT

03181

Service Bulletin/Repair Instructions

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

17107

Service Bulletin/Repair Instructions

DRIVELINE VIBRATION ON DRONE/BOOM AT HIGHWAY SPEEDS. *TT

17165

Service Bulletin/Repair Instructions

INTERMITTENT DIAGNOSTIC TROUBLE CODE (DTC) P2106 WITH THE MALFUNCTION INDICATOR LAMP (MIL) ON. *TT

17215

Service Bulletin/Repair Instructions

THE AMBER ANTI-LOCK BRAKE SYSTEM (ABS) WARNING LIGHT ON WITH DIAGNOSTIC TROUBLE CODES C1235, C1236/C1237 STORED IN MEMORY. *TT

17217

Service Bulletin/Repair Instructions

AIR CONDITIONER HOOTING NOISE DURING LIGHT LOAD ACCELERATION AT LOW SPEEDS, FROM 1000-1300 RPM. *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

17054

Service Bulletin/Repair Instructions

AXLE WHINE AT CRUISE OR DURING ACCELERATION/ DECELERATION. *TT

03144

Service Bulletin/Repair Instructions

ENGINE MISFIRE OR ROUGH RUNNING CONDITION WITH COIL ON PLUG (COP) IGNITION SYSTEMS MAY BE MORE ACCURATELY DIAGNOSED USING THE OPTIONAL WORLDWIDE DIAGNOSTIC SYSTEM (WDS) COIL ON PLUG (COP) KIT. 2003 SUPER DUTY F SERIES INCLUDED. *TT

03263

Service Bulletin/Repair Instructions

ANTI-LOCK BRAKE SYSTEM (ABS) LAMP ILLUMINATED AND DIAGNOSTIC TROUBLE CODE (DTC) C1235, C1236, C1237 ON VEHICLES WITH DIFFERENTIAL-MOUNTED RAR WHEEL SPEED SENSOR. *TT

06167

Service Bulletin/Repair Instructions

MIL ON WITH DTC P0463 OR ERRATIC FUEL GAUGE OPERATION. *KB

061710

Service Bulletin/Repair Instructions

MIL ON WITH P0463 OR ERRATIC FUEL GAUGE OPERATION. *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 Explorer Service Bulletins: 108 bulletins | CarFathom