2004 Ford EXPEDITION Manufacturer communications & TSBs.Page 1
Original record summaries, dates and identifiers for this model-year. Records 1–91 of 91, ordered newest first. Dated records on this page: Aug 1, 2003–Jul 24, 2024.
Read the applicability before drawing a conclusion.
This archive includes service bulletins, warranty notices, software instructions and other communications. Records may repeat or supersede earlier instructions. A model-year association is not proof that a document covers every engine, trim, VIN or reported symptom, or that a repair is free.
NHTSA download snapshot: Sep 28, 2026. These are communication associations for this vehicle, not unique defects. How records are joined and counted.
Jul 24, 2024Service Bulletin/Repair Instructions
TSB 24-2188
NHTSA communication ID: 11005305
NHTSA source summary · Original PDF not reviewed by Recallfolio
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.
NHTSA source summary · Original PDF not reviewed by Recallfolio
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.
NHTSA source summary · Original PDF not reviewed by Recallfolio
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.
NHTSA source summary · Original PDF not reviewed by Recallfolio
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.
Source components: ELECTRICAL SYSTEM · EQUIPMENT · WHEELS.
NHTSA source summary · Original PDF not reviewed by Recallfolio
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.
NHTSA source summary · Original PDF not reviewed by Recallfolio
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
NHTSA source summary · Original PDF not reviewed by Recallfolio
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
NHTSA source summary · Original PDF not reviewed by Recallfolio
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.
Source components: ENGINE · ENGINE AND ENGINE COOLING · ENGINE AND ENGINE COOLING:COOLING SYSTEM · ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN · ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSES/LINES/PIPING/FITTINGS · ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY · ENGINE AND ENGINE COOLING:ENGINE · ENGINE AND ENGINE COOLING:ENGINE:DIESEL · ENGINE AND ENGINE COOLING:ENGINE:GASOLINE · ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:BELTS AND ASSOCIATED PULLEYS · ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:TURBO/SUPERCHARGER · ENGINE AND ENGINE COOLING:ENGINE:OTHER FUEL TYPES:TURBO/SUPERCHARGER · ENGINE AND ENGINE COOLING:EXHAUST SYSTEM · ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL · ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR · ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CRANKCASE (PCV) · ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:GAS RECIRCULATION VALVE (EGR VALVE) · ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE.
NHTSA source summary · Original PDF not reviewed by Recallfolio
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
Source components: POWER TRAIN:AXLE ASSEMBLY:AXLE SHAFT · POWER TRAIN:AXLE ASSEMBLY:AXLE SHAFT:SEAL.
NHTSA source summary · Original PDF not reviewed by Recallfolio
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
Source components: ENGINE AND ENGINE COOLING:ENGINE.
NHTSA source summary · Original PDF not reviewed by Recallfolio
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
NHTSA source summary · Original PDF not reviewed by Recallfolio
FOUR CORNER LOAD LEVELING AIR SUSPENSION MAY EXHIBIT LEVELING CONCERNS, SUCH AS ONE FRONT CORNER DROPPING. INDIVIDUAL AIR SPRINGS AVAILABLE FOR SERVICE. *TT
NHTSA source summary · Original PDF not reviewed by Recallfolio
WARNING INDICATORS-PARKING AID-REVERSE SENSING SYSTEM (RSS) AND FORWARD SENSING SYSTEM (FSS)-FALSE ACTIVATION OF WARNING TONE-SERVICE TIPS. *MJ UPDATE. *TT
NHTSA source summary · Original PDF not reviewed by Recallfolio
MULTIPLE VEHICLES - FUEL LEVEL INDICATION CONCERNS - SERVICE TIP. VARIOUS MODELS INCLUDING 2005 SUPER DUTY F-SERIES, EXCURSION, EXPEDITION, EXPLORER, MOUNTAINEER AND AVIATOR. *TT
NHTSA source summary · Original PDF not reviewed by Recallfolio
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
NHTSA source summary · Original PDF not reviewed by Recallfolio
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.
Source components: ENGINE AND ENGINE COOLING:ENGINE.
NHTSA source summary · Original PDF not reviewed by Recallfolio
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
Source components: ENGINE AND ENGINE COOLING:EXHAUST SYSTEM.