2004 FORD EXPLORER Recalls (4)

Campaign:
06E026000 on 03/22/2006
Component:
Exterior lighting
Affected:
61,944
Defect:
Certain pro-a motors corner lamps, turn signals, and headlights sold as replacement lamps for use on certain passenger vehicles listed above. some combination lamps that are not equipped with amber side reflectors fail to conform to federal motor vehicle safety standard no. 108, lamps, reflective devices, and associated equipment.
Consequence:
Without the amber reflectors, the vehicle will be poorly illuminated, possibly resulting in a vehicle crash without warning.
Correction:
Pro-a motors will notify owners and offer to repurchase the lamps. the recall began on april 3, 2006. owners may contact pro-a motors at 323-838-2988.
Notes:
This recall only pertains to pro-a motors aftermarket lamps and has no relation to any original equipment installed on the listed passenger vehicles.for more information on the lamp model numbers, click on document search and view document titled "lamp model numbers."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:
06E049000 on 06/04/2006
Component:
Exterior lighting
Affected:
27,176
Defect:
Certain ck motorsports combination headlights, clear corner, bumper, and side marker lights sold as replacement lamps for use on the passenger vehicles listed above. some combination lamps that are not equipped with amber side reflectors fail to conform to federal motor vehicle safety standard no. 108, lamps, reflective devices, and associated equipment.
Consequence:
Without the amber reflectors, the vehicle will be poorly illuminated, possibly resulting in a vehicle crash without warning.
Correction:
Ck motorsport will notify owners and replace the noncompliant lamps free of charge. the recall began on july 1, 2006. owners may contact ck motorsport at 1-909-610-7211.
Notes:
This recall only pertains to aftermarket replacement equipment and has no relation to any original equipment installed on vehicles manufactured by the vehicle manufacturers.for more information on the lamp model numbers, click on document search and view document titled "lamp model numbers."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:
07E104000 on 12/10/2007
Component:
Visibility:glass, side/rear
Affected:
1,657
Defect:
Certain curved tempered replacement glass manufactured by hangzhou safety glass ltd and supplied to safelite by auto temp inc., identified as dot-430, and sold for use on certain domestic and foreign vehicles may not break into small pieces as expected of tempered glass and fails to conform to federal motor vehicle safety standard no. 205, "glazing materials."
Consequence:
In the event of a vehicle crash, the occupant(s) may be seriously injured by shattered glass.
Correction:
Safelite will notify its retail customers and replace the glass free of charge. retail customers can contact safelite toll free at 1-888-843-2906. safelite will notify its wholesale customers and reimburse wholesale customers for current inventory and at a specified rate for replacing their customer's glass. wholesale customers can contact safelite's wholesale division, service autoglass toll free at 1-888-246-6298. the recall began on january 15, 2008.
Notes:
This recall only pertains to certain curved tempered replacement glass manufactured by hangzhou safety glass, ltd. (dot-430) and supplied to safelite by auto temp inc., and has no relation to any original equipment installed on the vehicles listed above. 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:
09E025000 on 05/10/2009
Component:
Exterior lighting:headlights
Affected:
42,540
Defect:
Dope, inc. is recalling 42,540 combination corner and bumper lamp assemblies of various part numbers sold for use as aftermarket equipment for various passenger vehicles. these headlamps fail to conform to the requirements of federal motor vehicle safety standard no. 108, "lamps, reflective devices, and associated equipment." these lamps do not contain the required amber side reflectors.
Consequence:
Decreased lighting visibility may result in a vehicle crash.
Correction:
Dope, inc. will notify owners and offer a full refund for the noncompliant combination lamps. the safety recall began on july 28, 2009. owners may contact dope, inc. at 1-626-272-1798.
Notes:
This recall only pertains to aftermarket replacement equipment and has no relation to any original equipment installed on vehicles produced by the vehicle manufacturer.in order to determine if your aftermarket lamp assembly is affected by this noncompliance, please review the list of model numbers provided to us by dope, inc.the list can be found under "document search" located at the bottom of your screen. owners 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 <a href=http://www.safercar.gov>http://www.safercar.gov</a> .

2004 FORD EXPLORER TSBs (109)

Bulletin:
17030
Component:
199000 tires:pressure monitoring and regulating systems
Summary:
Vehicles with a silver valve stem tire pressure monitor system (tpms) may exhibit a warning light/message on. *tt
Bulletin:
17054
Component:
106000 power train:axle assembly
Summary:
Axle whine at cruise or during acceleration/ deceleration. *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:
03181
Component:
110000 electrical system
Summary:
Remote keyless entry (rke) - service tips. *tt
Bulletin:
03198
Component:
106000 power train:axle assembly
Summary:
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
Bulletin:
17107
Component:
105000 power train:driveline
Summary:
Driveline vibration on drone/boom at highway speeds. *tt
Bulletin:
17165
Component:
110000 electrical system
Summary:
Intermittent diagnostic trouble code (dtc) p2106 with the malfunction indicator lamp (mil) on. *tt
Bulletin:
17215
Component:
046400 service brakes, air:antilock:abs warning light
Summary:
The amber anti-lock brake system (abs) warning light on with diagnostic trouble codes c1235, c1236/c1237 stored in memory. *tt
Bulletin:
17217
Component:
353600 equipment:air conditioner
Summary:
Air conditioner hooting noise during light load acceleration at low speeds, from 1000-1300 rpm. *tt
Bulletin:
17276
Component:
162000 structure:body
Summary:
A popping or creaking noise that appears to be coming from the front exterior of the vehicle. *tt
Bulletin:
17285
Component:
110000 electrical system
Summary:
Malfunction indicator lamp/etc lamp lit with p0606 and one or several p21xx-series diagnostic trouble codes at low time in service. *tt
Bulletin:
17311
Component:
110000 electrical system
Summary:
Malfunction indicator lamp on and/or electronic throttle control lamp (etc) on with diagnostic trouble code (dtc) p2106. *tt
Bulletin:
04B15
Component:
106000 power train:axle assembly
Summary:
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
Bulletin:
17479
Component:
110000 electrical system
Summary:
Malfunction indicator lamp (mil) on with ignition coil related diagnostic trouble codes (p035x). *tt
Bulletin:
17494
Component:
090000 fuel system, other
Summary:
Distance to empty not displayed. *tt
Bulletin:
17592
Component:
110000 electrical system
Summary:
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
Bulletin:
17626
Component:
036400 service brakes, hydraulic:antilock:abs warning light
Summary:
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
Bulletin:
17640
Component:
141000 air bags:frontal
Summary:
Poor fit between driver air bag and steering wheel. *tt
Bulletin:
17641
Component:
106000 power train:axle assembly
Summary:
Rear 3.55 axle noise. certified rear axle or improved gear set available. *tt
Bulletin:
17664
Component:
061000 engine and engine cooling:engine
Summary:
Intermittent hard start, long crank time or multiple crank attempts before starting. *tt
Bulletin:
17666
Component:
061000 engine and engine cooling:engine
Summary:
Diagnostic trouble code (dtc) u0300 (internal control module software incompatibility) stored in the pcm with no other dtc's present. *tt
Bulletin:
17670
Component:
110000 electrical system
Summary:
Malfunction indicator (dtc) lamp on with diagnostic trouble code (dtc) p2106. *tt
Bulletin:
17680
Component:
162600 structure:body:hatchback/liftgate
Summary:
Rear liftgate rattle / light popping noise. *tt
Bulletin:
17544
Component:
061000 engine and engine cooling:engine
Summary:
Generator noise in cold ambient temperatures. *mj
Bulletin:
17555
Component:
100000 power train
Summary:
Certified rear axle available. *mj
Bulletin:
17558
Component:
110000 electrical system
Summary:
Intermittent air bag warning lamp on, memory seat, and/or adjustable pedal concerns. *mj
Bulletin:
17560
Component:
100000 power train
Summary:
Rear axle noise. also includes lincoln aviator 2002. *mj
Bulletin:
17561
Component:
110000 electrical system
Summary:
Delayed crank with no start, diagnostic trouble codes (dtc) u0300/p0606/p2105/p2107, malfunction indicator module (mil) and wrench light on. *mj
Bulletin:
17316
Component:
090000 fuel system, other
Summary:
Fuel signal to instrument cluster service tip. *tt
Bulletin:
17326
Component:
061000 engine and engine cooling:engine
Summary:
Engine auxiliary oil cooler line and the right side motor mount squeaking noise from front exterior while driving over bumps. *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:
17717
Component:
106000 power train:axle assembly
Summary:
Rear axle chatter, shudder, binding sensation, or vibration during low speed turns. *tt
Bulletin:
17728
Component:
036100 service brakes, hydraulic:antilock:control unit/module
Summary:
Anti-lock brake system (abs) light on with diagnostic trouble code (dtc) b2900, u1900 and c1805. *tt
Bulletin:
17736
Component:
106000 power train:axle assembly
Summary:
Rear axle noise. *tt
Bulletin:
17883
Component:
103000 power train:automatic transmission
Summary:
Delayed/harsh reverse engagement. *tt
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:
03263
Component:
036100 service brakes, hydraulic:antilock:control unit/module
Summary:
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
Bulletin:
03L17
Component:
063100 engine and engine cooling:exhaust system:emission control
Summary:
Demonstration/delivery hold - special field action 03l17. revised smog emissions information. *tt
Bulletin:
17411
Component:
199000 tires:pressure monitoring and regulating systems
Summary:
Tire pressure monitoring system (tpms) module configuration - service tip. *mj
Bulletin:
17422
Component:
110000 electrical system
Summary:
Multiple electrical concerns - fuse 2.17 open. *mj
Bulletin:
17455
Component:
104000 power train:transfer case (4-wheel drive)
Summary:
4x4 inoperative and/or indicators blinking. *tt
Bulletin:
0485
Component:
162000 structure:body
Summary:
Liftgate glass applique damaged/cracked. service procedure. *tt
Bulletin:
04B17
Component:
199000 tires:pressure monitoring and regulating systems
Summary:
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
Bulletin:
04105
Component:
106220 power train:axle assembly:axle shaft:seal
Summary:
Axle seal leaks. leaks from rear halfshaft axle seal. service tips. *tt
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:
04142
Component:
110000 electrical system
Summary:
No crank with diagnostic trouble code b1601 and/or b1213. pats security access issues with 4.0l engine. *tt
Bulletin:
17905
Component:
106000 power train:axle assembly
Summary:
Multiple vehicles using fehp rear axle fluid. fluid usage change. *tt
Bulletin:
04195
Component:
130000 visibility
Summary:
Front window clunk noise. *tt
Bulletin:
04197
Component:
110000 electrical system
Summary:
Malfunction indicator lamp (mil) illuminated with diagnostic trouble codes (dtc's) p0172 and/or p0175. *tt
Bulletin:
041910
Component:
061000 engine and engine cooling:engine
Summary:
Oil leak from oil filter adapter - 4.0l sohc engine built before 4/1/2004. *tt
Bulletin:
18202
Component:
100000 power train
Summary:
Unintended 4x4 engagement during low speed parking lot turns. various models including the 2005 explorer and mountaineer. *tt
Bulletin:
18215
Component:
162300 structure:body:door
Summary:
Broken rear cargo storage door lift handle. various models including 2005 explorer/mountaineer. *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:
18221
Component:
106000 power train:axle assembly
Summary:
Rear axle noise. oasis. various models including 2005 explorer, mountaineer and aviator. *tt
Bulletin:
18254
Component:
180000 vehicle speed control
Summary:
Speed control inoperative or not holding the set speed. oasis. various models including 2005 explorer, sport trac, 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:
18121
Component:
091200 fuel system, other:storage:fuel gauge system
Summary:
Fuel gauge slow to update. *tt
Bulletin:
18171
Component:
113000 electrical system:starter assembly
Summary:
No crank/no start condition when vehicle temperature is below freezing (32f/0c). *tt
Bulletin:
0527
Component:
103000 power train:automatic transmission
Summary:
5r55s transmission fluid leaks from converter housing area. diagnostic trouble code p1783 on vehicles built prior to 12/12/2004. *tt
Bulletin:
0531
Component:
061000 engine and engine cooling:engine
Summary:
Maf diagnostic service tip - vehicles equipped with egr system module (esm). *tt
Bulletin:
0538
Component:
010000 steering
Summary:
Increased turning effort during low speed sharp turns false 4x4 engagement. *eh
Bulletin:
0537
Component:
105000 power train:driveline
Summary:
Driveline 1st order vibration/boom/drone. *tt
Bulletin:
0539
Component:
060000 engine and engine cooling
Summary:
Mil on and/ or runs rough/misfire dtcs p0300-p0308 p0316 and or p0171/p0174 4.6l engine. *eh
Bulletin:
18423
Component:
106000 power train:axle assembly
Summary:
Axle whine howl service with individual parts instead of an axle assembly. *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:
041715
Component:
106000 power train:axle assembly
Summary:
Front axle tube leak. *eh
Bulletin:
04259
Component:
133000 visibility:power window devices and controls
Summary:
Rear power window(s) inoperative. *tt
Bulletin:
04B22
Component:
103000 power train:automatic transmission
Summary:
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
Bulletin:
18381
Component:
110000 electrical system
Summary:
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
Bulletin:
04219
Component:
110000 electrical system
Summary:
Malfunction indicator lamp (mil) and electronic throttle control (etc) lamps on with both diagnostic trouble code (dtc) p2106 and p2135. *tt
Bulletin:
042112
Component:
060000 engine and engine cooling
Summary:
Rough idle in drive. *eh
Bulletin:
042115
Component:
081100 fuel system, diesel:storage:tank assembly
Summary:
Fuel gauge slow to update after refueling. *eh
Bulletin:
042212
Component:
103300 power train:automatic transmission:gear position indication (prndl)
Summary:
Gear selector lever - increased effort to shift from drive to park. *tt
Bulletin:
04225
Component:
060000 engine and engine cooling
Summary:
Throttle pedal response on tip in vehicles built before 10/4/2004 equipped with a 4.0l engine. *eh
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:
06216
Component:
106000 power train:axle assembly
Summary:
Limited slip axle chatter, shudder, binding sensation, or vibration during low speed turning maneuvers. *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:
04268
Component:
100000 power train
Summary:
Increased effort during low speed sharp turns on 4x4 vehicles. *tt
Bulletin:
18466
Component:
106000 power train:axle assembly
Summary:
Axle whine howl. this includes 1997-05 ford vehicles. *eh
Bulletin:
05416
Component:
220000 seats
Summary:
Front seat(s) slight movement when accelerating and/or decelerating. *tt
Bulletin:
18478
Component:
106000 power train:axle assembly
Summary:
Axle seal leaks. *eh
Bulletin:
04262
Component:
342000 communications:back up alarm
Summary:
False parking aid warnings. *tt update. *tt
Bulletin:
050618
Component:
022000 suspension:rear
Summary:
Rear axle noise repair. *sc
Bulletin:
05136
Component:
132000 visibility:glass, side/rear
Summary:
Backglass difficult to close and an intermittent door ajar lamp. *tt
Bulletin:
18719
Component:
090000 fuel system, other
Summary:
Malfunction indicator lamp coming on with diagnostic trouble codes (dtcs) p0171, p0172, p0174 and/or p0175 (fuel system too rich or lean). *tt
Bulletin:
18573
Component:
060000 engine and engine cooling
Summary:
No start/hard start on cold soak. *tt
Bulletin:
05618
Component:
106000 power train:axle assembly
Summary:
Rear axle noise repair. *tt
Bulletin:
05612
Component:
100000 power train
Summary:
Delayed or harsh reverse engagements - 5r55s transmission - vehicles built prior to 09/23/2004. *tt
Bulletin:
05419
Component:
342000 communications:back up alarm
Summary:
False parking aid warnings. *tt
Bulletin:
0561
Component:
110000 electrical system
Summary:
Wrench lamp on and no diagnostic trouble code (dtc) stored. *tt
Bulletin:
051016
Component:
060000 engine and engine cooling
Summary:
No start/hard start on cold soak - 4.0l engine. *tt
Bulletin:
051710
Component:
021600 suspension:front:wheel bearing
Summary:
Noise from rear wheel hub bearings. *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:
05252
Component:
210000 trailer hitches
Summary:
Neutral tow capability -- service kit requirements. *tt
Bulletin:
05262
Component:
110000 electrical system
Summary:
Mil on with dtc p0191 with or without various drivability symptoms and/or additional dtcs. *tt
Bulletin:
052624
Component:
190000 tires
Summary:
Vibration diagnosis - tire/wheel runout. *tt
Bulletin:
05213
Component:
091200 fuel system, other:storage:fuel gauge system
Summary:
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
Bulletin:
0637
Component:
190000 tires
Summary:
Low tire indicator on - tpms system sensor wake up. *tt
Bulletin:
0645
Component:
100000 power train
Summary:
Neutral tow capability - service kit requirements. *tt
Bulletin:
061710
Component:
117000 digital instrument panel
Summary:
Mil on with p0463 or erratic fuel gauge operation. *kb
Bulletin:
06167
Component:
091200 fuel system, other:storage:fuel gauge system
Summary:
Mil on with dtc p0463 or erratic fuel gauge operation. *kb
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
Bulletin:
TSB-08-19-3
Component:
106200 power train:axle assembly:axle shaft
Summary:
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
Bulletin:
TSB-12-7-4
Component:
060000 engine (pws)
Summary:
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. *pe
Bulletin:
TSB-12-8-1
Component:
060000 engine (pws)
Summary:
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
Bulletin:
SSM 46085
Component:
060000 engine (pws)
Summary:
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

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