I have a 2004 Expedition. The dealer has replaced the limited slip differential two times in 10,000 miles. Now at 13,000 miles I am getting the same noise when making a left had turn. I took it to the dealer and it would not act up, this week I took the truck out and video taped/recorded the noise that it is making (it was a particularly bad day). Any one having this problem rapidly?

 

They've definitely had problems with the rearends on the newer Expys. You cases sound worse than most.

Good Luck.

 

If someone with an 03-04 EXP hasen't had the problem I would be surprised. I have a 2003 EB rev-C and on Rear End #3. At 18k on the odometer then I would say that the quality of those read ends is not too good. To further add fuel to the mess we are actually on the third version of that rear end. accouring to the area rep the current rear end, (Chunk/axles/etc.) is from the 04 production line. With close to 4k on it we have gained back the clutch chatter at 20 around a tight right turn and a slight clunk when at steady speed at 40 and then slight acceleration. I found that is is all about learning the way to duplicate the noise so that you can be specific for the service advisor. Currently thinking of looking for an OEM chunk.

 

Just a thought! But, has anyone had Ford check to see if the clutch packs are set to tight???I know that you can stack those limited slip clutch packs tight enough to almost act like a locker!!!

 

Yep. They replaced my clutch pack and adjusted them after that as well. I wonder if the recommended lube is sufficient.

 

I have a very early build (May of '02) 2003 Expedition and I HAVE NOT had the rear-end trouble that most have, neither has my doctor's wife who bought hers the same week I did from the same dealer. I have performed the cold, hard left and hard right acceleration test to determine whether there's any grinding or binding coming from the rear-end and I have had absolutely no noises or binding sensations at all. I have performed that test numerous times, on cold and hot days with a cold and warm engine, and every time I had no noises or vibrations/grinding/binding. I think that I lucked out and actually got a good rear-end. The only problems I have had are with the exterior rearview mirrors and the door rattles. However, I no longer have the door rattles AT ALL, they're completely gone, because the dealer replaced both door seals(hard and soft) and the door latches. Ever since, I have had no rattles. I hope to get the mirror module and motors replaced soon to solve the rearview mirror problems. I am coming up on 19,000 miles with no significant problems so I consider myself one of the lucky ones. However, I am experiencing the clunk at 40 mph when I let off the accelerator and then press it again. This same clunk can be heard right before I come to a complete stop. The weird thing is that it has made this noise ever since I drove it off the lot so I have always thought it was normal seeing as how it isn't causing any other problems. Other than that, I love my Eddie Bauer Expy.

 

I had the same problem. Had the groaning noise, and the dealer replaced a clutch pack (i think that's what it was). Then I had a whining from 30mph up, and they replaced the rear end. Now about 1500 mls later, I'm back with the groaning noise. The truck has 18k on it, and I'm not too happy about the time in the shop for a new truck.
Has anyone noticed where the top of the back doors meet the body there is metal to metal contact? How about rattles?

 

Ed......when do you experience the groaning noise? As far as the rattles go, have the dealer replace the door seals and latches per a Special Service Message that they should be aware of. And yes I have noticed the metal-to-metal contact, but I don't know if replacing the seals and latches on the rear doors will solve that problem. My rear doors do not rattle so I only had the new seals and latches placed on the front two doors, completely solving the rattles, solid ride now, even over hard and small bumps. There isn't but a tiny bit of metal-to-metal contact on my rear doors, how about you?

 

My front cladding rattled, they replaced per TSB. Back door rattles and they said they fixewd it (tightened latch) a day later it rattled again. Will fix when I take in to have seald replaced.

The clunk (faint only I could hear) when coming to a stop was fixed when I added Tranny fluid.

I saw no leaks, but the level was at the "ADD" mark. What's with that.

 

Khelms, I get the groan noise from the rear when making a turn from a stop. The metal to metal contact is at the top rear of the rear doors.