# Service bulletins for the 2004 Ford Expedition

A bulletin is a manufacturer's communication to its dealers, as NHTSA indexes it. The summary is NHTSA's. The document is the manufacturer's: read it at NHTSA. A bulletin is not a recall, and listing a model year does not mean every vehicle of it is concerned.

91 bulletins from NHTSA, as of 2026-10-19.

- [TSB 24\-2188](/bulletins/11005305.md), 2024-07-29, Service bulletin: WHEELS. 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.
- [SSM 51536](/bulletins/10235153.md), 2023-05-04, Service bulletin: 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. 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.
- [TSB 22\-2219](/bulletins/10214754.md), 2022-06-27, Service bulletin: POWER TRAIN. 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.
- [TSB 20\-2307](/bulletins/10181917.md), 2020-11-05, Service bulletin: ELECTRICAL SYSTEM; WHEELS; EQUIPMENT. 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.
- [TSB 20\-2233](/bulletins/10177863.md), 2020-08-06, Service bulletin: 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.
- [TSB 19\-2026](/bulletins/10156863.md), 2019-04-08, Service bulletin: EQUIPMENT; 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
- [TSB 19\-2026](/bulletins/10155551.md), 2019-04-01, Service bulletin: 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
- [SSM 46085](/bulletins/10109070.md), 2017-08-01, Service bulletin: ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL; ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE; ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR; ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:GAS RECIRCULATION VALVE \(EGR VALVE\); ENGINE AND ENGINE COOLING:ENGINE:OTHER FUEL TYPES:TURBO/SUPERCHARGER; ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSES/LINES/PIPING/FITTINGS; ENGINE AND ENGINE COOLING; ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY; ENGINE; ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CRANKCASE \(PCV\); ENGINE AND ENGINE COOLING:COOLING SYSTEM; ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:TURBO/SUPERCHARGER; ENGINE AND ENGINE COOLING:ENGINE:DIESEL; ENGINE AND ENGINE COOLING:EXHAUST SYSTEM; ENGINE AND ENGINE COOLING:ENGINE:GASOLINE; ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:BELTS AND ASSOCIATED PULLEYS; ENGINE AND ENGINE COOLING:ENGINE; ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN. 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\-08\-19\-3](/bulletins/10028736.md), 2009-05-21, Service bulletin: POWER TRAIN:AXLE ASSEMBLY:AXLE SHAFT:SEAL; POWER TRAIN:AXLE ASSEMBLY:AXLE SHAFT. 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](/bulletins/10023943.md), 2008-02-21, Service bulletin: ENGINE AND ENGINE COOLING:ENGINE. 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
- [061510](/bulletins/10021072.md), 2007-02-27, Service bulletin: SUSPENSION:FRONT:SPRINGS:AIR SUSPENSION SYSTEM. AIR SUSPENSION PERFORMANCE \- HEIGHT SENSOR LINKAGE ARM DISENGAGING. \*KB
- [06317](/bulletins/10020132.md), 2006-07-26, Service bulletin: SERVICE BRAKES, HYDRAULIC. BRAKE SHUDDER. \*TT
- [052621](/bulletins/10019415.md), 2006-03-15, Service bulletin: SERVICE BRAKES, HYDRAULIC:POWER ASSIST. UNINTENDED BRAKE ASSIST. \*TT
- [0637](/bulletins/10019384.md), 2006-03-14, Service bulletin: TIRES. LOW TIRE INDICATOR ON \- TPMS SYSTEM SENSOR WAKE UP. \*TT
- [052624](/bulletins/10018938.md), 2006-01-25, Service bulletin: TIRES; WHEELS. VIBRATION DIAGNOSIS \- TIRE/WHEEL RUNOUT. \*TT
- [041601](/bulletins/10018745.md), 2006-01-13, Service bulletin: ENGINE AND ENGINE COOLING. WDS COP KIT DIAGNOSTIC TIP \- COIL ON PLUG \(COP\) IGNITION SYSTEMS \- ENGINE MISFIRE OR ROUGH RUNNING. \*TT
- [18815](/bulletins/10018069.md), 2005-12-15, Service bulletin: POWER TRAIN:TRANSFER CASE \(4\-WHEEL DRIVE\). A TINY CRACK, OR CRACKS, AROUND THE TRANSFER CASE DRAIN PLUG HOLE. \*TT
- [0594](/bulletins/10018052.md), 2005-12-14, Service bulletin: SEATS:FRONT ASSEMBLY:POWER ADJUST. DRIVERS FRONT POWER SEAT WILL NOT MOVE FORWARD OR REARWARD. \*TT
- [05618](/bulletins/10017892.md), 2005-12-07, Service bulletin: POWER TRAIN:AXLE ASSEMBLY. REAR AXLE NOISE REPAIR. \*TT
- [031207](/bulletins/10017888.md), 2005-12-07, Service bulletin: STEERING. STEERING WHEEL AT 65 MPH \(105 KM/H\) OR HIGHER. \*TT
- [05198](/bulletins/10017805.md), 2005-12-01, Service bulletin: VISIBILITY:REAR WINDOW WIPER/WASHER. REAR WINDOW WIPER INOPERATIVE. \*TT
- [050618](/bulletins/10016789.md), 2005-10-07, Service bulletin: SUSPENSION:REAR. REAR AXLE NOISE REPAIR. \*SC
- [0554](/bulletins/10014685.md), 2005-05-05, Service bulletin: ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE. USE OF STAINLESS STEEL EXHAUST STUDS IN SERVICE FOR 5.4L 2V ENGINE. \*TT
- [18506](/bulletins/10014676.md), 2005-05-05, Service bulletin: WHEELS. ALUMINUM ALLOY WHEELS PITTING AND OR PEELING CLEANING PROCEDURES. \*EH
- [18478](/bulletins/10014668.md), 2005-05-05, Service bulletin: POWER TRAIN:AXLE ASSEMBLY. AXLE SEAL LEAKS. \*EH

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