2004 Ford Explorer TSBs
108 Explorer Technical Service Bulletins
Technical Service Bulletins, or TSBs for short, are notifications made directly by Ford to help automotive technicians diagnose and repair commonly reported Explorer problems. Interested in how this information is collected? Read more about TSBs.
Recent 2004 Explorer TSBs
STEERING
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Description: INCREASED TURNING EFFORT DURING LOW SPEED SHARP TURNS FALSE 4X4 ENGAGEMENT. *EH
SUSPENSION:FRONT:WHEEL BEARING
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Description: NOISE FROM REAR WHEEL HUB BEARINGS. *TT
SUSPENSION:REAR
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Description: REAR AXLE NOISE REPAIR. *SC
SERVICE BRAKES, HYDRAULIC:ANTILOCK:CONTROL UNIT/MODULE
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Description: ANTI-LOCK BRAKE SYSTEM (ABS) LIGHT ON WITH DIAGNOSTIC TROUBLE CODE (DTC) B2900, U1900 AND C1805. *TT
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Description: ANTI-LOCK BRAKE SYSTEM (ABS) LAMP ILLUMINATED AND DIAGNOSTIC TROUBLE CODE (DTC) C1235, C1236, C1237 ON VEHICLES WITH DIFFERENTIAL-MOUNTED RAR WHEEL SPEED SENSOR. *TT
SERVICE BRAKES, HYDRAULIC:ANTILOCK:ABS WARNING LIGHT
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Description: 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. *TT
SERVICE BRAKES, AIR:ANTILOCK:ABS WARNING LIGHT
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Description: THE AMBER ANTI-LOCK BRAKE SYSTEM (ABS) WARNING LIGHT ON WITH DIAGNOSTIC TROUBLE CODES C1235, C1236/C1237 STORED IN MEMORY. *TT
ENGINE AND ENGINE COOLING
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Description: WDS COP KIT DIAGNOSTIC TIP - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING. *TT
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Description: NO START/HARD START ON COLD SOAK - 4.0L ENGINE. *TT
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Description: NO START/HARD START ON COLD SOAK. *TT
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Description: MIL ON AND/ OR RUNS ROUGH/MISFIRE DTCS P0300-P0308 P0316 AND OR P0171/P0174 4.6L ENGINE. *EH
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Description: THROTTLE PEDAL RESPONSE ON TIP IN VEHICLES BUILT BEFORE 10/4/2004 EQUIPPED WITH A 4.0L ENGINE. *EH
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Description: ROUGH IDLE IN DRIVE. *EH
ENGINE AND ENGINE COOLING:ENGINE
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Description: 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
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Description: MAF DIAGNOSTIC SERVICE TIP - VEHICLES EQUIPPED WITH EGR SYSTEM MODULE (ESM). *TT
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Description: OIL LEAK FROM OIL FILTER ADAPTER - 4.0L SOHC ENGINE BUILT BEFORE 4/1/2004. *TT
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Description: 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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Description: DIAGNOSTIC TROUBLE CODE (DTC) U0300 (INTERNAL CONTROL MODULE SOFTWARE INCOMPATIBILITY) STORED IN THE PCM WITH NO OTHER DTC'S PRESENT. *TT
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Description: INTERMITTENT HARD START, LONG CRANK TIME OR MULTIPLE CRANK ATTEMPTS BEFORE STARTING. *TT
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Description: GENERATOR NOISE IN COLD AMBIENT TEMPERATURES. *MJ
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Description: ENGINE-ROMEO BUILT 4.6L 2V-TICK NOISE FROM ENGINE-ENGINES BUILT BEFORE 9/17/2003. *MJ
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Description: ENGINE AUXILIARY OIL COOLER LINE AND THE RIGHT SIDE MOTOR MOUNT SQUEAKING NOISE FROM FRONT EXTERIOR WHILE DRIVING OVER BUMPS. *TT
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Description: 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. *TT
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL
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Description: DEMONSTRATION/DELIVERY HOLD - SPECIAL FIELD ACTION 03L17. REVISED SMOG EMISSIONS INFORMATION. *TT
FUEL SYSTEM, DIESEL:STORAGE:TANK ASSEMBLY
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Description: FUEL GAUGE SLOW TO UPDATE AFTER REFUELING. *EH
FUEL SYSTEM, OTHER
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Description: MALFUNCTION INDICATOR LAMP COMING ON WITH DIAGNOSTIC TROUBLE CODES (DTCS) P0171, P0172, P0174 AND/OR P0175 (FUEL SYSTEM TOO RICH OR LEAN). *TT
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Description: MULTIPLE VEHICLES - FUEL LEVEL INDICATION CONCERNS - SERVICE TIP. VARIOUS MODELS INCLUDING 2005 SUPER DUTY F-SERIES, EXCURSION, EXPEDITION, EXPLORER, MOUNTAINEER AND AVIATOR. *TT
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Description: DISTANCE TO EMPTY NOT DISPLAYED. *TT
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Description: FUEL SIGNAL TO INSTRUMENT CLUSTER SERVICE TIP. *TT
FUEL SYSTEM, OTHER:STORAGE:FUEL GAUGE SYSTEM
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Description: 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. *TT
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Description: FUEL GAUGE SLOW TO UPDATE. *TT
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Description: MIL ON WITH DTC P0463 OR ERRATIC FUEL GAUGE OPERATION. *KB
POWER TRAIN
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Description: NEUTRAL TOW CAPABILITY - SERVICE KIT REQUIREMENTS. *TT
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Description: DELAYED OR HARSH REVERSE ENGAGEMENTS - 5R55S TRANSMISSION - VEHICLES BUILT PRIOR TO 09/23/2004. *TT
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Description: INCREASED EFFORT DURING LOW SPEED SHARP TURNS ON 4X4 VEHICLES. *TT
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Description: UNINTENDED 4X4 ENGAGEMENT DURING LOW SPEED PARKING LOT TURNS. VARIOUS MODELS INCLUDING THE 2005 EXPLORER AND MOUNTAINEER. *TT
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Description: REAR AXLE NOISE. ALSO INCLUDES LINCOLN AVIATOR 2002. *MJ
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Description: CERTIFIED REAR AXLE AVAILABLE. *MJ
POWER TRAIN:AUTOMATIC TRANSMISSION
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Description: IMPROPERLY FORMULATED TRANSMISSION FLUID THAT, OVER TIME, MAY CAUSE DELAYED/HARSH REVERSE ENGAGEMENTS. CUSTOMER SATISFACTION PROGRAM 04B22. 5R55S/E & 5R44E TRANSMISSION FLUID ADDITIVE. *TT SUPPLEMENT #1. *TT SUPPLEMENT #2. *TT SUPP
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Description: 5R55S TRANSMISSION FLUID LEAKS FROM CONVERTER HOUSING AREA. DIAGNOSTIC TROUBLE CODE P1783 ON VEHICLES BUILT PRIOR TO 12/12/2004. *TT
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Description: DELAYED/HARSH REVERSE ENGAGEMENT. *TT
POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM, PCM)
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Description: GENERAL (PCM) POWER TRAIN CONTROL MODULE PROGRAMMING PROCEDURES. *TT
POWER TRAIN:AUTOMATIC TRANSMISSION:GEAR POSITION INDICATION (PRNDL)
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Description: GEAR SELECTOR LEVER - INCREASED EFFORT TO SHIFT FROM DRIVE TO PARK. *TT
POWER TRAIN:TRANSFER CASE (4-WHEEL DRIVE)
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Description: 4X4 INOPERATIVE AND/OR INDICATORS BLINKING. *TT
POWER TRAIN:DRIVELINE
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Description: DRIVELINE 1ST ORDER VIBRATION/BOOM/DRONE. *TT
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Description: DRIVELINE VIBRATION ON DRONE/BOOM AT HIGHWAY SPEEDS. *TT
POWER TRAIN:AXLE ASSEMBLY
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Description: LIMITED SLIP AXLE CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNING MANEUVERS. *TT
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Description: AXLE SEAL LEAKS. *EH
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Description: REAR AXLE NOISE REPAIR. *TT
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Description: AXLE WHINE HOWL. THIS INCLUDES 1997-05 FORD VEHICLES. *EH
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Description: AXLE WHINE HOWL SERVICE WITH INDIVIDUAL PARTS INSTEAD OF AN AXLE ASSEMBLY. *EH
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Description: REAR AXLE NOISE. OASIS. VARIOUS MODELS INCLUDING 2005 EXPLORER, MOUNTAINEER AND AVIATOR. *TT
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Description: 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
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Description: FRONT AXLE TUBE LEAK. *EH
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Description: MULTIPLE VEHICLES USING FEHP REAR AXLE FLUID. FLUID USAGE CHANGE. *TT
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Description: 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. *TT *MJ
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Description: REAR AXLE CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNS. *TT
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Description: REAR AXLE NOISE. *TT
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Description: REAR 3.55 AXLE NOISE. CERTIFIED REAR AXLE OR IMPROVED GEAR SET AVAILABLE. *TT
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Description: AXLE WHINE AT CRUISE OR DURING ACCELERATION/ DECELERATION. *TT
POWER TRAIN:AXLE ASSEMBLY:AXLE SHAFT
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Description: 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
POWER TRAIN:AXLE ASSEMBLY:AXLE SHAFT:SEAL
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Description: 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
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Description: AXLE SEAL LEAKS. LEAKS FROM REAR HALFSHAFT AXLE SEAL. SERVICE TIPS. *TT
ELECTRICAL SYSTEM
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Description: MALFUNCTION INDICATOR LAMP (MIL) AND ELECTRONIC THROTTLE CONTROL (ETC) LAMPS ON WITH BOTH DIAGNOSTIC TROUBLE CODE (DTC) P2106 AND P2135. *TT
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Description: WRENCH LAMP ON AND NO DIAGNOSTIC TROUBLE CODE (DTC) STORED. *TT
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Description: MIL ON WITH DTC P0191 WITH OR WITHOUT VARIOUS DRIVABILITY SYMPTOMS AND/OR ADDITIONAL DTCS. *TT
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Description: 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. *TT
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Description: WARNING INDICATORS-PARKING AID-REVERSE SENSING SYSTEM (RSS) AND FORWARD SENSING SYSTEM (FSS)-FALSE ACTIVATION OF WARNING TONE-SERVICE TIPS. *MJ UPDATE. *TT
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Description: MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DIAGNOSTIC TROUBLE CODES (DTC'S) P0172 AND/OR P0175. *TT
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Description: MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - SYSTEM LEAN DIAGNOSTIC TROUBLE CODES (DTC'S) - SERVICE TIPS. VARIOUS MODELS INCLUDING 2004 F-SERIES. *TT
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Description: AN INTERMITTENT NO START AND/OR MALFUNCTION INDICATOR LAMP (MIL) ON WITH DIAGNOSTIC TROUBLE CODES (DTC'S) P1233, P1234, P1235, P1236, P1237 OR P1238. *TT
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Description: MALFUNCTION INDICATOR (DTC) LAMP ON WITH DIAGNOSTIC TROUBLE CODE (DTC) P2106. *TT
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Description: INTERMITTENT AIR BAG WARNING LAMP ON, MEMORY SEAT, AND/OR ADJUSTABLE PEDAL CONCERNS. *MJ
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Description: DELAYED CRANK WITH NO START, DIAGNOSTIC TROUBLE CODES (DTC) U0300/P0606/P2105/P2107, MALFUNCTION INDICATOR MODULE (MIL) AND WRENCH LIGHT ON. *MJ
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Description: NO CRANK WITH DIAGNOSTIC TROUBLE CODE B1601 AND/OR B1213. PATS SECURITY ACCESS ISSUES WITH 4.0L ENGINE. *TT
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Description: MALFUNCTION INDICATOR LAMP (MIL) ON WITH IGNITION COIL RELATED DIAGNOSTIC TROUBLE CODES (P035X). *TT
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Description: MULTIPLE ELECTRICAL CONCERNS - FUSE 2.17 OPEN. *MJ
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Description: MALFUNCTION INDICATOR LAMP ON AND/OR ELECTRONIC THROTTLE CONTROL LAMP (ETC) ON WITH DIAGNOSTIC TROUBLE CODE (DTC) P2106. *TT
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Description: MALFUNCTION INDICATOR LAMP/ETC LAMP LIT WITH P0606 AND ONE OR SEVERAL P21XX-SERIES DIAGNOSTIC TROUBLE CODES AT LOW TIME IN SERVICE. *TT
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Description: REMOTE KEYLESS ENTRY (RKE) - SERVICE TIPS. *TT
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Description: INTERMITTENT DIAGNOSTIC TROUBLE CODE (DTC) P2106 WITH THE MALFUNCTION INDICATOR LAMP (MIL) ON. *TT
ELECTRICAL SYSTEM:STARTER ASSEMBLY
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Description: NO CRANK/NO START CONDITION WHEN VEHICLE TEMPERATURE IS BELOW FREEZING (32F/0C). *TT
DIGITAL INSTRUMENT PANEL
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Description: MIL ON WITH P0463 OR ERRATIC FUEL GAUGE OPERATION. *KB
VISIBILITY
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Description: FRONT WINDOW CLUNK NOISE. *TT
VISIBILITY:GLASS, SIDE/REAR
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Description: BACKGLASS DIFFICULT TO CLOSE AND AN INTERMITTENT DOOR AJAR LAMP. *TT
VISIBILITY:POWER WINDOW DEVICES AND CONTROLS
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Description: REAR POWER WINDOW(S) INOPERATIVE. *TT
VISIBILITY:DEFROSTER/DEFOGGER SYSTEM:WINDSHIELD:CONTROLS/WIRING
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Description: REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR. *TT
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Description: INOPERATIVE ELECTRIC REAR WINDOW DEFROSTER (HEATED BACKLITE) GRID LINES, INTEGRAL ANTENNA CONCERNS. *TT
VISIBILITY:DEFROSTER/DEFOGGER SYSTEM:REAR WINDOW
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Description: REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR. *TT
AIR BAGS:FRONTAL
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Description: POOR FIT BETWEEN DRIVER AIR BAG AND STEERING WHEEL. *TT
SEAT BELTS:FRONT:RETRACTOR
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Description: SAFETY BELT RETRACTION SPEED. *TT
STRUCTURE:BODY
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Description: LIFTGATE GLASS APPLIQUE DAMAGED/CRACKED. SERVICE PROCEDURE. *TT
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Description: ALUMINUM CORROSION - SERVICE TIP. *TT
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Description: A POPPING OR CREAKING NOISE THAT APPEARS TO BE COMING FROM THE FRONT EXTERIOR OF THE VEHICLE. *TT
STRUCTURE:BODY:DOOR
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Description: BROKEN REAR CARGO STORAGE DOOR LIFT HANDLE. VARIOUS MODELS INCLUDING 2005 EXPLORER/MOUNTAINEER. *TT
STRUCTURE:BODY:HATCHBACK/LIFTGATE
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Description: REAR LIFTGATE RATTLE / LIGHT POPPING NOISE. *TT
VEHICLE SPEED CONTROL
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Description: SPEED CONTROL INOPERATIVE OR NOT HOLDING THE SET SPEED. OASIS. VARIOUS MODELS INCLUDING 2005 EXPLORER, SPORT TRAC, MOUNTAINEER AND AVIATOR. *TT
TIRES
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Description: LOW TIRE INDICATOR ON - TPMS SYSTEM SENSOR WAKE UP. *TT
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Description: VIBRATION DIAGNOSIS - TIRE/WHEEL RUNOUT. *TT
TIRES:PRESSURE MONITORING AND REGULATING SYSTEMS
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Description: 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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Description: TIRE PRESSURE MONITORING SYSTEM (TPMS) MODULE CONFIGURATION - SERVICE TIP. *MJ
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Description: VEHICLES WITH A SILVER VALVE STEM TIRE PRESSURE MONITOR SYSTEM (TPMS) MAY EXHIBIT A WARNING LIGHT/MESSAGE ON. *TT
WHEELS
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Description: VIBRATION DIAGNOSIS - TIRE/WHEEL RUNOUT. *TT
TRAILER HITCHES
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Description: NEUTRAL TOW CAPABILITY -- SERVICE KIT REQUIREMENTS. *TT
SEATS
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Description: FRONT SEAT(S) SLIGHT MOVEMENT WHEN ACCELERATING AND/OR DECELERATING. *TT
COMMUNICATIONS:BACK UP ALARM
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Description: FALSE PARKING AID WARNINGS. *TT
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Description: FALSE PARKING AID WARNINGS. *TT UPDATE. *TT
EQUIPMENT:ELECTRICAL:AIR CONDITIONER
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Description: AIR CONDITIONER HOOTING NOISE DURING LIGHT LOAD ACCELERATION AT LOW SPEEDS, FROM 1000-1300 RPM. *TT