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2002 Ford E-Series van Technical Service Bulletins (TSBs)

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TSB Date Problem Area TSB Text
01/20/12 NHTSA ID: 10042864
TSB ID: TSB-11-11-21

Ford: the blower motor on some vehicles are operating either incorrectly or not operating or just functioning on one speed.
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.
02/10/06 NHTSA ID: 10019075
TSB ID: 19015

Fuel conditioner. low power, poor fuel economy, fuel gelling in cold weather, excessive white smoke on cold start, hard start, or coking of components exposed to exhaust.
01/25/06 NHTSA ID: 10018941
TSB ID: 05248

Vibration/harshness above 45 mph (72 km/h) after tire balance.
01/12/06 NHTSA ID: 10018741
TSB ID: 05173

Malfunction indicator lamp on with diagnostic trouble code p1131 and/or p1151 - 4.2l engine.
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.
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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.
04/18/05 NHTSA ID: 10013403
TSB ID: 04228

Hard start or no start. *eh
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.
08/05/04 NHTSA ID: 10008580
TSB ID: 02176

Lamp-brake-invadvertent disabling of brake shift interlock. *mj
08/04/04 NHTSA ID: 10008552
TSB ID: 17777

Rear leaf spring noise.
07/28/04 NHTSA ID: 10008334
TSB ID: 16403

Engine-light tick or rattle type noise from engine after cold start. *mj
07/28/04 NHTSA ID: 10008337
TSB ID: 16407

Water pump pulley bolts loose. *mj
07/27/04 NHTSA ID: 10008304
TSB ID: 02221

Engine-gear driven synchronizers-incorrect installation-camshaft position synchronizer (cmp) installation tool correct application. *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
07/26/04 NHTSA ID: 10008288
TSB ID: 17406

Low power, poor fuel economy, fuel gelling cold, excessive white smoke cold, or hard start. *mj this oasis updates previous oasis dated 12/01/03.
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07/22/04 NHTSA ID: 10008169
TSB ID: 17320

Broken exhaust manifold studs.
07/22/04 NHTSA ID: 10008193
TSB ID: 17381

Front brake pad wear.
07/12/04 NHTSA ID: 10007812
TSB ID: 04E10

Emission recall 04e10: compressed natural gas (cng) vehicles - fitting connector replacement. *mj
06/14/04 NHTSA ID: 10007350
TSB ID: 17520

Clunk from front suspension.
06/10/04 NHTSA ID: 10007319
TSB ID: 17467

Engine or fuel system concerns when using fuel with greater than 5% biodiesel concentration.
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
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01/29/04 NHTSA ID: 10005089
TSB ID: 16515

Oil leak at high pressure pump fittings and/or plug. this includes super duty f-series. oasis.
01/20/04 NHTSA ID: 10004913
TSB ID: 17259

Rough idle and/or misfire with diagnostic trouble code p0316 after an overnight soak in extreme cold and high humidity conditions.
01/14/04 NHTSA ID: 10004908
TSB ID: 17254

Clicking/popping noise from upper steering column area when turning. 2004 e series and explorer sport trac also included.
01/14/04 NHTSA ID: 10004889
TSB ID: 03206

Some dedicated cng vehicles may exhibit various driveability conditions due to a loss of injector performance, resulting from fuel quality. loss of power at heavy load, diagnostic trouble codes (dtcs) for lean fuel, rough idle, hard start,
01/13/04 NHTSA ID: 10004882
TSB ID: 16589

Gradual loss of power at cruise. ford special service message. various models including 2003 super duty f series.
01/12/04 NHTSA ID: 10004856
TSB ID: 032145

External oil leak diagnosis for 7.3l dit engines. various models including 2003 super duty f series.
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01/12/04 NHTSA ID: 10004857
TSB ID: 032146

Engine oil pan corrosion on vehicles equipped with the 7.3l diesel engine. various models including 2003 super duty f series.
01/12/04 NHTSA ID: 10004861
TSB ID: 032150

High pressure oil pump leak on vehicles equipped with 7.3l diesel engine.
01/12/04 NHTSA ID: 10004862
TSB ID: 032151

Some 7.3l diesel turbocharger pedestals may leak oil around the exhaust back pressure actuator (ebp). this article supersedes tsb 03-21-51 dated 10/30/2003.
11/17/03 NHTSA ID: 10004045
TSB ID: 17104

Ticking/tapping noise with the engine warmed up and the transmission in gear at idle. 2003 e150 included.
11/17/03 NHTSA ID: 10004072
TSB ID: 17211

A bump steer steering feeling, noted when the vehicle's front wheels/tires contact road surface irregularities.
11/14/03 NHTSA ID: 10004032
TSB ID: 03192

Leak oil around the exhaust backpressure actuator (ebp) - 7.3l diesel turbocharger pedestals.
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11/14/03 NHTSA ID: 10004023
TSB ID: 03171

7.3l diesel high pressure oil pump leak.
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.
10/29/03 NHTSA ID: 10003750
TSB ID: 031410

Turbo pedestal seal oil leak around the exhaust back pressure (ebp) actuator. 2003 super duty f series included.
10/09/03 NHTSA ID: 10003178
TSB ID: 17079

Water pump pulley bolts loosening.
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: 10002783
TSB ID: 03911

Rough idle and/or hesitation when acclerating on certain super duty vehicles equipped with a 5.4l or 6.8l engine.
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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.
09/04/03 NHTSA ID: 10002517
TSB ID: 030402

On some dedicated cng vehicles, a possible fuel leak may occur at the fuel fill valve. revised service parts.
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
07/24/03 NHTSA ID: 10001895
TSB ID: 0342

Possible fuel leak may occur at the fuel fill valve, on some dedicated cng vehicles. *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
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03/25/03 NHTSA ID: 10000592
TSB ID: 870197

Incorrectly installed gear driven camshaft position (cmp) sensor synchronizer assemblies causing surge, lost of power, malfunction indicator lamp on and diagnostic trouble codes p1336, p1309 and p0340.
12/06/02 NHTSA ID: 637767
TSB ID: 15890

Subject regarding early wear of the inner brake pad on the rear disc brakes.
12/06/02 NHTSA ID: 637826
TSB ID: 15923

Exhibiting a steering wheel vibration / shimmy.
11/08/02 NHTSA ID: 636408
TSB ID: 15761

Some dedicated cng vehicles may exhibit driveability conditions of hard start / no start / rough running.
11/08/02 NHTSA ID: 636417
TSB ID: 020503

Guidance for cng tank inspection for vehicles produced after december 2, 1996. update.
11/07/02 NHTSA ID: 636252
TSB ID: 16055

Some vehicles equipped with a 5.4l engine / 4r100 transmission federal emissions powertrain may exhibit a rough idle and / or hesitation when accelerating.
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11/06/02 NHTSA ID: 636235
TSB ID: 16040

Experiencing a clicking / popping noise from the upper steering column area when turning the steering wheel.
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: 635974
TSB ID: 02168

Reports that certain vehicles appear to be dogtracking.
11/04/02 NHTSA ID: 636042
TSB ID: 0253

Subject regarding alternative fuel vehicle compressed natural gas tank inspection.
04/19/02 NHTSA ID: 630674
TSB ID: 15626

Concerns with intermittent rough idle on initial start up.
04/19/02 NHTSA ID: 630683
TSB ID: 15634

Concerns with bump steer steering feeling noted when front wheels / tires contact road surface irregularities.
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04/18/02 NHTSA ID: 630515
TSB ID: 01246

Engine oil system priming procedures, service tips for reports of premature engine failure.
04/17/02 NHTSA ID: 630412
TSB ID: 15397

Some vehicles may exhibit a condition of oil contamination in cooling system.
04/17/02 NHTSA ID: 630414
TSB ID: 15398

Some vehicles may exhibit a coolant leak due to a broken radiator hose clamp.
04/15/02 NHTSA ID: 630152
TSB ID: 15593

Some vehicles built between 11/29/01 and 11/30/01 may exhibit a serpentine belt squeal.
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.
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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: 625804
TSB ID: 15271

Dedicated cng regulator bowl kit available. *jg
10/22/01 NHTSA ID: 622744
TSB ID: 14963

Some cut-away vehicles may exhibit anti-skid brake system diagnostic trouble code c1229, c1230 and c1237.
04/16/02 Engine NHTSA ID: 630338
TSB ID: 01234

Some vehicles equipped with aftermarket high-current devices may exhibit diagnostic trouble codes b1876, b1880, b1915 and/or b1920 airbag electronic crash sensor module.
04/15/02 Engine NHTSA ID: 630273
TSB ID: 15355

Some vehicles equipped with 7.3l di engine may exhibit false diagnostic trouble codes p1105, p1106 (upper and lower alternator faults).
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
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12/03/01 Engine NHTSA ID: 625800
TSB ID: 15255

Concerns with diagnostic trouble codes p1516, p1518, p1519, and p1520.
10/17/08 Transmission and Drivetrain NHTSA ID: 10026321
TSB ID: CSP-48B01

Ford: vehicles mistakenly charged $100 powertrain warranty deductible for fuel injector repair or repairs. no model or model years provided. econoline, excursion and f-series super duty vehicles, model years 2002-2005. updated
04/29/05 Transmission and Drivetrain NHTSA ID: 10014275
TSB ID: 04266

A driveline clunk or bump when starting from a stop.
04/28/05 Transmission and Drivetrain NHTSA ID: 10014086
TSB ID: 042107

General (pcm) power train control module programming procedures.
04/14/05 Transmission and Drivetrain NHTSA ID: 10013316
TSB ID: 18376

A cold weather reverse engagement stall.
12/07/04 Transmission and Drivetrain NHTSA ID: 10010743
TSB ID: 18250

Intermittent clunk on 3-2 downshift during coastdown/tip-in. oasis. to include 2005 f-150, e-series and expedition.
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09/23/04 Transmission and Drivetrain NHTSA ID: 10009332
TSB ID: 17905

Multiple vehicles using fehp rear axle fluid. fluid usage change.
07/26/04 Transmission and Drivetrain NHTSA ID: 10008279
TSB ID: 03261

New service part - number 5 needle bearing and race kit - 4r70w transmission - service tip.
01/12/04 Transmission and Drivetrain NHTSA ID: 10004859
TSB ID: 032148

Some 7.3l dit vehicles may exhibit the occurrence of p0340 camshaft position sensor false diagnostic trouble code (dtc). others may exhibit a late 4r100 3-4 shift (hanging in 3rd gear) at light throttle due to potential lack of converter l
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.
12/02/02 Transmission and Drivetrain NHTSA ID: 637519
TSB ID: 15799

Some vehicles equipped with 4r70w transmission (driveshaft >70 inch) may exhibit a vibration / roughness on acceleration or under load at about 50-55 mph.
11/07/02 Transmission and Drivetrain NHTSA ID: 636320
TSB ID: 15686

Concerns of diagnostic trouble code p1280 retrived fromthe power train control module (pcm).
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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.
09/23/02 Transmission and Drivetrain NHTSA ID: 633564
TSB ID: 02E20

Subject regarding demonstration/ delivery hold: powertrain control module reprogramming. *jg
11/30/01 Transmission and Drivetrain NHTSA ID: 625715
TSB ID: 01181

Brake shift interlock.*jb
10/23/01 Transmission and Drivetrain NHTSA ID: 622802
TSB ID: 14992

Some vehicles equipped with 4r70w transmission (driveshaft >70 inch) may exhibit a driveline vibration / roughness on acceleration or under load at about 50 - 55 mph.
07/23/07 Electrical and Air Conditioning NHTSA ID: 10022232
TSB ID: 19527

Headlight adjustment needed.
12/05/05 Electrical and Air Conditioning NHTSA ID: 10017865
TSB ID: 18735

Headlight adjustment - chassis cab incomplete vehicles.
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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.
04/07/05 Electrical and Air Conditioning NHTSA ID: 10013078
TSB ID: 16309

High side pressure fluctuations on vehicles equipped with a fixed scroll a/c compressor.
04/04/05 Electrical and Air Conditioning NHTSA ID: 10012941
TSB ID: 032306

Diagnostic trouble code b1876, b1880, b1915 and/or b1920 in the ecs module - vehicles equipped with aftermarket high current devices.
07/22/04 Electrical and Air Conditioning NHTSA ID: 10008155
TSB ID: 03236

Diagnostic trouble codes (dtc) b1876, b1880, b1915 and/or b1920 airbag electronic crash sensor (ecs) module on vehicles equipped with aftermarket high current devices.
07/22/04 Electrical and Air Conditioning NHTSA ID: 10008195
TSB ID: 17385

Air bag lamp illuminated.
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.
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01/13/04 Electrical and Air Conditioning NHTSA ID: 10004879
TSB ID: 16258

Vehicles equipped with a 7.3l engine (after serial number 0661894) - under valve cover (uvc) harness retainer clip released for service. includes 2003 econoline, super duty, f650/750 and excursion.
01/13/04 Electrical and Air Conditioning NHTSA ID: 10004880
TSB ID: 16480

Diagnostic trouble code (dtc) p0340, possible false code. various models including 1994-1996 ford excursion.
11/14/03 Electrical and Air Conditioning NHTSA ID: 10004029
TSB ID: 03183

Dedicated compressed natural gas (cng) rough idle or no start when cold vehicles equipped with dedicated 4.6l or 5.4l cng engine only.
11/14/03 Electrical and Air Conditioning NHTSA ID: 10004027
TSB ID: 03181

Remote keyless entry (rke) - service tips.
09/16/03 Electrical and Air Conditioning NHTSA ID: 10002754
TSB ID: 16818

Throttle control splash shield installation requirements.
09/10/03 Electrical and Air Conditioning NHTSA ID: 10002660
TSB ID: 16776

Servicing multifunction switch wiring interference.
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09/08/03 Electrical and Air Conditioning NHTSA ID: 10002627
TSB ID: 16916

Repeated blown fuses for rear in vehicle circuits with inoperative rear brake or tail lamps.
07/28/03 Electrical and Air Conditioning NHTSA ID: 10001943
TSB ID: 16697

Exhaust air rush noise and lower power. *jb
12/06/02 Electrical and Air Conditioning NHTSA ID: 637807
TSB ID: 15912

Subject regarding family or rear seat entertainment system handle concerns.
12/04/02 Electrical and Air Conditioning NHTSA ID: 637689
TSB ID: 15871

Some vehicles may exhibit interference and / or static in the land-mobile radio.
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: 630665
TSB ID: 15621

Some vehicles with the rear seat entertainment system may exhibit an inoperative condition.
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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
03/27/17 Other NHTSA ID: 10096433
TSB ID: TSB T2007-03

Merlin multiplex system when a proer/ground lug is not correctly tightened or becomes loose for any reason; erratic system operation is possible.
04/28/05 Other NHTSA ID: 10014138
TSB ID: 042421

Safety belt retraction speed.
04/14/05 Other NHTSA ID: 10013298
TSB ID: 0511

Cracks in the left or right spring tower flange. spring tower weld repair and replacement procedure.
08/05/04 Other NHTSA ID: 10008578
TSB ID: 02174

Body-waterleak-cowl to dash washleak-water accumulation and/or leak at the driver's floor pan area. *mj
08/04/04 Other NHTSA ID: 10008545
TSB ID: 0484

Chassis component torque update for e-coated frames.
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01/13/04 Other NHTSA ID: 10004884
TSB ID: 17023

No turbine shaft speed (tss) displayed using ngs or wds.
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).
11/06/02 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,
11/06/02 Other NHTSA ID: 636237
TSB ID: 16041

Some vehicles may exhibit a malfunction indicator lamp on with either p0171 - p0174 or p0172 - p0175 codes with reduced performance and poor fuel economy.
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).
09/24/02 Other NHTSA ID: 633750
TSB ID: 02L09

Subject regarding incorrect vehicle emission information label installed . *jg
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09/23/02 Other NHTSA ID: 633525
TSB ID: 02T49

Subject regarding service engine soon (ses) lamp illuminated with diagnostic trouble code (dtc) p1441 set in pcm history (install new pcm calibration) *jg
09/23/02 Other NHTSA ID: 633577
TSB ID: 02L09

Incorrect vehicle emission control information label installed. *jg
04/19/02 Other NHTSA ID: 630647
TSB ID: 15597

Concerns with malfunction indicator lamp illuminated with p0171 - p0174 or p0172 - p0175 codes with reduced performance and poor fuel economy.
04/16/02 Other NHTSA ID: 630354
TSB ID: 15373

Some vehicles may run rough at cruise or momentarily after stopping, a check engine light,and p030x codes.
11/30/01 Other NHTSA ID: 625663
TSB ID: 01T04

Information regarding imrc set screw warranty repair.*jb
11/01/01 Other NHTSA ID: 624140
TSB ID: 15110

Information regarding rear entertainment system lock down screws. *slc
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10/31/01 Other NHTSA ID: 623988
TSB ID: 01157

Information regarding transmission fluid usage charts. *slc

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Ford E-Series van 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.