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2004 Ford Expedition CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Ford REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Tire Pressure Monitoring System
- Starter & Alternator Replacement
- Cabin Air Filter Locations & Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 2004 Ford Expedition AUTOMOBILES
General Service Domestic Vehicles -> 2003-04 -> System Inspection -> Compressor -> Condenser -> Evaporator -> Receiver-Drier/Accumulator -> Refrigerant Line Restrictions -> Thermostatic Expansion Valve
Vehicle: 2004 Ford Expedition 5.4 V8 GAS
While a detailed diagnostic procedure for all air conditioning systems would be impractical due to the many variations in construction and operation, there are three fundamental components of a total diagnosis:
- Refrigerant systems must have an adequate, but not excessive charge.
- Determination must be made whether the refrigerant system is governed by a cycling clutch compressor or by valves which control evaporator pressure.
- The air distribution system (blower motor, switches, vacuum lines and air ducts) must be operational before checking the ...
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BRAKE SERVICE PROCEDURES FOR 2004 Ford Expedition AUTOMOBILES
Hydraulic Brake Systems -> Component Replacement -> Aviator -> E-Series -> Escape & Mariner -> Excursion & F-Super Duty -> Expedition, Explorer, Explorer Sport & Sport/Trac, F-150, Mark LT, Mountaineer & Navigator -> Freestar & Monterey -> Less Hydro Max -> Master Cylinder -> Ranger -> With Hydro-Max
Vehicle: 2004 Ford Expedition 4.6 V8 GAS
Master Cylinder
Aviator
Remove components in sequence illustrated, Fig. .
E-Series
- Drain brake master cylinder with suitable suction device.
- Remove coolant reservoir.
- On models equipped with Hydro Boost, remove three power distribution box bracket bolts and position box aside.
- On all models, remove speed control deactivator switch.
- Disconnect fluid level sensor connector.
- Remove and discard master cylinder mounting nuts.
- Disconnect master cylinder brake tubes.
- Remove master cylinder cylinder.
- Reverse procedure to install, noting the following:
- Torque master cylinder mounting nuts to 18...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Ford Expedition AUTOMOBILES
Ford Motor Co. Light Trucks, SUVs & Vans -> Component Locations -> Blackwood, 1997-03 F150, 1997-06 F250LD, Expedition & Navigator
Vehicle: 2004 Ford Expedition 4.6 V8 GAS
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2004 Ford Expedition AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 2004 Ford Expedition 5.4 V8 GAS
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Failure to follow these instructions may result in personal injury.
- With vehicle in neutral, position vehicle on a hoist.
- Remove the front wheel and tire assembly.
- Remove front halfshaft hub ...
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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR 2004 Ford Expedition AUTOMOBILES
Relearn Procedures -> TPMS Sensor Activation -> TPMS Sensor Training
Vehicle: 2004 Ford Expedition 4.6 V8 GAS
TPMS Sensor Activation
To conserve battery power, the TPMS sensors will go into a sleep mode after approximately 30 minutes of inactivity. The sensors will not transmit tire pressure information while in sleep mode. The sensors must be activated to transmit the latest tire pressure information.
- Place the ignition switch in the On position.
- Position Ford TPMS activation tool, or equivalent, against the LF tire side wall 180° from the valve stem.
- The TPMS activation tool will flash a green light and sound a beep for each successful response from a TPMS sensor.
- Press the TPMS activat...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2004 Ford Expedition AUTOMOBILES
Alternator, Replace
Vehicle: 2004 Ford Expedition 5.4 V8 GAS
- Remove battery ground cable.
- Remove air cleaner outlet tube assembly.
- Drain cooling system into suitable container.
- Remove front air deflector.
- Remove upper radiator hose from radiator.
- Remove overflow bottle from radiator.
- Remove fan and clutch using suitable fan pulley holding wrench tool and suitable fan clutch wrench.
- Remove fan shroud attaching bolts, then fan and shroud.
- Rotate...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2004 Ford Expedition AUTOMOBILES
Cabin Air Filter Service -> Ford Motor Co. -> 1997-2007 Expedition, F-150, Navigator, 2002 Blackwood & 2006-07 Mark LT
Vehicle: 2004 Ford Expedition 5.4 V8 GAS
On these models, the cabin air filter is an option.
Under normal operating conditions the cabin air filter should be replaced every 15,000 miles. In dusty areas change the cabin air filter more often.
- From under passenger side of the instrument panel behind the glove compartment, remove the cabin air filter cover to the bottom of the heater plenu...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2004 Ford Expedition AUTOMOBILES
Ford Motor Co. Trucks -> Rear Load Leveling (CHECK SUSP) ->
Vehicle: 2004 Ford Expedition 5.4 V8 GAS
The CHECK SUSP indicator lights when there is a fault of the rear load ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Ford Expedition AUTOMOBILES
Radiator, Replace
Vehicle: 2004 Ford Expedition 5.4 V8 GAS
- Drain cooling system into a suitable container.
- Remove front air deflector if required.
- Remove fan blade and lefthand thread clutch using a suitable fan clutch holding tool and fan clutch wrench tool.
- Disconnect transmission fluid cooler lines from radiato...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2004 Ford Expedition AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2004 Ford Expedition 4.6 V8 GAS
- Remove air cleaner outlet pipe.
- Rotate belt tensioner clockwise, using a suitable tool to relieve t...
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COMPONENT LOCATION DIAGRAMS FOR 2004 Ford Expedition AUTOMOBILES
Component location diagrams for most 2004 Ford Expedition cars and light trucks sold in the U.S. from 1990+.
Engine Rear End Components Diagram for 2004 Ford Expedition 4.6 V8 GAS Components on diagram: |
Engine Compartment Components Diagram for 2004 Ford Expedition 5.4 V8 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 2004 Ford Expedition AUTOMOBILES
OEM drawn wiring diagrams for most 2004 Ford Expedition cars and light trucks sold in the U.S.
2004 Ford Expedition 5.4 V8 GAS Wiring Diagram Components on diagram: |
2004 Ford Expedition 4.6 V8 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2004 Ford Expedition AUTOMOBILES
OEM TSB listings for most 2004 Ford Expedition cars and light trucks sold in the U.S. from 1985+.
Document: WHITE FLAKES COMING FROM A/C VENTS - REVISED Vehicle: 2004 Ford Expedition 4.6 V8 GAS Auto Systems: |
Document: 4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON ACCELERATION / DECELERATION OR BINDING ON SLOW TURNS Vehicle: 2004 Ford Expedition 4.6 V8 GAS Symptoms: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2004 Ford Expedition AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2004 Ford Expedition cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2004 Ford Expedition cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2004 Ford Expedition cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2004 Ford Expedition cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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