2002 FORD EXPEDITION Recalls (4)

Campaign:
03V094000 on 03/17/2003
Component:
Structure
Manufactured:
07/31/2000 - 03/02/2003
Affected:
3,674
Defect:
Certain pickup truck, van, and mini van conversions equipped with southern comfort built running boards that contain certain courtesy lights manufactured by american technology components, inc. these units contain a courtesy light or lights that might overheat when the wire harness is exposed to excessive moisture and road salt.
Consequence:
This overheating condition can cause the running board to melt or cause a fire.
Correction:
Dealers will replace the wiring harness on these running boards. owner notification began march 7, 2003. owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact southern comfort at 1-800-745-6096.
Notes:
Customers can also contact the national highway traffic safety administration's auto safety hotline at 1-888-dash-2-dot (1-888-327-4236).
Campaign:
05V388000 on 09/06/2005
Component:
Vehicle speed control
Affected:
4,500,000
Defect:
On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn.
Consequence:
A fire at the switch could occur.
Correction:
By letter dated september 12, 2005, owners were instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. owners who have had their speed control deactivated are being notified that parts will be available and advised to make an appointment to reconnect the speed control beginning in february 2006. owners who did not have their speed control deactivated are being notified to have their system remedied beginning in february 2006. owners are urged to avail themselves of the free disconnect service as soon as possible because of the significant risk of fire. owners may contact ford at 1-800-392-3673. (note: also see recalls 05v017 and 06v286)
Notes:
Ford recall no. 05s28.customers may also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to http://www.safercar.gov.
Campaign:
06E056000 on 06/22/2006
Component:
Fuel system, gasoline
Affected:
58,640
Defect:
Certain aftermarket fuel filters sold under the purolator brand name, p/n f65277, shipped from january 16 through june 2, 2006, for use on the above listed passenger vehicles. due to incorrect design, the quick connectors may not fully seat with the tube interface, even though the person making the connection may believe that the quick connector is fully attached.
Consequence:
Failure of this connection could lead to fuel spillage and, in the presence of an ignition source, a fire could occur.
Correction:
Ufi will notify owners and replace the filters free of charge. the recall began on august 4, 2006. owners may contact ufi filters usa at 800-230-5876.
Notes:
This recall only pertains to ufi filters usa (purolator) aftermarket fuel filters and has no relation to any original equipment installed on the listed passenger vehicles.customers may contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty: 1-800-424-9153); or go to http://www.safercar.gov.
Campaign:
06E067000 on 07/31/2006
Component:
Exterior lighting:headlights
Affected:
19,413
Defect:
Certain maxzone headlight assemblies, depo brand, p/nos. 331-1129l-asn and 331-1129r-asn, sold for use as aftermarket equipment for the above listed passenger vehicles. these headlamps fail to conform to the photometric requirements of federal motor vehicle safety standard no. 108, lamps, reflective devices, and associated equipment.
Consequence:
Decreased lighting visibility may result in a vehicle crash.
Correction:
Maxzone will notify owners and offer reimbursement for any noncompliant headlights. the recall began on july 28, 2006. owners may contact maxzone at 909-822-3288.
Notes:
This recall only pertains to aftermarket replacement equipment and has no relation to any original equipment installed on vehicles manufactured by ford motor company.customers may contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty: 1-800-424-9153); or go to http://www.safercar.gov.

2002 FORD EXPEDITION TSBs (101)

Bulletin:
15094
Component:
075000 fuel system, gasoline:carburetor system
Summary:
Information regarding intake manifold valley stuffers. *tt
Bulletin:
01156
Component:
138120 visibility:defroster/defogger system:windshield:heater core
Summary:
Some vehicles may exhibit heater core leaks. *slc
Bulletin:
01157
Component:
980000 unknown or other
Summary:
Information regarding transmission fluid usage charts. *slc
Bulletin:
15122
Component:
161000 structure:frame and members
Summary:
Some vehicles may exhibit a vibration at idle and/or engine droaning noise on acceleration from a stop. *slc
Bulletin:
15123
Component:
105000 power train:driveline
Summary:
Some vehicles may exhibit a driveline vibration at speeds between 60-70 mph. *slc
Bulletin:
15137
Component:
160000 structure
Summary:
Customers may complain of wind noise. *yd
Bulletin:
01181
Component:
103800 power train:automatic transmission:park/neutral start switch
Summary:
Brake shift interlock.*jb
Bulletin:
15259
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Concerns with the lower power in high ambient temepratures. *tt
Bulletin:
01215
Component:
180000 vehicle speed control
Summary:
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. *tt
Bulletin:
012113
Component:
116100 electrical system:ignition:switch
Summary:
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
Bulletin:
01205
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Some vehicles may exhibit vacuum or air leaks in the intake manifold and / or engine system causing diagnostic trouble codes p0171 and or p0174. *tt
Bulletin:
0212
Component:
341000 communications:horn assembly
Summary:
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. *tt
Bulletin:
0214
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
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. *tt
Bulletin:
15504
Component:
980000 unknown or other
Summary:
Some vehicles may exhibit driveabilty conditions and/or check engine lamp illuminated with a diagnostic trouble code p0455 (gross leak detected). *tt
Bulletin:
15517
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Subject regarding exaggerated engine braking on deceleration. *yd
Bulletin:
15528
Component:
021230 suspension:front:springs:air suspension system
Summary:
Subject regarding air suspension compressor quality. *yd
Bulletin:
15549
Component:
133000 visibility:power window devices and controls
Summary:
Information regarding pop/thump noise from power window. *yh
Bulletin:
15326
Component:
021000 suspension:front
Summary:
Some vehicles may exhibit a pop/clunk/click noise from the front suspension when making low speed turns in either forward or reverse. *tt
Bulletin:
15433
Component:
116200 electrical system:ignition:module
Summary:
Some vehicles built after 4/10/2001 and equipped with air suspension , may exhibit an electronic variable orifice (evo) steering diagnostic trouble code c1917. *tt
Bulletin:
15377
Component:
106000 power train:axle assembly
Summary:
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. *tt
Bulletin:
15395
Component:
341000 communications:horn assembly
Summary:
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. *tt
Bulletin:
15407
Component:
021000 suspension:front
Summary:
Concerns with a pop/clunk/click noise coming from the front suspension when making low-speed turns in forward or reverse gears. *tt
Bulletin:
15431
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Exhibiting lack of power condition when vehicle is operated in ambient temperatures. *tt
Bulletin:
15432
Component:
116200 electrical system:ignition:module
Summary:
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. *tt
Bulletin:
01246
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Engine oil system priming procedures, service tips for reports of premature engine failure. *tt
Bulletin:
15480
Component:
072100 fuel system, gasoline:delivery:fuel pump
Summary:
Some vehicles may exhibit a slow fuel fill condition and/or premature shutoff of the gas pump when the vehicle is being re-fueled. *tt
Bulletin:
15502
Component:
021000 suspension:front
Summary:
Concerns with pop/clunk/click noise from the front suspension when making low-speed turns in forward or reverse gears. *tt
Bulletin:
15605
Component:
980000 unknown or other
Summary:
Some vehicles may exhibit driveability conditions and / or check engine lamp illuminated with a diagnostic trouble p0455 (gross leak detected). *tt
Bulletin:
15630
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Concerns with vehicles with a 5.4l 2v engine exhibitingng a lack of power condition. *tt
Bulletin:
15648
Component:
070000 fuel system, gasoline
Summary:
Some vehicles may exhibit a slow fuel fill condition and/or premature shutoff of the gas pump when the vehicle is being refueled. *tt
Bulletin:
15651
Component:
021230 suspension:front:springs:air suspension system
Summary:
Some vehicles equipped with air suspension may exhibit an air leak and/or overnight bleed down of the air suspension. *tt
Bulletin:
15652
Component:
353600 equipment:air conditioner
Summary:
Concerns with climate control system air discharged through the defroster ducts only, regardless of setting. *tt
Bulletin:
0256
Component:
980000 unknown or other
Summary:
This bulletin involves proper procedures for preparation of service sheet metal parts coated with electro deposition primer (e-coat). *tt
Bulletin:
0258
Component:
100000 power train
Summary:
Inoperative or inacurrate speedometer, 4x4 lamp illuminatd, and / or diagnostic trouble code p1635 or p1639. *tt
Bulletin:
0241
Component:
017300 steering:linkages:arm:idler and attachment
Summary:
Subject regarding idler arm replacement specifications. *tt
Bulletin:
0245
Component:
111000 electrical system:battery
Summary:
Information regarding discharged battery charging service tips and guidelines. *tt
Bulletin:
02108
Component:
061100 engine and engine cooling:engine:gasoline
Summary:
Some vehicles equipped with the 5.4l 2v engine may exhibit a whistling noise fromthe formed nylon tube inthe idle-air bypass flow circuit. *tt
Bulletin:
16170
Component:
980000 unknown or other
Summary:
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,
Bulletin:
16015
Component:
021230 suspension:front:springs:air suspension system
Summary:
Some vehicles with air suspension may exhibit an initial or repeat compressor dryer failure. *tt
Bulletin:
16033
Component:
103400 power train:automatic transmission:lever and linkage:column shift
Summary:
Some vehicles with electronic shift-on-the fly may exhibit an inadvertent 4x4 low engagement while driving. *tt
Bulletin:
16087
Component:
980000 unknown or other
Summary:
Some vehicles may exhibit a flashing transmission control indicator lamp (tcil) and diagnostic trouble codes p0740, p0741, p0743, and p1744 (torque converter clutch). *tt
Bulletin:
15692
Component:
020000 suspension
Summary:
Some vehicles may exhibit a squeak, snap, rattle, or clunk in the front end when turning or going over bumps. *tt
Bulletin:
15708
Component:
200000 wheels
Summary:
Some vehicles may exhibit wheels that seize to the hubs and are difficult to remove during service. *tt
Bulletin:
15727
Component:
190000 tires
Summary:
Some 4x2 vehicles equipped with p275/60/r17 continental general tires may exhibit a highway speed tire vibration. *tt
Bulletin:
15749
Component:
103000 power train:automatic transmission
Summary:
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. *tt
Bulletin:
15794
Component:
190000 tires
Summary:
Some 4x2 vehicles equipped with p275/60/r17 continental-general tires may exhibit a highway speed tire vibration. *tt
Bulletin:
15897
Component:
105500 power train:driveline:differential unit
Summary:
Subject regarding driveline angle-related vibration at various speeds and load conditions. *tt
Bulletin:
15939
Component:
162000 structure:body
Summary:
Concerns with speed body boom. *tt
Bulletin:
02121
Component:
353600 equipment:air conditioner
Summary:
White flakes coming from the air conditioner vents when the blower motor is engaged. *tt
Bulletin:
0361
Component:
060000 engine and engine cooling
Summary:
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. *tt *jb
Bulletin:
03610
Component:
017500 steering:linkages:tie rod assembly
Summary:
Tie rod end inspection procedure. canada vehicles only. *tt *jb
Bulletin:
16683
Component:
061000 engine and engine cooling:engine
Summary:
False failure of the vapor management valve (vmv). *tt *jb
Bulletin:
0322
Component:
061000 engine and engine cooling:engine
Summary:
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
Bulletin:
16797
Component:
110000 electrical system
Summary:
Vehicles with keyless entry pad may exhibit dead battery, no start, interior lamp/headlamp self-activation, or inoperative keyless entry pad. *tt
Bulletin:
030709
Component:
020000 suspension
Summary:
Repeat air suspension compressor drier failures. *tt
Bulletin:
0392
Component:
021230 suspension:front:springs:air suspension system
Summary:
Repeat air suspension compressor drier failures. *tt
Bulletin:
0398
Component:
090000 fuel system, other
Summary:
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. *tt
Bulletin:
0399
Component:
010000 steering
Summary:
Tie rod end inspection procedure. *tt
Bulletin:
03164
Component:
061000 engine and engine cooling:engine
Summary:
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. *tt
Bulletin:
031513
Component:
017500 steering:linkages:tie rod assembly
Summary:
Tie rod end inspection procedure. *tt
Bulletin:
03144
Component:
061000 engine and engine cooling:engine
Summary:
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
Bulletin:
03148
Component:
103600 power train:automatic transmission:cooling unit and lines
Summary:
New transmission cooler flusher - service tips. 2003 escort and super duty f series included. *tt
Bulletin:
03181
Component:
110000 electrical system
Summary:
Remote keyless entry (rke) - service tips. *tt
Bulletin:
02M01
Component:
063130 engine and engine cooling:exhaust system:emission control:gas recirculation valve (egr valve)
Summary:
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. *tt supplement #3. *mj supplement #6
Bulletin:
17459
Component:
330000 interior lighting
Summary:
Courtesy rail lamps do not operate correctly or cause a battery draw. *tt
Bulletin:
03223
Component:
110000 electrical system
Summary:
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. *tt
Bulletin:
99263
Component:
203000 wheels:lugs/nuts/bolts
Summary:
Correct lug nut torque specifications - increase wheel nut and stud size - service tip. *tt
Bulletin:
17316
Component:
090000 fuel system, other
Summary:
Fuel signal to instrument cluster service tip. *tt
Bulletin:
17320
Component:
063200 engine and engine cooling:exhaust system:manifold/header/muffler/tail pipe
Summary:
Broken exhaust manifold studs. *tt
Bulletin:
17346
Component:
017300 steering:linkages:arm:idler and attachment
Summary:
Steering idler arm noise. *tt
Bulletin:
0471
Component:
110000 electrical system
Summary:
Warning indicators-parking aid-reverse sensing system (rss) and forward sensing system (fss)-false activation of warning tone-service tips. *mj update. *tt
Bulletin:
17720
Component:
110000 electrical system
Summary:
Airbag warning lamp on with diagnostic trouble code (dtc) b1994/b1998 on vehicles without side air bags. *tt
Bulletin:
04111
Component:
110000 electrical system
Summary:
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.
Bulletin:
03256
Component:
061000 engine and engine cooling:engine
Summary:
Engine-romeo built 4.6l 2v-tick noise from engine-engines built before 9/17/2003. *mj
Bulletin:
02227
Component:
061000 engine and engine cooling:engine
Summary:
Engine-cylinder head deck leak-4.6 and 5.4l engines-new service-only gasket and cylinder head kits availability. *mj
Bulletin:
16400
Component:
106000 power train:axle assembly
Summary:
Rear axle seal leak - contact request. *mj
Bulletin:
16403
Component:
061000 engine and engine cooling:engine
Summary:
Engine-light tick or rattle type noise from engine after cold start. *mj
Bulletin:
0454
Component:
022130 suspension:rear:springs:air suspension system
Summary:
Air suspension compressor noise. *tt
Bulletin:
0457
Component:
130000 visibility
Summary:
Pop/thump noise at end of window movement and/or driver's window bounce back and reverse to mid-position. *tt
Bulletin:
02176
Component:
032100 service brakes, hydraulic:switches:brake light
Summary:
Lamp-brake-invadvertent disabling of brake shift interlock. *mj
Bulletin:
02193
Component:
073000 fuel system, gasoline:fuel injection system
Summary:
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
Bulletin:
031501
Component:
138130 visibility:defroster/defogger system:windshield:controls/wiring
Summary:
Inoperative electric rear window defroster (heated backlite) grid lines, integral antenna concerns. *tt
Bulletin:
17905
Component:
106000 power train:axle assembly
Summary:
Multiple vehicles using fehp rear axle fluid. fluid usage change. *tt
Bulletin:
04L19
Component:
017500 steering:linkages:tie rod assembly
Summary:
Customer maintenance reminder - literature program 04l19 - tie rod inspection procedure. *tt
Bulletin:
18217
Component:
090000 fuel system, other
Summary:
Multiple vehicles - fuel level indication concerns - service tip. various models including 2005 super duty f-series, excursion, expedition, explorer, mountaineer and aviator. *tt
Bulletin:
041514
Component:
138130 visibility:defroster/defogger system:windshield:controls/wiring
Summary:
Rear window defroster grid/integral antenna diagnosis and repair - terminal tab repair. *tt
Bulletin:
031404
Component:
061000 engine and engine cooling:engine
Summary:
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.
Bulletin:
02208
Component:
353600 equipment:air conditioner
Summary:
Climate control a/c service tech tips. *eh
Bulletin:
04174
Component:
110000 electrical system
Summary:
Malfunction indicator lamp (mil) illuminated - system lean diagnostic trouble codes (dtc's) - service tips. various models including 2004 f-series. *tt
Bulletin:
04189
Component:
138200 visibility:defroster/defogger system:rear window
Summary:
Rear window defroster grid/integral antenna diagnosis and repair - terminal tab repair. *tt
Bulletin:
042107
Component:
103100 power train:automatic transmission:control module (tcm, pcm)
Summary:
General (pcm) power train control module programming procedures. *tt
Bulletin:
042421
Component:
151300 seat belts:front:retractor
Summary:
Safety belt retraction speed. *tt
Bulletin:
04251
Component:
162000 structure:body
Summary:
Aluminum corrosion - service tip. *tt
Bulletin:
05417
Component:
063130 engine and engine cooling:exhaust system:emission control:gas recirculation valve (egr valve)
Summary:
Intermittent rough idle - non-commanded egr (exhaust gas recirculation valve) flow. *tt
Bulletin:
04262
Component:
342000 communications:back up alarm
Summary:
False parking aid warnings. *tt update. *tt
Bulletin:
0554
Component:
063200 engine and engine cooling:exhaust system:manifold/header/muffler/tail pipe
Summary:
Use of stainless steel exhaust studs in service for 5.4l 2v engine. *tt
Bulletin:
050618
Component:
022000 suspension:rear
Summary:
Rear axle noise repair. *sc
Bulletin:
05618
Component:
106000 power train:axle assembly
Summary:
Rear axle noise repair. *tt
Bulletin:
05419
Component:
342000 communications:back up alarm
Summary:
False parking aid warnings. *tt
Bulletin:
041601
Component:
060000 engine and engine cooling
Summary:
Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running. *tt
Bulletin:
07212
Component:
061000 engine and engine cooling:engine
Summary:
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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