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2002 Ford Expedition Technical Service Bulletins (TSBs)

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TSB Date Problem Area TSB Text
02/20/08 NHTSA ID: 10023943
TSB ID: 07212

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.
01/12/06 NHTSA ID: 10018745
TSB ID: 041601

Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running.
10/07/05 NHTSA ID: 10016789
TSB ID: 050618

Rear axle noise repair. *sc
05/05/05 NHTSA ID: 10014666
TSB ID: 05417

Intermittent rough idle - non-commanded egr (exhaust gas recirculation valve) flow.
05/05/05 NHTSA ID: 10014685
TSB ID: 0554

Use of stainless steel exhaust studs in service for 5.4l 2v engine.
01/06/05 NHTSA ID: 10011162
TSB ID: 031404

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.
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12/07/04 NHTSA ID: 10010731
TSB ID: 18217

Multiple vehicles - fuel level indication concerns - service tip. various models including 2005 super duty f-series, excursion, expedition, explorer, mountaineer and aviator.
11/03/04 NHTSA ID: 10010001
TSB ID: 04L19

Customer maintenance reminder - literature program 04l19 - tie rod inspection procedure.
08/05/04 NHTSA ID: 10008580
TSB ID: 02176

Lamp-brake-invadvertent disabling of brake shift interlock. *mj
08/04/04 NHTSA ID: 10008539
TSB ID: 0454

Air suspension compressor noise.
07/28/04 NHTSA ID: 10008334
TSB ID: 16403

Engine-light tick or rattle type noise from engine after cold start. *mj
07/27/04 NHTSA ID: 10008310
TSB ID: 02227

Engine-cylinder head deck leak-4.6 and 5.4l engines-new service-only gasket and cylinder head kits availability. *mj
07/26/04 NHTSA ID: 10008278
TSB ID: 03256

Engine-romeo built 4.6l 2v-tick noise from engine-engines built before 9/17/2003. *mj
07/22/04 NHTSA ID: 10008166
TSB ID: 17316

Fuel signal to instrument cluster service tip.
07/22/04 NHTSA ID: 10008169
TSB ID: 17320

Broken exhaust manifold studs.
07/22/04 NHTSA ID: 10008177
TSB ID: 17346

Steering idler arm noise.
06/03/04 NHTSA ID: 10007207
TSB ID: 02M01

Customer satisfaction program 02m01 supplement #4. certain ford 2000 through 2003 vehicles equipped with a tube-mounted egr pressure sensor - additional egr pressure sensor warranty coverage. supplement #3. *mj supplement #6
10/29/03 NHTSA ID: 10003744
TSB ID: 03144

Engine misfire or rough running condition with coil on plug (cop) ignition systems may be more accurately diagnosed using the optional worldwide diagnostic system (wds) coil on plug (cop) kit. 2003 super duty f series included.
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10/10/03 NHTSA ID: 10003192
TSB ID: 031513

Tie rod end inspection procedure.
10/08/03 NHTSA ID: 10003118
TSB ID: 03164

Some vehicles, equipped with the 4.6l 2v engine, with an engine build date prior to 8/29/03 may exhibit an engine tick noise that is present at all temperatures during idle. 2004 models included.
09/17/03 NHTSA ID: 10002775
TSB ID: 0392

Repeat air suspension compressor drier failures.
09/17/03 NHTSA ID: 10002780
TSB ID: 0398

Malfunction indicator lamp (mil) illumination with diagnostic trouble codes p0442, p0455, p0456, p0457, p1442 or check fuel cap lamp illuminated with diagnostic trouble code p0457.
09/17/03 NHTSA ID: 10002781
TSB ID: 0399

Tie rod end inspection procedure.
09/10/03 NHTSA ID: 10002680
TSB ID: 030709

Repeat air suspension compressor drier failures.
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09/03/03 NHTSA ID: 10002472
TSB ID: 0322

Streamlined diagnostic procedure for vehicles with malfunction indicator lamp (mil) on and diagnostic trouble codes (dtcs) p0401, p0402, p1400 or p1401, or runs rough, lacks power, surge, poor fuel economy, and the above listed dtcs without
07/28/03 NHTSA ID: 10001937
TSB ID: 16683

False failure of the vapor management valve (vmv). *jb
07/23/03 NHTSA ID: 10001855
TSB ID: 0361

Malfunction indicator lamp on with or without rough running, lack of power, surge or poor fuel economy with diagnostic trouble codes p0401, p0402, p1400, p1401. *jb
07/23/03 NHTSA ID: 10001861
TSB ID: 03610

Tie rod end inspection procedure. canada vehicles only. *jb
11/07/02 NHTSA ID: 636326
TSB ID: 15692

Some vehicles may exhibit a squeak, snap, rattle, or clunk in the front end when turning or going over bumps.
11/06/02 NHTSA ID: 636202
TSB ID: 16015

Some vehicles with air suspension may exhibit an initial or repeat compressor dryer failure.
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11/05/02 NHTSA ID: 636083
TSB ID: 02108

Some vehicles equipped with the 5.4l 2v engine may exhibit a whistling noise fromthe formed nylon tube inthe idle-air bypass flow circuit.
11/04/02 NHTSA ID: 636054
TSB ID: 0241

Subject regarding idler arm replacement specifications.
04/19/02 NHTSA ID: 630679
TSB ID: 15630

Concerns with vehicles with a 5.4l 2v engine exhibitingng a lack of power condition.
04/19/02 NHTSA ID: 630702
TSB ID: 15648

Some vehicles may exhibit a slow fuel fill condition and/or premature shutoff of the gas pump when the vehicle is being refueled.
04/19/02 NHTSA ID: 630704
TSB ID: 15651

Some vehicles equipped with air suspension may exhibit an air leak and/or overnight bleed down of the air suspension.
04/18/02 NHTSA ID: 630515
TSB ID: 01246

Engine oil system priming procedures, service tips for reports of premature engine failure.
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04/18/02 NHTSA ID: 630585
TSB ID: 15480

Some vehicles may exhibit a slow fuel fill condition and/or premature shutoff of the gas pump when the vehicle is being re-fueled.
04/18/02 NHTSA ID: 630612
TSB ID: 15502

Concerns with pop/clunk/click noise from the front suspension when making low-speed turns in forward or reverse gears.
04/17/02 NHTSA ID: 630420
TSB ID: 15407

Concerns with a pop/clunk/click noise coming from the front suspension when making low-speed turns in forward or reverse gears.
04/17/02 NHTSA ID: 630452
TSB ID: 15431

Exhibiting lack of power condition when vehicle is operated in ambient temperatures.
04/15/02 NHTSA ID: 630235
TSB ID: 15326

Some vehicles may exhibit a pop/clunk/click noise from the front suspension when making low speed turns in either forward or reverse.
04/12/02 NHTSA ID: 630059
TSB ID: 15528

Subject regarding air suspension compressor quality. *yd
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04/12/02 NHTSA ID: 630043
TSB ID: 15517

Subject regarding exaggerated engine braking on deceleration. *yd
04/11/02 NHTSA ID: 630001
TSB ID: 0214

Some engine assemblies with aluminum cylinder heads repaired in-vehile have been found to leak coolant and/or oil from the cylinder head gasket area.
02/26/02 NHTSA ID: 627927
TSB ID: 01205

Some vehicles may exhibit vacuum or air leaks in the intake manifold and / or engine system causing diagnostic trouble codes p0171 and or p0174.
12/03/01 NHTSA ID: 625807
TSB ID: 15259

Concerns with the lower power in high ambient temepratures.
09/06/01 NHTSA ID: 621019
TSB ID: 15094

Information regarding intake manifold valley stuffers.
04/17/02 Engine NHTSA ID: 630454
TSB ID: 15432

Some vehicles not equipped with side air bags may exhibit diagnostic trouble code b1998 (passenger side air bag circuit resistance high) in the restraints control module.
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04/16/02 Engine NHTSA ID: 630362
TSB ID: 15433

Some vehicles built after 4/10/2001 and equipped with air suspension , may exhibit an electronic variable orifice (evo) steering diagnostic trouble code c1917.
02/22/02 Engine NHTSA ID: 627774
TSB ID: 012113

Some ignition switch lock cylinder assemblies may exhibit rougness and / or excess effort in turning, key does not fully return from start, a malfunction indicator lamp may illuminate with p0500, p1502 and u1039 stored in powertrian control
12/06/05 Transmission and Drivetrain NHTSA ID: 10017892
TSB ID: 05618

Rear axle noise repair.
04/28/05 Transmission and Drivetrain NHTSA ID: 10014086
TSB ID: 042107

General (pcm) power train control module programming procedures.
09/23/04 Transmission and Drivetrain NHTSA ID: 10009332
TSB ID: 17905

Multiple vehicles using fehp rear axle fluid. fluid usage change.
07/27/04 Transmission and Drivetrain NHTSA ID: 10008331
TSB ID: 16400

Rear axle seal leak - contact request. *mj
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10/29/03 Transmission and Drivetrain NHTSA ID: 10003748
TSB ID: 03148

New transmission cooler flusher - service tips. 2003 escort and super duty f series included.
12/06/02 Transmission and Drivetrain NHTSA ID: 637779
TSB ID: 15897

Subject regarding driveline angle-related vibration at various speeds and load conditions.
11/07/02 Transmission and Drivetrain NHTSA ID: 636384
TSB ID: 15749

Some vehicles equipped with 4 wheel drive may exhibit a notchy or sticking feeling in slow speed turns with no effect on steering efforts or assist while in the automatic 4x4 position.
11/06/02 Transmission and Drivetrain NHTSA ID: 636226
TSB ID: 16033

Some vehicles with electronic shift-on-the fly may exhibit an inadvertent 4x4 low engagement while driving.
11/04/02 Transmission and Drivetrain NHTSA ID: 636052
TSB ID: 0258

Inoperative or inacurrate speedometer, 4x4 lamp illuminatd, and / or diagnostic trouble code p1635 or p1639.
04/16/02 Transmission and Drivetrain NHTSA ID: 630386
TSB ID: 15377

Some vehicles may exhibit an axle tube seal leakage and an axle bearing that is loose in the axle housing, and/or a replacement service bearing that is loose in the housing.
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11/30/01 Transmission and Drivetrain NHTSA ID: 625715
TSB ID: 01181

Brake shift interlock.*jb
11/08/01 Transmission and Drivetrain NHTSA ID: 624629
TSB ID: 15123

Some vehicles may exhibit a driveline vibration at speeds between 60-70 mph. *slc
12/07/05 Electrical and Air Conditioning NHTSA ID: 10017904
TSB ID: 05419

False parking aid warnings.
05/05/05 Electrical and Air Conditioning NHTSA ID: 10014671
TSB ID: 04262

False parking aid warnings. update.
04/27/05 Electrical and Air Conditioning NHTSA ID: 10014062
TSB ID: 04189

Rear window defroster grid/integral antenna diagnosis and repair - terminal tab repair.
04/08/05 Electrical and Air Conditioning NHTSA ID: 10013116
TSB ID: 04174

Malfunction indicator lamp (mil) illuminated - system lean diagnostic trouble codes (dtc's) - service tips. various models including 2004 f-series.
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04/07/05 Electrical and Air Conditioning NHTSA ID: 10013060
TSB ID: 02208

Climate control a/c service tech tips. *eh
01/04/05 Electrical and Air Conditioning NHTSA ID: 10011159
TSB ID: 041514

Rear window defroster grid/integral antenna diagnosis and repair - terminal tab repair.
09/23/04 Electrical and Air Conditioning NHTSA ID: 10009321
TSB ID: 031501

Inoperative electric rear window defroster (heated backlite) grid lines, integral antenna concerns.
08/09/04 Electrical and Air Conditioning NHTSA ID: 10008588
TSB ID: 02193

Driveability-idle-high idle speeds-throttle sticks after steady state driving in extreme cold ambient temperatures-vehicles built through 12/31/01 equipped with 4.6l engine. *mj
07/23/04 Electrical and Air Conditioning NHTSA ID: 10008225
TSB ID: 17720

Airbag warning lamp on with diagnostic trouble code (dtc) b1994/b1998 on vehicles without side air bags.
07/23/04 Electrical and Air Conditioning NHTSA ID: 10008252
TSB ID: 04111

Streamlined diagnostic procedure for vehicles with malfunction indicator lamp (mil) on and diagnostic trouble codes (dtcs) p0401, p0402, p1400 or p1401. additional symptoms may include runs rough, lacks power, surge, poor fuel economy.
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07/23/04 Electrical and Air Conditioning NHTSA ID: 10008201
TSB ID: 0471

Warning indicators-parking aid-reverse sensing system (rss) and forward sensing system (fss)-false activation of warning tone-service tips. *mj update.
06/16/04 Electrical and Air Conditioning NHTSA ID: 10007360
TSB ID: 03223

Streamlined diagnostic procedure for vehicles with malfunction indicator lamp on and diagnostic trouble codes (dtcs) p0401, p0402, p1400 or p1401. additional symptoms may include runs rough, lacks power, surge, poor fuel economy.
06/10/04 Electrical and Air Conditioning NHTSA ID: 10007316
TSB ID: 17459

Courtesy rail lamps do not operate correctly or cause a battery draw.
11/14/03 Electrical and Air Conditioning NHTSA ID: 10004027
TSB ID: 03181

Remote keyless entry (rke) - service tips.
09/10/03 Electrical and Air Conditioning NHTSA ID: 10002670
TSB ID: 16797

Vehicles with keyless entry pad may exhibit dead battery, no start, interior lamp/headlamp self-activation, or inoperative keyless entry pad.
12/06/02 Electrical and Air Conditioning NHTSA ID: 637882
TSB ID: 02121

White flakes coming from the air conditioner vents when the blower motor is engaged.
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11/05/02 Electrical and Air Conditioning NHTSA ID: 636065
TSB ID: 0245

Information regarding discharged battery charging service tips and guidelines.
04/19/02 Electrical and Air Conditioning NHTSA ID: 630706
TSB ID: 15652

Concerns with climate control system air discharged through the defroster ducts only, regardless of setting.
04/17/02 Electrical and Air Conditioning NHTSA ID: 630410
TSB ID: 15395

Some vehicles may exhibit a weak horn chirp confirmation when the transmitter is used to lock the doors and/or an inoperative horn when the vehicle's engine is not running.
04/12/02 Electrical and Air Conditioning NHTSA ID: 630081
TSB ID: 15549

Information regarding pop/thump noise from power window. *yh
04/11/02 Electrical and Air Conditioning NHTSA ID: 629997
TSB ID: 0212

Some vehicles may exhibit a weak horn chirp confirmation when the key fob is used, or an inoperative horn when the engine is not running.
02/22/02 Electrical and Air Conditioning NHTSA ID: 627762
TSB ID: 01215

A condition may exist, where throttle sticking may occur on a few vehicles in very cold ambient temperatures after operating at steady speed or extended idle for a period of time.
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10/31/01 Electrical and Air Conditioning NHTSA ID: 623944
TSB ID: 01156

Some vehicles may exhibit heater core leaks. *slc
04/28/05 Other NHTSA ID: 10014138
TSB ID: 042421

Safety belt retraction speed.
04/28/05 Other NHTSA ID: 10014165
TSB ID: 04251

Aluminum corrosion - service tip.
08/04/04 Other NHTSA ID: 10008542
TSB ID: 0457

Pop/thump noise at end of window movement and/or driver's window bounce back and reverse to mid-position.
07/22/04 Other NHTSA ID: 10008157
TSB ID: 99263

Correct lug nut torque specifications - increase wheel nut and stud size - service tip.
12/06/02 Other NHTSA ID: 637848
TSB ID: 15939

Concerns with speed body boom.
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12/02/02 Other NHTSA ID: 637511
TSB ID: 15794

Some 4x2 vehicles equipped with p275/60/r17 continental-general tires may exhibit a highway speed tire vibration.
11/07/02 Other NHTSA ID: 636289
TSB ID: 16087

Some vehicles may exhibit a flashing transmission control indicator lamp (tcil) and diagnostic trouble codes p0740, p0741, p0743, and p1744 (torque converter clutch).
11/07/02 Other NHTSA ID: 636344
TSB ID: 15708

Some vehicles may exhibit wheels that seize to the hubs and are difficult to remove during service.
11/07/02 Other NHTSA ID: 636371
TSB ID: 15727

Some 4x2 vehicles equipped with p275/60/r17 continental general tires may exhibit a highway speed tire vibration.
11/06/02 Other NHTSA ID: 636178
TSB ID: 16170

Some vehicles equipped with a 4r100 transmission and built between january 1, 2001 and may 1, 2002 may exhibit flashing transmission control indicator lamp and any or all torque converter clutch diagnostic trouble codes p0740, p0741, p0743,
11/04/02 Other NHTSA ID: 636049
TSB ID: 0256

This bulletin involves proper procedures for preparation of service sheet metal parts coated with electro deposition primer (e-coat).
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04/19/02 Other NHTSA ID: 630653
TSB ID: 15605

Some vehicles may exhibit driveability conditions and / or check engine lamp illuminated with a diagnostic trouble p0455 (gross leak detected).
04/11/02 Other NHTSA ID: 630026
TSB ID: 15504

Some vehicles may exhibit driveabilty conditions and/or check engine lamp illuminated with a diagnostic trouble code p0455 (gross leak detected).
11/08/01 Other NHTSA ID: 624622
TSB ID: 15122

Some vehicles may exhibit a vibration at idle and/or engine droaning noise on acceleration from a stop. *slc
11/08/01 Other NHTSA ID: 624715
TSB ID: 15137

Customers may complain of wind noise. *yd
10/31/01 Other NHTSA ID: 623988
TSB ID: 01157

Information regarding transmission fluid usage charts. *slc

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Ford Expedition TSBs (Technical Service Bulletins)

Some things are often misunderstood about recalls and technical service bulletins (TSBs). Plus a disclaimer.

  1. Recalls do not have to be issued only because something is prone to failure. NHTSA (a government agency) can only require a recall if a failure will affect safety, emissions, fuel economy, or compliance with some other regulation or law. Manufacturers can voluntarily recall cars for problems that do not affect these, though.
  2. Recalls often apply to only some cars of a specific model year, rather than all of them. You should receive a letter from the manufacturer if your car has been recalled. You can also check with the dealer, which will know which (if any) recalls pertain to your car.
  3. The primary purpose of TSBs is to inform dealers about known problems with a car and how to fix them. They are not the same as recalls. As with recalls, TSBs often only apply to some cars, not the entire model year.
  4. Dealers often will not provide a preventive repair just because a problem described in a TSB might happen to your car. They'll usually want to observe symptoms that the problem is already affecting your car.
  5. Even if there are symptoms, a manufacturer doesn't have to pick up the cost of a TSB repair if the car is out of warranty, though sometimes they do.

We provide the text of recalls and TSBs as provided by NHTSA. There can be errors in the text. If you sign up for notifications in My Garage, we will try to get these to do, but for various reasons (some beyond our control) cannot guarantee you will receive them. When in doubt about a recall or TSB, contact the dealer.