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 | |
| 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 - 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 | |
| 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 | |
| 17466 | 01/01/2004 | 10007318 | Chatter, shudder, binding sensation, or vibration from limited slip rear axle during low speed turns. *tt | 06/10/2004 | |
| 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 |
| 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 | |
| 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 - AUTOMATIC TRANSMISSION | |||
| 04/20/2010 | 124000 | ||
| Shutter/grinding niose coming from rear axle. | |||
| 10/10/2009 | 38000 | ||
| Tl* the contact owns a 2004 ford expedition. after he started the ignition he applied pressure to the accelerator pedal, but the vehicle would not accelerate. after several attempts he was able to drive. however when driving the transmission kept slipping gears. the vehicle was taken to an authorized dealer for diagnostic testing. the technician stated the failure was contributed to the forward clutch piston seal. the vehicle was repaired for the malfunction. the failure mileage was 38,000. the current mileage was 38,500. the vehicle identification number was unavailable. | |||
| 12/31/2007 | 88594 | 1 | 10/01/2004 |
| Tl*the contact owns a 2004 ford expedition. the contact stated that the vehicle would not move when shifted into reverse. the mechanic stated that the transmission failed. as of january 10, 2008, the mechanic had not repaired the vehicle. the current and failure mileages were 88,594. updated 3/4/08 *cn | |||
| 05/10/2005 | 3 | ||
| Humming coming from bottom of vehicle (rear axle). knock is also heard when coming to stop in same area (rear axle). dealer replaced gears and components may 2005. got vehicle back but knock was louder, found out that needed the correct shims to prevent problem. waited for parts for 3-4 weeks. dealer said ford will not replace the entire axle only replace components. ford service log shows repair rear axle as per tsb 050618. but problem still present. waiting on parts again. as of october 10, 2005, have had dealer try to fixed problem three (3) times. now my park brake does not work, dealer said need to get parts in to fix both problems (axle and brake) at same time. but i will take back to dealer to fix park brake even if axle parts are not available. *nm | |||
| 05/19/2005 | 17000 | 1 | 08/18/2004 |
| I dropped my kids off at school then headed for work taking the freeway. traffic began to build so i had slowed down to about 20 miles per hour (mpr), when i tried to accelerate the vehicle would only reach 30 miles per hour. i was in the far right lane so i took the next exit off the freeway. i put it in | |||
| 12/01/2004 | 5078 | 1 | |
| While down shifting gears there was a loud clung coming from transmission. consumer took vehicle to dealer to be serviced. after picking up the vehicle consumer experienced the same problem. he then called dealer and asked what was wrong, and was told that the transmission fluid was low. he took vehicle back, and then was notified that there was a tsb for the transmission.*ak | |||
| 01/13/2004 | 1100 | 2 | |
| When coming off a ramp and merging into oncoming traffic the accelerator became stuck. the driver had to slam on the brakes and place the transmission into neutral. at 1,470 miles while pulling into the driveway the truck suddenly stopped accelerating and would only go in reverse. the automatic transmission piston had disintegrated. *jb *sc | |||
| POWER TRAIN - AUTOMATIC TRANSMISSION - GEAR POSITION INDICATION (PRNDL) | |||
| 02/01/2007 | 1 | 04/01/2004 | |
| Tl*- the contact owns a 2004 ford expedition. while parking the vehicle the gear shift sheared off from the steering column. no excessive force was applied to the gear shift while attempting to shift from reverse position to park. the vehicle was towed to the dealer, and they informed him of the repair cost. the contact stated that there was a defect in the gear shift. the contact stated that the dealer indicated that the steering column needed to be replaced. *ak | |||
| 03/01/2006 | 15500 | 50 | 12/11/2004 |
| When the vehicle is placed in park, the gear shift position lever will move to the p position, but the gear shift position indicator stops at n or r. the car will turn off and the keys can be removed as normal. this has happened many times over the past two months. the vehicle is at the dealer now for the second attempt at repairing this situation. *jb | |||
| 08/19/2005 | 15000 | 100 | 08/18/2004 |
| Dt: 2004 ford expedition - the gear shift indicator does not shift when put into gear. it has been doing this off and on for the past three months. took the vehicle to the dealer to have it looked at and made an the appointment to have it repaired, the gear shift indicator was not in the proper gear when the consumer brought vehicle back for the appointment, it was working properly. therefore, it was not repaired at that time. currently, it is happened again. it has been in the wrong gear for about two weeks. the vehicle is still under warranty. the gear shift indicator failed at least 100 times.*ak | |||
| 07/25/2005 | 13350 | 1 | 01/12/2005 |
| July 25, 2005 my 2004 ford expedition automatic transmission lever failed. it will not move past the reverse setting, yet it will go into park. the transmission functions properly as far as i know. i am to take into dealership tommorrow. my mileage is about 13,500. *jb | |||
| 10/03/2004 | 17000 | 2 | 03/01/2004 |
| My car would not go into reverse and lost full speed pressure on the highway, nearly causing a very bad accident. *ak | |||
| POWER TRAIN - AUTOMATIC TRANSMISSION - LEVER AND LINKAGE - COLUMN SHIFT | |||
| 03/22/2005 | 1 | ||
| After parking the vehicle in the lot at work consumer proceeded to exit the vehicle when the driver's side door knocked her down as the vehicle rolled backwards. consumer got up, entered the vehicle, placed both hands on the brakes to stop the vehicle, then placed the vehicle into park before it struck anything. no injuries were sustained by the consumer. the vehicle was placed into park prior to it rolling back.*ak | |||
| POWER TRAIN - AXLE ASSEMBLY | |||
| 12/06/2009 | 104000 | ||
| Tl*the contact owns a 2004 expedition. while driving 25 mph the torsion bar snapped under the vehicle and then the rear axle pulled the drive shaft from the transmission. the vehicle was towed to a auto repair shop. the dealer nor the manufacturer have been contacted. the vin was unknown. the failure mileage was 104,000. | |||
| POWER TRAIN - AXLE ASSEMBLY - AXLE SHAFT | |||
| 01/01/2002 | 1 | ||
| Dt: while driving on the road at 30-40 mph the front wheel wobbled back and forth. before being able to pull to the side of the road the left wheel came off the car. the axle was bend very badly. no one was hurt, but the axle had to be replaced. the dealer refused to do it without charging the consumer an excessive price. *ak | |||
| POWER TRAIN - AXLE ASSEMBLY - AXLE SHAFT - SEAL | |||
| 02/14/2005 | 4 | ||
| Vehicle experienced a leak in the rear axle seals. this problem was recognized by the dealer and the vehicle had been in the repair shop for the last 8 weeks. however, the problem had not been remedied. owner contacted the manufacturer, and was told that there was not enough evidence for them to take action and repair the vehicle. *ak | |||
| POWER TRAIN - DRIVELINE - DIFFERENTIAL UNIT | |||
| 08/07/2007 | 31000 | 1 | 12/27/2003 |
| 2004 expedition xlt 2wd. trying to find out more about (technical service bulletin) dealing with the rear end/differential problem. i also mentioned that just recently there is a gurgling sound coming from the exhaust. sounds like it wants to backfire or like there is water in the system. i was told by the art hill dealership that has to do with the differential and that they can not fix the exhaust until i get the differential fixed. every other dealership i talk to gives me the run around and say it's my problem. we've had mustangs in the past and this is our second expedition. we've always loved fords up until now!!! there is a known problem with the 03-05 expeditions rear end/differential but it seems to be ignored. i was told it was the tires at first so i replace them, then i was told it would go away. well it hasn't and then i was told it would cost 1,727.00 to fix!!!! this is an outrage!!! we were thinking of purchasing a 2007 model but the service that we have been receiving lately.....we may try another brand. please help we want to stay with ford.. *tr | |||
| POWER TRAIN - MANUAL TRANSMISSION - SHIFT PATTERN INDICATOR | |||
| 10/03/2004 | 17000 | 2 | 03/01/2004 |
| My car would not go into reverse and lost full speed pressure on the highway, nearly causing a very bad accident. *ak | |||