TSB's Etc.

[twodogs]

Our 2004 XLT has about 34,000 mi. We took it in to the shop Monday after recently noticing strange sensations in the drive train. Especially when maneuvering about, making several turns, etc. in areas like shopping mall parking lots. Felt like a sort of engage/disengage of 4X4 or slipping clutches in txfr case.

Tech diagnosed problem as something to do with differential clutch pack and car is still in shop awaiting parts. It's under warranty so that isn't critical at this time.

However, it was indicated that the problem is covered in an existing TSB.

Now, we all know that the only way learn about TSB's is to continuously keep searching for them or to actually have the failure occur to our vehicle. Anyway, once I got home from the shop I started checking and there are several other TSB's which apply to our rig.

Being the gullible gopher I am, I called the shop manager and asked if they had planned to check out these other TSB's so long as they have the vehicle in the shop.

Guess what the reply was.

Good guess. As long as we hadn't specifically complained about those issues they would not be checking for them.

We'll soon be out of warranty and then I assume there's a good chance these failures will occur. Otherwise there wouldn't be bulletins out, right?

Here for your info are a few TSB #' that apply to 2004 's if you're interested:

04268..Increased effort in low speed turns.

05612..Harsh Reverse gear engagement.

17555..Rear axle noise.

17568..Rear axle noise.

18202..Unintended 4X4 engagement, low speed.

Maybe if we start asking or insisting that these get checked when our vehicles are in for other service they'll eventually change their attitudes.

I'd guess in most cases these sort of things are going to fail and they'll have to be fixed one way or another. I'd sure rather see that happen under warranty as opposed to after.

 

[jimbo74]

only 5 tsbs? thats almost nothing, i doubt you have the whole list, if you have a program like alldata, im sure there are at least 20 tsbs for your vehicle

 

[twodogs]

You're right.

Those were only drive line or transmission as I recall.

 

[Glacier991]

I would specifically ask that they check and do these TSB's in writing. CC the next level at FORD, it used to be called Zone Rep, someone here can tell you better what it is now. If they refuse I'd inform them you will be looking to them for out of warranty repairs on those items.

 

[gijoecam]

There's WAY more than 20. Not all of them apply to your vehicle though... For '04, there are 57 to be exact.

Technical Service Bulletins
2004 EXPLORER - US (English)


06-7-1
NEUTRAL TOW CAPABILITY - SERVICE KIT REQUIREMENTS
06-4-4
LIMITED SLIP AXLE CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNING MANEUVERS
06-4-2
BATTERY SERVICE - OPERATION OF BATTERY EYE - CHARGING SERVICE TIPS
06-3-7
LOW TIRE INDICATOR ON - TPMS SYSTEM SENSOR WAKE UP
06-2-12
MIL ON WITH PCM DTC P0463 AND/OR IC DTC B1201 - FUEL GAUGE DROPS TO EMPTY OR SLOW TO UPDATE AFTER REFUELING
06-1-3
LEATHER SEAT MATERIAL CRACKING
05-26-24
VIBRATION DIAGNOSIS - TIRE/WHEEL RUNOUT
05-26-2
MIL ON DTC P0191 WITH OR WITHOUT VARIOUS DRIVABILITY SYMPTOMS AND/OR ADDITIONAL DTCS
05-25-8
NOISE FROM REAR WHEEL HUB BEARINGS
05-24-2
BODY - LIFTGATE GLASS APPLIQUE DAMAGED/CRACKED - SERVICE PROCEDURE
05-23-3
REAR AXLE NOISE REPAIR
05-22-8
WDS COP KIT DIAGNOSTIC TIPS - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING
05-21-11
DOOR SPEAKER INOPERATIVE - TERMINAL CORROSION
05-21-8
DELAYED OR HARSH REVERSE ENGAGEMENTS - 5R55S TRANSMISSION - VEHICLES BUILT PRIOR TO 09/23/2004
05-18-7
WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS
05-17-8
CHIRP NOISE FROM FEAD BELT WHEN A/C COMPRESSOR IS ENGAGING
05-16-11
SAFETY BELT RETRACTION SPEED
05-16-4
DRIVELINE 1ST ORDER VIBRATION/BOOM/DRONE
05-15-5
LEAKS FROM REAR HALFSHAFT AXLE SEAL
05-14-4
WRENCH LIGHT ON WITH BOTH DTC P2106 AND P2135 - VEHICLES BUILT 11/29/2004 AND PRIOR
05-13-6
BACKGLASS DIFFICULT TO CLOSE
05-10-16
NO START/HARD START ON COLD SOAK - 4.0L ENGINE
05-6-4
FALSE PARKING AID WARNINGS
05-6-1
WRENCH LAMP ON AND NO DTC STORED
05-4-16
FRONT SEAT(S) SLIGHT MOVEMENT WHEN ACCELERATING AND/OR DECELERATING
05-3-10
SAFETY BELT WEB STOP BUTTON SERVICE
05-3-9
MIL ON AND/OR RUNS ROUGH/MISFIRE - DTCS P0300-P0308, P0316 AND/OR P0171/ P0174, - 4.6L ENGINE
05-3-8
INCREASED TURNING EFFORT DURING LOW SPEED SHARP TURNS - FALSE 4X4 ENGAGEMENT
05-3-4
MOONROOF SQUEAK AND/OR RATTLE NOISE - CORNER INSERT REPAIR
05-3-1
MAF DIAGNOSTIC SERVICE TIP - VEHICLES EQUIPPED WITH EGR SYSTEM MODULE (ESM)
05-2-7
5R55S TRANSMISSION FLUID LEAKS FROM CONVERTER HOUSING AREA - DTC P1783 - VEHICLES BUILT PRIOR TO 12/12/2004
05-1-5
REAR POWER WINDOW(S) INOPERATIVE
04-26-20
THROTTLE PEDAL RESPONSE ON TIP-IN
04-25-1
ALUMINUM CORROSION - SERVICE TIP
04-24-14
GENERAL PCM PROGRAMMING PROCEDURES
04-24-6
NOISE DURING A/C OPERATION FROM REAR OF VEHICLE
04-24-5
REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR
04-24-3
LEATHER-WRAPPED STEERING WHEEL - LEATHER COMING LOOSE
04-24-1
RATTLE OR VIBRATION FROM REAR SEAT ENTERTAINMENT SYSTEM DVD PLAYER - DEALER INSTALLED UNIT
04-22-12
GEAR SELECTOR LEVER - INCREASED EFFORT TO SHIFT FROM DRIVE TO PARK
04-22-11
MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DIAGNOSTIC TROUBLE CODES (DTC'S) P0172, P0175, P0171 AND/OR P0174 - 4.0L SOHC ENGINE - VEHICLES BUILT PRIOR TO 10/4/2004
04-21-12
4.0L - ROUGH IDLE IN DRIVE
04-19-10
OIL LEAK FROM OIL FILTER ADAPTER - 4.0L SOHC ENGINE BUILT BEFORE 4/1/2004
04-19-5
FRONT WINDOW CLUNK NOISE
04-18-3
A/C HOOT NOISE WHILE DRIVING
04-17-15
FRONT AXLE TUBE SEAL LEAK
04-17-4
MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - SYSTEM LEAN DIAGNOSTIC TROUBLE CODES (DTC'S) - SERVICE TIPS
04-17-3
RATTLE FROM REAR SEAT ENTERTAINMENT SYSTEM (RES) DVD PLAYER
04-17-1
MESSAGE CENTER - DISTANCE TO EMPTY DISPLAYS THREE DASHES
04-14-6
RATTLE FROM DVD SCREEN LATCH ASSEMBLY
04-14-2
NO CRANK WITH DTC B1601 AND/OR B1213 - PATS SECURITY ACCESS ISSUES - 4.0L ENGINE
04-13-3
BODY - HEADLAMP - MOISTURE IN HEADLAMP
04-9-6
BODY - PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION
04-4-5
BODY - TRIM - PAINT PEEL-OFF - ROOF RACK SIDE RAIL
03-26-3
BRAKES - ABS LAMP ILLUMINATED AND DTC C1235, C1236, C1237 - VEHICLES WITH DIFFERENTIAL-MOUNTED REAR WHEEL SPEED SENSOR
03-25-6
ENGINE - ROMEO BUILT 4.6L 2V - TICK NOISE FROM ENGINE - ENGINES BUILT BEFORE 9/17/2003
03-23-2
BODY - MIRROR - EXTERIOR MIRROR GLASS AND MOTOR REPLACEMENT - SERVICE TIPS
________________
TSBs found:57

As for which ones might apply for yours? Don't know...

-Joe

 

[gijoecam]

FYI, this is probably the one they're doing on the rear end:

TSB
06-4-4 LIMITED SLIP AXLE CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNING MANEUVERS

Publication Date: February 13, 2006

FORD: 2002-2004 Mustang, Explorer
2003-2004 Expedition
2004 F-150
LINCOLN: 2003 Navigator
MERCURY: 2002-2004 Mountaineer


This article supersedes TSB 06-02-16 to update the Service Procedure.

ISSUE:
Some 2003-2004 Expedition, 2003 Navigator, 2004 F-150 vehicles equipped with a 9.75" or 8.8" limited slip rear axle, and 2002-2004 Explorer 4dr, Mountaineer, and Mustang vehicles equipped with 8.8" limited slip rear axle, may exhibit a chatter, shudder, a binding sensation, or a vibration during low speed turns. On 4X4 vehicles, the sensation may appear to be originating from the front axle or the steering gear.

ACTION:
First verify the condition. On 4X4 trucks ensure that the vehicle is in 2WD, to isolate the rear axle. On all vehicles, turn the wheel fully right (or fully left) and then accelerate the vehicle. If the condition is verified to be in the rear axle, replace the limited slip clutch pack.

SERVICE PROCEDURE

CAUTION: INSTRUCT THE CUSTOMER NOT TO TOW WITH THE VEHICLE FOR 500 MILES (805 KM) AFTER THIS REPAIR, TO ALLOW THE AXLE TO BREAK-IN PROPERLY.



Order and install the appropriate clutch pack, follow the instructions detailed in the Workshop Manual.

6L1Z-4947-A (9.75" limited slip)
F5AZ-4947-BA (8.8" limited slip)
NOTE: INSTALLING A CLUTCH PACK INTO AN INDEPENDENT REAR SUSPENSION (IRS) AXLE IS DIFFERENT FROM INSTALLING A CLUTCH PACK INTO A SOLID-BEAM AXLE. BE SURE TO FOLLOW THE APPROPRIATE WORKSHOP MANUAL PROCEDURE.



INSTALLATION TIPS

Be sure to install NEW circlips and halfshaft/wheel end nuts on IRS rear axle (not included in the service kit)
Soak the new clutch packs in Additive Friction Modifier (XL-3) for fifteen (15) minutes prior to installation
For IRS axles, the half shaft seals need to be replaced. Expedition and Explorer/Mountaineer applications should use seal kit part number 5L1Z-4A109-A. Removal of the half shaft excluder seal 1L2Z-1N013 may be required, if equipped, to facilitate re-assembly
Refill axles with 4 oz. Additive Friction Modifier (XL-3) and the necessary amount of Rear Axle Lubricant (XY-75W140-QL), regardless of the axle lubricant system originally used in the axle. Fill to capacity recommended in the Workshop Manual
NOTE: AXLE FLUID REQUIREMENTS HAVE BEEN CHANGED. ALL VEHICLES BEING REPAIRED BY THIS TSB MUST HAVE REAR AXLE LUBE XY-75W140-QL INSTALLED, IN PLACE OF XY- 75W90-QFEHP. AS PART OF THIS REPAIR, CHECK AND REPLACE IF NECESSARY THE CURRENT XY-75W90-Q"FEHP" METAL TAG, WITH A NEW 75W140 TAG (F3TZ-4121-AA). ADDITIONALLY, REMOVE THE MULTI-COLORED LABEL WHICH IS LOCATED ON THE RIGHT SIDE AXLE TUBE, OR BLOCK OUT ANY/ALL "FEHP" OR "75W90" REFERENCES ON THE LABEL.



PART NUMBER PART NAME
6L1Z-4947-A 9.75" Axle Clutch Kit
F5AZ-4947-BA 8.8" Axle Clutch Kit
5L1Z-4A109-A Axle Seal
XY-75W140-QL Rear Axle Lubricant
XL-3 Additive Friction Modifier
W710084-S439 Nut (Wheel End)
2L1Z-4B422-CA Circlips (for 9.75")
1L2Z-4B422-BA Circlips (for 8.8")
F3TZ-4121-AA Metal Tag - 75W140



WARRANTY STATUS:
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

OPERATION DESCRIPTION TIME
060404A 2003-2004 Expedition Without Air Suspension: Replace Clutch Pack (Includes Time For Road Test To Verify Concern, Replace Rear Clutch Pack, And Re-Road Test) (Do Not Use With 4010A, 4010D, 4010D1, 4010D4, 4010D5, 4010D6, 4010D12, 4010D13, 4033A, 4200B,4205A, 4205A4, 4205A5, 4205A6, 4205A8, 4205A12, 4205A13, 4205A14, 4234A, 4139A, 4139A2, 052303, 051505, 4602A) 4.5 Hrs.
060404B 2003-2004 Expedition, 2003 Navigator With Air Suspension: Replace Clutch Pack (Includes Time For Road Test To Verify Concern, Replace Rear Clutch Pack, And Re-Road Test) (Do Not Use With 4010A, 4010D, 4010D1, 4010D4, 4010D5, 4010D6, 4010D12, 4010D13, 4033A, 4200B,4205A, 4205A4, 4205A5, 4205A6, 4205A8, 4205A12, 4205A13, 4205A14, 4234A, 4139A, 4139A2, 052303, 051505, 4602A) 4.7 Hrs.
060404C 2002-2004 Explorer, Mountaineer: Replace Clutch Pack (Includes Time For Road Test To Verify Concern, Replace Rear Clutch Pack, And Re-Road Test) (Do Not Use With 4010A, 4010D, 4010D1, 4010D4, 4010D5, 4010D6, 4010D12, 4010D13, 4033A, 4200B,4205A, 4205A4, 4205A5, 4205A6, 4205A8, 4205A12, 4205A13, 4205A14, 4234A, 4139A, 4139A2, 052303, 051505, 4602A) 4.9 Hrs.
060404D 2004 F-150: Replace Clutch Pack (Includes Time For Road Test To Verify Concern, Replace Rear Clutch Pack, And Re-Road Test) (Do Not Use With 4010A, 4010D, 4010D1, 4010D4, 4010D5, 4010D6, 4010D12, 4010D13, 4033A, 4200B,4205A, 4205A4, 4205A5, 4205A6, 4205A8, 4205A12, 4205A13, 4205A14, 4234A, 4139A, 4139A2, 052303, 051505, 4602A) 3.2 Hrs.
060404E 2002-2004 Mustang: Replace Clutch Pack (Includes Time For Road Test To Verify Concern, Replace Rear Clutch Pack, And Re-Road Test) (Do Not Use With 4010A, 4010D, 4010D1, 4010D4, 4010D5, 4010D6, 4010D12, 4010D13, 4033A, 4200B,4205A, 4205A4, 4205A5, 4205A6, 4205A8, 4205A12, 4205A13, 4205A14, 4234A, 4139A, 4139A2, 052303, 051505, 4602A) 3.1 Hrs.
060404F 2002-2004 Mustang Cobra: Replace Clutch Pack (Includes Time For Road Test To Verify Concern, Replace Rear Clutch Pack, And Re-Road Test) (Do Not Use With 4010A, 4010D, 4010D1, 4010D4, 4010D5, 4010D6, 4010D12, 4010D13, 4033A, 4200B,4205A, 4205A4, 4205A5, 4205A6, 4205A8, 4205A12, 4205A13, 4205A14, 4234A, 4139A, 4139A2, 052303, 051505, 4602A) 5.9 Hrs.

DEALER CODING
BASIC PART NO. CONDITION CODE
4947 D4

-Joe

 

[twodogs]

That certainly is the exact description of the problem I was having. I'd have sworn the shudder, etc. was in the front end and they told me it was most likely in the rear end and that's what they claim to be fixing.

It's sure disgusting to see that long list of problems. Knowing that they also know about them but leave it to us to live with them or take the time to go in and complain as we find them one by one just BITES.

Thanks

 

[BrooklynBay]

I would suggest printing that list of TSBs, and showing it to them the next time you go there.

 

[jakedrew]

(3 years later)

thank you! i have a 04 and it runs out of warrenty here in 5k miles. I will have a nice "list" to give to the service advisor.

thanks again.

 

[Jim Lewis]

Hello. I'm a new member. I'm joining this site because I'm tired of giving my money to the Auto service departments and not receiving quality service. So I'm going to try to service my auto instead. And I'm probably going to need as much help as I can get from this community. Thanks for having me. Jim

 

[Bani]

I would suggest printing that list of TSBs, and showing it to them the next time you go there.

Hi,
When you take the TSB to the Ford Dealer do they do the repair for Free. In other words what are the benefits of showing the TSB to the dealer. I am new to this.
My TSB is http://ww2.justanswer.com/uploads/crzydrvr00/2009-03-14_023256_2004_explorer_fuel_sender_tsb.pdf.
OBD CODE - PO463

 

[BrooklynBay]

A recall is performed for free & a TSB is not. A TSB is a technical service bullentin which is basically a factory update for a specific issue.

 

[Bani]

Thanks, I now understand. Ford/Manufacturer clearly stating an update on what the problem is and what the solution is puts out a TSB.