2004 Ford Expedition Technical Service Bulletins

48 technical service bulletins (TSBs) are on record for the 2004 Ford Expedition. TSBs are notes manufacturers send to dealers about repair procedures for issues seen in the field. They are not recalls and do not by themselves mean a vehicle has a fault.

• 11005305Jul 24, 2024Wheels. 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).
• 10235153Apr 4, 2023Body and structure. 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.
• 10214754Jun 21, 2022Transmission and drivetrain. 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…
• 10181917Oct 16, 2020Equipment, Wheels, Electrical system. 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.
• 10177863Jul 13, 2020Body and structure. 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.
• 10156863Feb 7, 2019Body and structure, Equipment. 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
• 10155551Feb 7, 2019Body and structure. 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
• 10109070Sep 21, 2016Engine cooling, Engine. 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…
• 10028736May 1, 2009Transmission and drivetrain. 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.
• 10023943Oct 1, 2007Engine cooling. 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.
• 10021072Feb 27, 2007Suspension. Air suspension performance - height sensor linkage arm disengaging.
• 10020132Jan 1, 2006Brakes. BRAKE SHUDDER.
• 10019384Jan 1, 2006Tires. Low tire indicator on - tpms system sensor wake up.
• 10014100Jan 1, 2006Transmission and drivetrain. Limited slip axle chatter, shudder, binding sensation, or vibration during low speed turning maneuvers.
• 10013301Jan 1, 2006Brakes. 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.
• 10018745Nov 14, 2005Engine cooling. Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running.
• 10018052Oct 7, 2005Seats. Drivers front power seat will not move forward or rearward.
• 10017805Oct 3, 2005Visibility (wipers, defrost, mirrors). Rear window wiper inoperative.
• 10018069Sep 1, 2005Transmission and drivetrain. A tiny crack, or cracks, around the transfer case drain plug hole.
• 10014138Jun 7, 2005Seat belts. Safety belt retraction speed.
• 10014668May 1, 2005Transmission and drivetrain. Axle seal leaks.
• 10017892Apr 1, 2005Transmission and drivetrain. Rear axle noise repair.
• 10017888Apr 1, 2005Steering. Steering wheel at 65 mph (105 km/h) or higher.
• 10014685Mar 21, 2005Engine cooling. Use of stainless steel exhaust studs in service for 5.4l 2v engine.
• 10014666Mar 7, 2005Engine cooling. Intermittent rough idle - non-commanded egr (exhaust gas recirculation valve) flow.
• 10014654Mar 7, 2005Equipment. Noise from a/c (air conditioning) or insufficient a/c cooling.
• 10014676Mar 1, 2005Wheels. Aluminum alloy wheels pitting and or peeling cleaning procedures.
• 10014659Mar 1, 2005Transmission and drivetrain. Axle whine howl. This includes 1997-05 ford vehicles.
• 10012954Feb 21, 2005Seat belts. Safety belt web stop button service.
• 10012977Feb 1, 2005Transmission and drivetrain. Tiny crack or cracks around the transfer case drain plug.
• 10012963Feb 1, 2005Suspension. Four corner load leveling air suspension may exhibit leveling concerns, such as one front corner dropping. Individual air springs available for service.
• 10012959Feb 1, 2005Transmission and drivetrain. Axle whine howl service with individual parts instead of an axle assembly.
• 10019415Jan 1, 2005Brakes. Unintended brake assist.
• 10018938Jan 1, 2005Wheels, Tires. Vibration diagnosis - tire/wheel runout.
• 10016789Jan 1, 2005Suspension. Rear axle noise repair.
• 10013322Jan 1, 2005Electrical system. Popping or quavering from radio on the am band.
• 10014314Dec 31, 2004Seats. Climate controlled seat diagnosis - service tips.
• 10011173Dec 31, 2004Steering. Steering column clunk, pop or creak. *ar update.
• 10014165Dec 27, 2004Body and structure. Aluminum corrosion - service tip.
• 10014086Dec 13, 2004Transmission and drivetrain. General (pcm) power train control module programming procedures.
• 10014062Dec 13, 2004Visibility (wipers, defrost, mirrors). Rear window defroster grid/integral antenna diagnosis and repair - terminal tab repair.
• 10013389Nov 1, 2004Visibility (wipers, defrost, mirrors). Reverse tilt mirror system diagnostics and repair.
• 10013116Sep 6, 2004Electrical system. Malfunction indicator lamp (mil) illuminated - system lean diagnostic trouble codes (dtc's) - service tips. Various models including 2004 f-series.
• 10011343Sep 1, 2004Electrical system. Reverse sensing system defaulting off, setting diagnostic trouble codes, or losing communication with diagnostic scan tool.
• 10011334Sep 1, 2004Electrical system. 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.
• 10011162Aug 23, 2004Engine cooling. 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.
• 10011159Aug 9, 2004Visibility (wipers, defrost, mirrors). Rear window defroster grid/integral antenna diagnosis and repair - terminal tab repair.
• 10011156Aug 9, 2004Engine cooling. Misfire at idle with diagnostic trouble codes p0300-p0308, p0316.

← All problems reported for the 2004 Ford Expedition