Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| POWER TRAIN | |||||
| 18439 | 02/01/2005 | 10012977 | Tiny crack or cracks around the transfer case drain plug. *eh | 04/05/2005 | |
| 16806 | 04/01/2003 | 10002674 | Fluid leaks from the rear halfshaft seal. 2002-2003 explorer/mountaineer/aviator added. *tt | 09/10/2003 | |
| 16726 | 03/01/2003 | 10001958 | Fluid leaks from the rear halfshaft seal. *tt *jb | 07/29/2003 | |
| 16729 | 03/01/2003 | 10001959 | Transmission fluid leak between the radiator transmission oil cooler and the transmission oil cooler fitting (not the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmi | 07/29/2003 | |
| POWER TRAIN - AUTOMATIC TRANSMISSION - CONTROL MODULE (TCM, PCM) | |||||
| 042107 | 12/13/2004 | 042414 | 10014086 | General (pcm) power train control module programming procedures. *tt | 04/28/2005 |
| POWER TRAIN - AUTOMATIC TRANSMISSION - COOLING UNIT AND LINES | |||||
| 03148 | 07/21/2003 | 10003748 | New transmission cooler flusher - service tips. 2003 escort and super duty f series included. *tt | 10/29/2003 | |
| POWER TRAIN - AXLE ASSEMBLY | |||||
| 05618 | 04/01/2005 | 10017892 | Rear axle noise repair. *tt | 12/06/2005 | |
| 18478 | 05/01/2005 | 18590 | 10014668 | Axle seal leaks. *eh | 05/05/2005 |
| 18466 | 03/01/2005 | 10014659 | Axle whine howl. this includes 1997-05 ford vehicles. *eh | 05/05/2005 | |
| 06216 | 01/01/2006 | 0644 | 10014100 | Limited slip axle chatter, shudder, binding sensation, or vibration during low speed turning maneuvers. *tt | 04/28/2005 |
| 18423 | 02/01/2005 | 10012959 | Axle whine howl service with individual parts instead of an axle assembly. *eh | 04/05/2005 | |
| 18213 | 10/01/2004 | 10010729 | Grinding noise from front axle wheel hubs on acceleration in 2wd - service tip. various models including 2005 expedition/navigator. *tt | 12/07/2004 | |
| 17905 | 07/01/2004 | 10009332 | Multiple vehicles using fehp rear axle fluid. fluid usage change. *tt | 09/23/2004 | |
| 16430 | 11/01/2002 | 10008355 | Limited-slip rear axle chatter noise - contact request. *tt | 07/28/2004 | |
| 16400 | 11/01/2002 | 10008331 | Rear axle seal leak - contact request. *mj | 07/27/2004 | |
| 17755 | 04/01/2004 | 10008245 | Axle whine at highway speeds (40-60 mph). *tt | 07/23/2004 | |
| 17632 | 03/01/2004 | 10007407 | Axle whine at highway speeds (40-60 mph). *tt | 06/22/2004 | |
| 17598 | 03/01/2004 | 10007393 | Rear axle halfshaft seal leak. *tt | 06/17/2004 | |
| 17521 | 01/01/2004 | 10007351 | Click/pop/creak from rear axle. *tt | 06/14/2004 | |
| 17488 | 01/01/2004 | 10007330 | Axle whine between 58-62 mph. *tt | 06/10/2004 | |
| 03198 | 09/06/2004 | 04175 | 10004037 | 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 | 11/14/2003 |
| 16923 | 06/01/2003 | 10002634 | Chatter, shudder, binding sensation, or vibration during low speed turns. concerns may seem to originate from front axle, or steering gear. *tt | 09/09/2003 | |
| 0364 | 03/31/2003 | 10001856 | Front axle groan or hum, and/or a slight vibration when operated in 2 high mode. *tt *jb | 07/23/2003 | |
| 16088 | 07/01/2002 | 636291 | Some 4x2 vehicles may exhibit a rear axle whine at 50 and 62 mph in coast or drive. *tt | 11/07/2002 | |
| 16070 | 07/01/2002 | 636267 | Some 4x4s may exhibit a front axle groan or hum, and / or a slight vibration when operated in 2 high mode. *tt | 11/07/2002 | |
| POWER TRAIN - AXLE ASSEMBLY - AXLE SHAFT | |||||
| TSB-08-19-3 | 05/01/2009 | 10028736 | 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 | 05/20/2009 | |
| 0391 | 05/12/2003 | 10002774 | Procedure to separate inboard cv joint halfshafts from differential. *tt | 09/17/2003 | |
| POWER TRAIN - AXLE ASSEMBLY - AXLE SHAFT - SEAL | |||||
| TSB-08-19-3 | 05/01/2009 | 10028736 | 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 | 05/20/2009 | |
| 04105 | 06/07/2005 | 05155 | 10008994 | Axle seal leaks. leaks from rear halfshaft axle seal. service tips. *tt | 09/07/2004 |
| POWER TRAIN - TRANSFER CASE (4-WHEEL DRIVE) | |||||
| 18815 | 09/01/2005 | 10018069 | A tiny crack, or cracks, around the transfer case drain plug hole. *tt | 12/14/2005 | |
Consumer Complaints
| Fail date | miles | occurences | Purchase date |
|---|---|---|---|
| POWER TRAIN | |||
| 12/01/2011 | 95905 | ||
| Why is there no warning light,or signal of any kind when the pcm fails? our pcm failed, which caused our catalytic converters, 02 sensors, & fuel pump to fail. & our ignition coils had to be replaced. would have been nice if a warning light came on the dash. this has caused our expedition engine to randomly shut off while driving countless times! i have miraculously been able to maneuver my expedition to the side of the freeway &have it towed eight times without killing myself, my family or any one else! we have had odd electrical and performance problems since august of 2002 when we purchased it. not one ford mechanic (3 different dealerships) could ever diagnose or repair issues. because there is no warning light/code when the pcm is out, the damage snowballs. there are no computer codes, or warning lights to show up on the dash board when the pcm is out, which befuddles the mechanics. we are literally $5,000 in the hole so far! ford dealership repaired our expedition by replacing the pcm ($1,300.00). 48 hours after they replaced the pcm, and 18 miles after we drove expedition off the ford lot, the service engine soon light came up on the dashboard -for the first time ever! we drove back to the ford dealership, and he said for $3,400 plus tax he could replace our new catalytic converters in bank one that were destroyed again, & the bank two converters which are now very weak, not up to spec. the driver's seat motor that has been fickle since aug of 2002, stopped working when we went to pick it up, so i can't drive it, because i can't reach the gas or brake pedals. $800 will fix that, ford says. if you google 2003 ford expedition eddie bauer engine shuts off randomly, thousands of people are reporting the same issues. until someone crashes and dies, i don't think ford cares. | |||
| 04/05/2004 | 25000 | ||
| The transmission has failed twice in my ford explorer, first at about 2500 and now, after a rebuilt engine was installed, at 205,000. as well, i have had differential problems, moon roof issues, paint issues, cracked head, etc. | |||
| 06/11/2009 | 79000 | ||
| My wife and i own a 2003 ford expedition xlt 4wd since 2004. every since we owned this vehicle we have had problems from the rear lsd being replaces twice, the electrical harness replacement, all power locks replaced (due to coming open by themselves), and recently the two coil packs blowing out of the motor. we spent over a thousand dollars to get vehicle to pass smog due to outrageous spark plug prices along with labor cost of $400. i am fed up with ford and want everyone to know how their quality is so sub-standard. this vehicle has been in the shop around 6-7 times and i have to worry every time i drive it. please issue a recall on the spark plug issue as ford agrees it is a defect, they will not take responsibility for their shabby work- chris fisher moreno valley california | |||
| 05/03/2009 | 80000 | 1 | |
| We you make a turn you her a noise from the rear end. *tr | |||
| 07/09/2006 | 53000 | 1 | |
| I have a rubbing / grinding noise coming from my rear end on my 2003 ford expedition. and as i look on the internet there are 100's of people that are complaining about the same problem. this has to be a known issue with ford and they aren't standing behind there product. *tr | |||
| 1 | 06/04/2003 | ||
| There is a rattling noise in passenger side door. and at time it is hard to close. when the vehicle reached 43 mph a humming noise could be heard. the humming continued when the vehicle reached 59-72 mph. the technicians replaced the drive shaft twice but the noise continued. there was a roaring noise which came from the wheel area. the dealer adjusted the park brake shoes. the was noise the steering wheel was turn right or left. the technician added a wheel additive. the passenger door was difficult to close. the dealer adjusted the striker. the front windshield weather strip was loose. the dealer resealed it. the was rattling in the center of the dash. the dealer removed and reinstalled a cluster and reinstalled the insulation. the driver side seat belt twisted. *nlm | |||
| POWER TRAIN - AUTOMATIC TRANSMISSION | |||
| 03/27/2011 | 180000 | ||
| Tl-the contact owns a 2003 ford expedition. the contact stated that while driving 50 mph, the vehicle stalled. the vehicle restarted after ten minutes and was taken to a private mechanic. the manufacturer was not made aware of the failure. the vehicle was not repaired. the failure and current mileages were 180,000. sm. | |||
| 03/27/2011 | 180000 | ||
| Tl- the contact owns a 2003 ford expedition. the contact stated while traveling 50 mph the vehicle loss power and the engine shut down. the vehicle restarted after ten minutes, and was taken to a private mechanic. the vehicle was not taken to the dealer, and the manufacturer was not contacted. the vehicle was not repaired. the failure and current mileage was 180,000. rds | |||
| 02/27/2011 | 107000 | ||
| 2003 ford expedition would not start after long tow to mechanic it was a burnt relay switch but now it turns off while driving, change the relay switch and problem is temporarily fixed now since the relay is for the fuel pump and pcm my transmission is acting up not shifting 3rd or over drive no one can figure out the problem but we are scared to drive the truck! | |||
| 12/26/2009 | 56000 | 1 | |
| I was driving down the freeway when my expedition made a noise, the inside dash lights flickered and the transmission started acting up. i pulled over at a hotel. i called a tow truck who came to pick it up a few days later. when he started it the wiring harness caught unfire. the entire wiring burned up on the lift side of the vehicle. the mechanic told us we were luck to have stopped. if we continued down the highway my family and i would have been in great danger. i believe the fire was the fault of bad wiring. i check the recall sites and my vehilce was not part of the faulty wiring recall. *tr | |||
| 12/21/2007 | 92900 | 1 | 05/29/2003 |
| Tl*the contact owns a 2003 ford expedition. while driving 50mph, the vehicle began to hesitate after making a loud noise. after describing the symptoms to the dealer via phone, he stated that the failure appeared to be the transmission. the noise is getting progressively worse. the warranty has expired. the dealer is diagnosing the failure today. the current mileage was 93000 and the failure mileage was 92900. | |||
| 04/24/2005 | 36500 | 1 | 04/16/2003 |
| Consumer states: had car in park with slight incline, and left vehicle running ,and the vehicle slipped out of gear and went into reverse. no one was in the vehicle. *ak | |||
| 11/17/2004 | 38000 | 1 | 12/27/2002 |
| Consumer was unloading some materials from the rear of the vehicle when all of a sudden it jumped from park into reverse on its own. consumer was dragged into the other side of the street, resulting in injury. *ak *sb | |||
| 07/09/2003 | 6200 | 1 | |
| While parked on incline vehicle slipped out of park gear into reverse, and vehicle rolled back, and rolled over consumer's knees when trying to stop the vehicle. dealership was notified, but did not resolve the problem. *ak | |||
| 02/14/2005 | 1 | ||
| The vehicle will not engage into reverse keeping it from moving out of a parking space. manufacturer has been notified by owner. *nm | |||
| 08/28/2002 | 33000 | 1 | 03/01/2002 |
| While driving 30 mph, the vehicle vibrated uncontrollably. suddenly, the vehicle stalled. the driver tried to restart the vehicle and was not able to do so. the vehicle was towed to the dealer for inspection. the mechanic informed the driver that the alternator and battery needed to be replaced. while unlocking the driver's door with the automatic switch both side rear view mirrors would automatically move up and down. the vehicle was taken to the dealer for inspection. the mechanic replaced both side rear view mirror motors. please provide further details. *jb consumer adds both side view mirrors motors replaced 2 to 3 more times. the fog light housing replaced, rear light covers replaced due to moisture, heater core switch replaced from dash. brakes squealing when applied. transmission slipping and power steering pump winding. *tt | |||
| 07/31/2004 | 34400 | 1 | 07/09/2003 |
| I parked my 2003 ford expedition in my driveway. i put it in park and engaged the emergency brake. as i went to open my door i turned to see the truck rolling down the driveway. it hit my neighbor's truck and when i got to the truck, it was still in park. after having the truck at the dealership for several days i was told there was nothing wrong with it. i asked for a ford rep to examine the vehicle but with no success. the people at the dealership have been helpful however they are running up against a brick wall as well.the owner and service manager were told by ford that an independent engineer would be sent out to look at the truck. when i called i was told the notes stated that there was no further action necessary by ford.*ak | |||
| 07/19/2004 | 1 | 05/31/2003 | |
| My 2003 ford expediton jumped from park to reverse while idleing on a slight incline, after approximately 12 minutes, went in reverse , and struck a house. i ran after the expedition, as it only gained speed, towards the house, and i was not able to catch the vehicle without being injured myself. *la | |||
| 12/23/2003 | 400 | 1 | 09/22/2003 |
| Transmission popped out of park while idling on a slight incline and struck a light pole. this was a marked police unit. | |||
| 11/30/2003 | 1700 | 1 | |
| Consumer shifted the transmission gear into reverse, but vehicle was unable to accelerate in reverse. dealership was notified, but the problem was not resolved.*ak | |||
| 11/15/2003 | 7000 | 10 | 07/01/2003 |
| Vehicle will shift from park to reverse without the brake pedal depressed. *la | |||
| 08/31/2003 | 1 | 06/29/2002 | |
| I own a 2003 for expedition. it recently came to my attention that i do not have to actually apply my brake to move my car from park to reverse. i only have to barely touch the brake pedal and can put the vehicle in reverse. i feel that this can be very dangerous should a child be left alone in a running vehicle. hen i took the vehicle to the dealer he later informed me that all 2003's do this.*ak i contacted ford motor company but, also feel it is necessary to inform you and ask for your assisstance in this matter. | |||
| 04/05/2003 | 1 | ||
| While parked on a slight incline the vehicle coasted backwards without warning. *nlm | |||
| 10/28/2002 | 2755 | 1 | 09/20/2002 |
| The vehicle experienced a severe vibration, when the gear was transferred to 4-wheel drive, the dealer was unable to fix the problem. *ak *jb | |||
| POWER TRAIN - AUTOMATIC TRANSMISSION - CONTROL MODULE (TCM, PCM) | |||
| 08/17/2002 | |||
| While driving at highway speeds advance track system light illuminated, then all electrical components started to flash. heard a rattling noise, pulled over, turned off engine to see what problem was, and vehicle would not restart. took vehicle to dealer, and they stated it was the alternator. *ak | |||
| POWER TRAIN - AUTOMATIC TRANSMISSION - GEAR POSITION INDICATION (PRNDL) | |||
| 10/02/2004 | 10000 | 1 | |
| Upon parking the vehicle and putting the emergency brake on the vehicle put itself into reverse, rolled back into the neighbors yard, hitting a vehicle. consumer contacted an independent repair shop. *ak | |||
| POWER TRAIN - AUTOMATIC TRANSMISSION - LEVER AND LINKAGE - COLUMN SHIFT | |||
| 01/27/2006 | 38949 | 1 | 09/01/2002 |
| Dt*: the contact stated while attempting to change gears the gear shifter broke. the engine was idling when the shifter broke. the vehicle was towed to the dealership. upon inspection the dealer determined the gear shifter was defective. the entire steering column was replaced. updated 3/10/2006 - *nm | |||
| 08/04/2002 | |||
| While driving 60 mph consumer tried to increase speed, vehicle would not accelerate. vehicle was towed to dealer, it was determined that transfer case needed to be replaced.*ak | |||
| POWER TRAIN - AXLE ASSEMBLY | |||
| 08/09/2004 | 17493 | 2 | 10/23/2002 |
| Dt: the drivers side tie rod has broken twice. both times was without warning. the dealer has fixed it once and now it is back to the dealer for the second time for same problem. the manufacturer took information from the consumer, but she has not heard back from them. *jb passenger side rear window does not go down from master switch. door ajar light does not go off. left front ball joint separated, then vehicle hit sign. lower control arm broken, upper ball joint bad, spindle broken sway bar link broken, cv boot torn and axle pulled out of front differential. tie rod end on left side broken and vacuum hub cracked on spindle and tire and rim damaged. also fender liner ripped out. spindle, upper control arm, lower control arm, cv boot replaced. clip for axle vacuum hub and wheel and tire, removed front differential to reinstall, axle and clip replaced wheel and tire and performed alignment. damage to hood when knuckle split. *tt *sb | |||
| 09/27/2004 | 15600 | 3 | |
| Rear axle repaired 3 times, problem persists. *ak | |||
| 09/28/2003 | 2 | ||
| My 2003 expedition has had the rear differential fail twice in less than five months. the first time with 1668 miles on it, the failure resulted in the total loss of my 22 foot travel trailer. the second time it failed the vehicle had 5142 miles on it! | |||
| 01/25/2003 | 0 | 1 | 01/23/2003 |
| Grinding noise in the rear axle when turning left or right after vehicle has set overnight or for a long enough period so axle components cool down to ambient temperature. i have had vehicle in for service 4 times and it spent almost 3 weeks in the shop. problemseemed to be fixed after last visit, but noise has reappeared again. sounds worse. vehicle will now be going in for the fifth time for the same problem. there is something wrong, but i cannot get ford to admit anything.*ak | |||
| POWER TRAIN - CLUTCH ASSEMBLY | |||
| 05/14/2007 | 24000 | 1 | 10/15/2003 |
| Clutch failed, causing the tires to produce a grinding noise when turning. this problem was noticed, by me, while still under warranty, but i thought it was just systematic of the vehicle until passengers noticed and eventually it got so bad that it felt like a very unsafe and serious problem. dealer is charging $1600 half of which is parts. next week when i get the vehicle back, will determine if i am keeping the car or have lost confidence in the safety or future problems. *ak | |||
| 10/01/2006 | 40000 | 1 | 03/01/2002 |
| Tl*-the contact stated that while researching the service bulletin on the nhtsa website, he noticed that there was a bulletin on the 2003 ford expedition. the contact owns a 2003 ford expedition with the current mileage of 40,000. the contact stated while driving 45 mph the vehicle had a vibration of the clutch slip differential.*ak | |||
| 10/25/2006 | 40000 | 09/01/2003 | |
| I kept feeling a slipping feeling in the rear of my 2003 ford expedition. like a gear and notches of the gear were not lining up properly to inter-lock and turn. it would feel like a jumping, slipping. i took it local dealership, they replaced the rear clutches. since that time, it has been in two different dealerships in less than a year and the rear clutches have been replaced five times and now i am about to take in for number six. | |||
| 07/18/2006 | 1 | ||
| Clutch plate and pinion gear is faulty and ford motor company does not want take full responsibility for the problem. *nm | |||
| 12/03/2003 | 5000 | 1 | 06/29/2002 |
| Loud roar from rear end due to gears not meshing properly. the ford zone manager told me to turn my radio up louder if the noise was bothering me.*jb | |||
| 09/20/2003 | 1 | ||
| Clutch failed, causing the tires to produce a grinding noise when turning.*ak | |||
| POWER TRAIN - DRIVELINE - DIFFERENTIAL UNIT | |||
| 10/01/2006 | 40000 | 1 | 03/01/2002 |
| Tl*-the contact stated that while researching the service bulletin on the nhtsa website, he noticed that there was a bulletin on the 2003 ford expedition. the contact owns a 2003 ford expedition with the current mileage of 40,000. the contact stated while driving 45 mph the vehicle had a vibration of the clutch slip differential.*ak | |||
| 04/20/2005 | 8 | ||
| Since we have owned this 2003 expedition we have had the windshield replaced due to noise and loose stripping, then, the contracting person put in the wrong years windshield. the emissions canister was cracked and was replaced. the muffler would pop after turning off the engine, but couldn't be fixed until verified by ford. i waited for 3-4 hours one day with 3 children while they let my car run and shut off. we finally called ahead, and had them wait outside on us until we killed the engine to hear it pop. it was a poor muffler weld and was repaired. the side molding rattled badly, and was terribly faded, and that was replaced. the door gets a lot of wind noise , and a whistle in the window. they said window passed the dollar bill test and was fine but it still whistles. they, put a clear strip along inside of door to help noise. it doesn't. then ,the rear continental tire had such horrible, uneven wear, it was extremely dangerous. bought new tires for $600. then rear differential malfunctioned, and would make a grinding on turning left or right. they fixed that in march 2005, and it just started doing it again. now, there is a strange noise when revving the engine to drive coming from under the hood. it is going in tomorrow for the noise and the rear differential. on top of all the repairs, we have had a squeaky brake issue. also, they have said they were good. they just get a lot of brake dust, just sand them. our side windows shimmies all the time. ! i did invest in an extended warranty!. *ak | |||
| 09/03/1999 | 2450 | 08/09/2003 | |
| Humming noise from front differentials. spring required to be added to front differential. rear differential also had to be replaced due to parts missing from factory according to the dealer. all this happen within 2,000 miles of purchase on my 2003 ford expedition. | |||
| POWER TRAIN - DRIVELINE - DRIVESHAFT | |||
| 11/27/2004 | 52000 | 2 | |
| While driving 65 mph driveshaft and the tie rod broke . as a result, vehicle accelerated. *ak | |||
| 10/12/2003 | 100000 | 1 | |
| While driving various speeds and without warning consumer heard loud noises. dealership mechanic informed consumer that the loud noises were due to rear driveshaft failure. *ak | |||