rearend chatter
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New User
Joined: Jul 2003
Posts: 22
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From: Acushnet, MA
rearend chatter
Hi all, i have a question about the rearend chatter some of you folks have had in your 03- 04 Expeditions...was it a constant chattering,or more of a sporadic type of noise during cornering? i have just started to notice some chatter/ratcheting sound on 3 occations...for the most part the Expy is very quiet...i did go to my dealer yesterday,and spoke to him about the sound...he knew rightaway what i was talking about...its going in Tuesday...hope all goes well 
Junior User
Joined: Feb 2004
Posts: 81
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From: Washingtonville, NY
Rear end chatter
This was the first of many. It happened from a stop to making a turn. They replaced the clutch pack. Developed a whine after this at 40 mph. then they replaced the rear gear. good luck
Junior User
Joined: Feb 2004
Posts: 81
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From: Washingtonville, NY
There was 2 other tsb's listed for this. I think 1 was the drive shaft and the other may have been the transfer case. Search other posts to find it. Good luck again. Mine is going back in on Friday to see if they can cure the problem with the nibbling. 4th time. after this its going to arbitration. Too many problems with this truck. Love the truck though.
New User
Joined: Oct 2004
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My service rep tried and suceeded in making me feel like an idiot. He's claiming that this nibbling is the limited slip rear end and is normal. I told that I'd be back with some proof that this is not normal. Can someone post the TSB on this? I can't get the TSB link to come up on my computer!
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From: Brentwood,CA
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New User
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Can someone explain what 'nibbling' is? I have an 03 exp 4x4 that had a bad whine at light throttle and serious chatter or growling when turning from a stop. Turns out the rear differential was full of metal and needed to be replaced. I originally thought it needed additive. It must have been the metal in the clutch pack. If you add the additive, try doing tight figure eights for a while to work the additive in.
Junior User
Joined: Feb 2004
Posts: 81
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From: Washingtonville, NY
Nibbling
Nibbling is the vibration transmitted through the tires or front end. It causes the steering wheel to shake back and forth. This happened with my 03 above 70 MPH. I also had the chatter when making a turn from a stop. It was the clutch pack. Ford replaced the rear fluid with a synthetic grease. I developed the whine at 40mph under light acceleration. Ford replaced the gears in the rear. 