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2004 Ford Explorer Technical Service Bulletins (TSBs)

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TSB Date Problem Area TSB Text
12/12/12 NHTSA ID: 10048099
TSB ID: TSB-12-8-1

Ford/lincoln/mercury: may have sludge buildup in throttle body leading to less airflow or engine idling rpm fluctuation and hard starts or battery disconnect or dead battery after keep alive memory (kam) clear. models 2003-05 thunderbird
08/28/12 NHTSA ID: 10045340
TSB ID: TSB-12-7-4

Ford/lincoln/mercury: if battery was disconnected or dead, vehicles/trucks may experience hard starts and engine idle rpm fluctuation and exhibit diagnostic trouble codes (dtcs) p0505, p0506, p2111 and p2112.
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.
03/13/06 NHTSA ID: 10019379
TSB ID: 05213

Malfunction indicator lamp on with pcm diagnostic trouble code p0463 and/or ic diagnostic trouble code b1201 - fuel gauge drops to empty or slow to update after refueling.
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.
12/14/05 NHTSA ID: 10018064
TSB ID: 051710

Noise from rear wheel hub bearings.
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12/07/05 NHTSA ID: 10017931
TSB ID: 051016

No start/hard start on cold soak - 4.0l engine.
12/06/05 NHTSA ID: 10017882
TSB ID: 18573

No start/hard start on cold soak.
12/05/05 NHTSA ID: 10017860
TSB ID: 18719

Malfunction indicator lamp coming on with diagnostic trouble codes (dtcs) p0171, p0172, p0174 and/or p0175 (fuel system too rich or lean).
10/07/05 NHTSA ID: 10016789
TSB ID: 050618

Rear axle noise repair. *sc
04/18/05 NHTSA ID: 10013383
TSB ID: 042112

Rough idle in drive. *eh
04/18/05 NHTSA ID: 10013388
TSB ID: 042115

Fuel gauge slow to update after refueling. *eh
04/18/05 NHTSA ID: 10013399
TSB ID: 04225

Throttle pedal response on tip in vehicles built before 10/4/2004 equipped with a 4.0l engine. *eh
04/05/05 NHTSA ID: 10012947
TSB ID: 0531

Maf diagnostic service tip - vehicles equipped with egr system module (esm).
04/05/05 NHTSA ID: 10012950
TSB ID: 0538

Increased turning effort during low speed sharp turns false 4x4 engagement. *eh
04/05/05 NHTSA ID: 10012953
TSB ID: 0539

Mil on and/ or runs rough/misfire dtcs p0300-p0308 p0316 and or p0171/p0174 4.6l engine. *eh
01/18/05 NHTSA ID: 10011332
TSB ID: 18121

Fuel gauge slow to update.
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: 10010719
TSB ID: 041910

Oil leak from oil filter adapter - 4.0l sohc engine built before 4/1/2004.
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.
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
07/26/04 NHTSA ID: 10008281
TSB ID: 03263

Anti-lock brake system (abs) lamp illuminated and diagnostic trouble code (dtc) c1235, c1236, c1237 on vehicles with differential-mounted rar wheel speed sensor.
07/26/04 NHTSA ID: 10008284
TSB ID: 03L17

Demonstration/delivery hold - special field action 03l17. revised smog emissions information.
07/23/04 NHTSA ID: 10008229
TSB ID: 17728

Anti-lock brake system (abs) light on with diagnostic trouble code (dtc) b2900, u1900 and c1805.
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07/22/04 NHTSA ID: 10008166
TSB ID: 17316

Fuel signal to instrument cluster service tip.
07/22/04 NHTSA ID: 10008171
TSB ID: 17326

Engine auxiliary oil cooler line and the right side motor mount squeaking noise from front exterior while driving over bumps.
07/22/04 NHTSA ID: 10008115
TSB ID: 17544

Generator noise in cold ambient temperatures. *mj
06/22/04 NHTSA ID: 10007422
TSB ID: 17664

Intermittent hard start, long crank time or multiple crank attempts before starting.
06/22/04 NHTSA ID: 10007423
TSB ID: 17666

Diagnostic trouble code (dtc) u0300 (internal control module software incompatibility) stored in the pcm with no other dtc's present.
06/21/04 NHTSA ID: 10007404
TSB ID: 17626

Standard abs (not advance trac/ivd) built prior to 2/9/2004 may exhibit an intermittent amber abs light on with diagnostic trouble code (dtc's) b2900, u1900 and possibly c1805 stored in memory.
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06/10/04 NHTSA ID: 10007334
TSB ID: 17494

Distance to empty not displayed.
11/17/03 NHTSA ID: 10004076
TSB ID: 17215

The amber anti-lock brake system (abs) warning light on with diagnostic trouble codes c1235, c1236/c1237 stored in memory.
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.
08/01/17 Transmission and Drivetrain NHTSA ID: 10109070
TSB ID: SSM 46085

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
05/20/09 Transmission and Drivetrain NHTSA ID: 10028736
TSB ID: TSB-08-19-3

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.
05/17/06 Transmission and Drivetrain NHTSA ID: 10019947
TSB ID: 0645

Neutral tow capability - service kit requirements.
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12/07/05 Transmission and Drivetrain NHTSA ID: 10017898
TSB ID: 05612

Delayed or harsh reverse engagements - 5r55s transmission - vehicles built prior to 09/23/2004.
12/06/05 Transmission and Drivetrain NHTSA ID: 10017892
TSB ID: 05618

Rear axle noise repair.
05/05/05 Transmission and Drivetrain NHTSA ID: 10014659
TSB ID: 18466

Axle whine howl. this includes 1997-05 ford vehicles. *eh
05/05/05 Transmission and Drivetrain NHTSA ID: 10014668
TSB ID: 18478

Axle seal leaks. *eh
04/29/05 Transmission and Drivetrain NHTSA ID: 10014277
TSB ID: 04268

Increased effort during low speed sharp turns on 4x4 vehicles.
04/28/05 Transmission and Drivetrain NHTSA ID: 10014086
TSB ID: 042107

General (pcm) power train control module programming procedures.
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04/28/05 Transmission and Drivetrain NHTSA ID: 10014100
TSB ID: 06216

Limited slip axle chatter, shudder, binding sensation, or vibration during low speed turning maneuvers.
04/18/05 Transmission and Drivetrain NHTSA ID: 10013398
TSB ID: 042212

Gear selector lever - increased effort to shift from drive to park.
04/14/05 Transmission and Drivetrain NHTSA ID: 10013306
TSB ID: 04B22

Improperly formulated transmission fluid that, over time, may cause delayed/harsh reverse engagements. customer satisfaction program 04b22. 5r55s/e & 5r44e transmission fluid additive. supplement #1. supplement #2. supp
04/08/05 Transmission and Drivetrain NHTSA ID: 10013121
TSB ID: 041715

Front axle tube leak. *eh
04/05/05 Transmission and Drivetrain NHTSA ID: 10012959
TSB ID: 18423

Axle whine howl service with individual parts instead of an axle assembly. *eh
04/05/05 Transmission and Drivetrain NHTSA ID: 10012952
TSB ID: 0537

Driveline 1st order vibration/boom/drone.
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04/04/05 Transmission and Drivetrain NHTSA ID: 10012938
TSB ID: 0527

5r55s transmission fluid leaks from converter housing area. diagnostic trouble code p1783 on vehicles built prior to 12/12/2004.
12/07/04 Transmission and Drivetrain NHTSA ID: 10010726
TSB ID: 18202

Unintended 4x4 engagement during low speed parking lot turns. various models including the 2005 explorer and mountaineer.
12/07/04 Transmission and Drivetrain NHTSA ID: 10010732
TSB ID: 18221

Rear axle noise. oasis. various models including 2005 explorer, mountaineer and aviator.
09/23/04 Transmission and Drivetrain NHTSA ID: 10009332
TSB ID: 17905

Multiple vehicles using fehp rear axle fluid. fluid usage change.
09/07/04 Transmission and Drivetrain NHTSA ID: 10008994
TSB ID: 04105

Axle seal leaks. leaks from rear halfshaft axle seal. service tips.
07/27/04 Transmission and Drivetrain NHTSA ID: 10008303
TSB ID: 17455

4x4 inoperative and/or indicators blinking.
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07/23/04 Transmission and Drivetrain NHTSA ID: 10008236
TSB ID: 17736

Rear axle noise.
07/23/04 Transmission and Drivetrain NHTSA ID: 10008268
TSB ID: 17883

Delayed/harsh reverse engagement.
07/23/04 Transmission and Drivetrain NHTSA ID: 10008222
TSB ID: 17717

Rear axle chatter, shudder, binding sensation, or vibration during low speed turns.
07/22/04 Transmission and Drivetrain NHTSA ID: 10008120
TSB ID: 17555

Certified rear axle available. *mj
07/22/04 Transmission and Drivetrain NHTSA ID: 10008124
TSB ID: 17560

Rear axle noise. also includes lincoln aviator 2002. *mj
06/22/04 Transmission and Drivetrain NHTSA ID: 10007413
TSB ID: 17641

Rear 3.55 axle noise. certified rear axle or improved gear set available.
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05/21/04 Transmission and Drivetrain NHTSA ID: 10007006
TSB ID: 04B15

Rear axle date code inspection and service. vehicles may have been built with an improper mix of rear axle lubricant and friction modifier additive. if so, the customer may experience noise and vibration while driving. *mj
11/17/03 Transmission and Drivetrain NHTSA ID: 10004046
TSB ID: 17107

Driveline vibration on drone/boom at highway speeds.
11/14/03 Transmission and Drivetrain NHTSA ID: 10004037
TSB ID: 03198

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.
10/09/03 Transmission and Drivetrain NHTSA ID: 10003164
TSB ID: 17054

Axle whine at cruise or during acceleration/ deceleration.
01/25/06 Electrical and Air Conditioning NHTSA ID: 10018937
TSB ID: 05262

Mil on with dtc p0191 with or without various drivability symptoms and/or additional dtcs.
12/07/05 Electrical and Air Conditioning NHTSA ID: 10017904
TSB ID: 05419

False parking aid warnings.
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12/07/05 Electrical and Air Conditioning NHTSA ID: 10017905
TSB ID: 0561

Wrench lamp on and no diagnostic trouble code (dtc) stored.
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.
04/15/05 Electrical and Air Conditioning NHTSA ID: 10013371
TSB ID: 04219

Malfunction indicator lamp (mil) and electronic throttle control (etc) lamps on with both diagnostic trouble code (dtc) p2106 and p2135.
04/14/05 Electrical and Air Conditioning NHTSA ID: 10013303
TSB ID: 04259

Rear power window(s) inoperative.
04/14/05 Electrical and Air Conditioning NHTSA ID: 10013319
TSB ID: 18381

Open fuse f2.20 (5 amp) and/or f2.1 (30 amp) which may result in loss of function of several systems including power seats, adjustable pedals and power door locks.
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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.
01/18/05 Electrical and Air Conditioning NHTSA ID: 10011342
TSB ID: 18171

No crank/no start condition when vehicle temperature is below freezing (32f/0c).
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.
12/07/04 Electrical and Air Conditioning NHTSA ID: 10010717
TSB ID: 04197

Malfunction indicator lamp (mil) illuminated with diagnostic trouble codes (dtc's) p0172 and/or p0175.
12/07/04 Electrical and Air Conditioning NHTSA ID: 10010746
TSB ID: 18254

Speed control inoperative or not holding the set speed. oasis. various models including 2005 explorer, sport trac, mountaineer and aviator.
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.
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09/23/04 Electrical and Air Conditioning NHTSA ID: 10009324
TSB ID: 04142

No crank with diagnostic trouble code b1601 and/or b1213. pats security access issues with 4.0l engine.
07/26/04 Electrical and Air Conditioning NHTSA ID: 10008292
TSB ID: 17422

Multiple electrical concerns - fuse 2.17 open. *mj
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.
07/22/04 Electrical and Air Conditioning NHTSA ID: 10008123
TSB ID: 17558

Intermittent air bag warning lamp on, memory seat, and/or adjustable pedal concerns. *mj
07/22/04 Electrical and Air Conditioning NHTSA ID: 10008125
TSB ID: 17561

Delayed crank with no start, diagnostic trouble codes (dtc) u0300/p0606/p2105/p2107, malfunction indicator module (mil) and wrench light on. *mj
06/22/04 Electrical and Air Conditioning NHTSA ID: 10007412
TSB ID: 17640

Poor fit between driver air bag and steering wheel.
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06/22/04 Electrical and Air Conditioning NHTSA ID: 10007426
TSB ID: 17670

Malfunction indicator (dtc) lamp on with diagnostic trouble code (dtc) p2106.
06/17/04 Electrical and Air Conditioning NHTSA ID: 10007389
TSB ID: 17592

An intermittent no start and/or malfunction indicator lamp (mil) on with diagnostic trouble codes (dtc's) p1233, p1234, p1235, p1236, p1237 or p1238.
06/10/04 Electrical and Air Conditioning NHTSA ID: 10007323
TSB ID: 17479

Malfunction indicator lamp (mil) on with ignition coil related diagnostic trouble codes (p035x).
01/21/04 Electrical and Air Conditioning NHTSA ID: 10004952
TSB ID: 17311

Malfunction indicator lamp on and/or electronic throttle control lamp (etc) on with diagnostic trouble code (dtc) p2106.
01/20/04 Electrical and Air Conditioning NHTSA ID: 10004929
TSB ID: 17285

Malfunction indicator lamp/etc lamp lit with p0606 and one or several p21xx-series diagnostic trouble codes at low time in service.
11/18/03 Electrical and Air Conditioning NHTSA ID: 10004079
TSB ID: 17217

Air conditioner hooting noise during light load acceleration at low speeds, from 1000-1300 rpm.
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11/17/03 Electrical and Air Conditioning NHTSA ID: 10004058
TSB ID: 17165

Intermittent diagnostic trouble code (dtc) p2106 with the malfunction indicator lamp (mil) on.
11/14/03 Electrical and Air Conditioning NHTSA ID: 10004027
TSB ID: 03181

Remote keyless entry (rke) - service tips.
03/13/06 Other NHTSA ID: 10019384
TSB ID: 0637

Low tire indicator on - tpms system sensor wake up.
01/25/06 Other NHTSA ID: 10018934
TSB ID: 05252

Neutral tow capability -- service kit requirements.
01/25/06 Other NHTSA ID: 10018938
TSB ID: 052624

Vibration diagnosis - tire/wheel runout.
10/12/05 Other NHTSA ID: 10016832
TSB ID: 05136

Backglass difficult to close and an intermittent door ajar lamp.
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05/05/05 Other NHTSA ID: 10014664
TSB ID: 05416

Front seat(s) slight movement when accelerating and/or decelerating.
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.
12/07/04 Other NHTSA ID: 10010716
TSB ID: 04195

Front window clunk noise.
12/07/04 Other NHTSA ID: 10010730
TSB ID: 18215

Broken rear cargo storage door lift handle. various models including 2005 explorer/mountaineer.
08/25/04 Other NHTSA ID: 10008875
TSB ID: 04B17

Some of the vehicles were built with instrument clusters that were not configured properly for use with a revised tpms module. the tire pressure module system (tpms) is fully functional, but there is no visual indication to a driver if the
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08/04/04 Other NHTSA ID: 10008546
TSB ID: 0485

Liftgate glass applique damaged/cracked. service procedure.
07/26/04 Other NHTSA ID: 10008289
TSB ID: 17411

Tire pressure monitoring system (tpms) module configuration - service tip. *mj
06/22/04 Other NHTSA ID: 10007429
TSB ID: 17680

Rear liftgate rattle / light popping noise.
01/20/04 Other NHTSA ID: 10004920
TSB ID: 17276

A popping or creaking noise that appears to be coming from the front exterior of the vehicle.
10/09/03 Other NHTSA ID: 10003156
TSB ID: 17030

Vehicles with a silver valve stem tire pressure monitor system (tpms) may exhibit a warning light/message on.

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Ford Explorer 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.