2004 Ford Expedition Service and Repair Manual

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Factory-Grade Data

2004 Ford Expedition service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Built for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and use wiring diagrams and system sections to diagnose problems faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical coverage with wiring diagrams
  • Coverage across key systems: engine, transmission, brakes, steering, suspension, HVAC, and more

Trims covered

  • NBX Sport Utility 4-Door
  • Eddie Bauer Sport Utility 4-Door
  • XLT Sport Sport Utility 4-Door
  • XLS Sport Utility 4-Door
  • XLT Sport Utility 4-Door

Engines covered

  • 4.6L 281Cu. In. V8 GAS SOHC Naturally Aspirated
  • 5.4L 330Cu. In. V8 GAS SOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2004 Ford Expedition Recalls & Complaints

NHTSA #06E02300013/03/2006Component: EXTERIOR LIGHTING:HEADLIGHTS

CERTAIN ANZO COMBINATION HEADLAMP ASSEMBLIES SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES. SOME COMBINATION LAMPS ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS WH

Consequence

WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING I

Remedy

ANZO WILL NOTIFY OWNERS AND REPLACE THE HEADLAMPS FREE OF CHARGE. THE RECALL BEGAN MAY 9,

NHTSA #09E01200007/04/2009Component: EXTERIOR LIGHTING

SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HE

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAM

TSB #11005305

This article supersedes TSB 22-2219 to update the Parts List and Service Procedure to clarify applicable steps by vehicle application. Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 (non-Raptor) vehicles equipped with 4WD may exhib

TSB #10235153

For 2000-2024 Ford and Lincoln vehicles, swapping a module from a vehicle for diagnosis purposes is likely to cause errors and is not recommended. It is also not recommended to order a replacement module using a vehicle identification numbe

TSB #10214754

Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 (non-Raptor) vehicles equipped with 4WD may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (IW

TSB #10181917

Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 vehicles equipped with TOD transfer cases may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (

TSB #10177863

This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint wi

TSB #10156863

Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Fo

TSB #10155551

Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Fo

TSB #10109070

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

Showing the 8 most recent of 91 technical service bulletins on file with NHTSA.

20070515Component: AIR BAGSCrash reportedFire reported2 injured

TL*THE CONTACT OWNS A 2004 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 40 MPH UNDER DRY CONDITIONS, A VEHICLE CUT IN FRONT OF THE CONTACT WHILE MAKING A LEFT TURN. THE CONTACT C

20110527Component: SERVICE BRAKES, HYDRAULICCrash reportedFire reported

TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. THE CONTACT WAS COMING TO A STOP AND DEPRESSED THE BRAKE PEDAL WHEN THE VEHICLE WOULD NOT STOP OR SLOW DOWN. THE CONTACT CRASHED INTO A

20151230Component: AIR BAGSCrash reported4 injured

TL* THE CONTACT OWNED A 2004 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 35 MPH AND TURNING TO AVOID A CRASH, THE CONTACT LOST CONTROL OF THE VEHICLE. THE VEHICLE WENT OVER THE ME

20080807Component: TIRESCrash reported4 injured

WE WERE DRIVING WITH CONTINENTAL TIRES (P265/70R17113S) ON AN ARIZONA HIGHWAY WHEN OUR REAR RIGHT TIRE SEPARATED. OUR VEHICLE IMMEDIATELY VEERED TO THE LEFT AND WENT UP A GUARDRAI

Showing the 4 most serious of 381 complaints filed with NHTSA.

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