03 Expedition AWD Problems
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03 Expedition AWD Problems
I just had the left hub and actuator on my 03 Expd replaced with 59,000 miles. I was traveling down the highway @ 50 mph in 2WD and switched to AWD and there was a terrible noise so I switched back to 2WD. Tried it a couple of times with the same results.
I don't believe the S clip has been installed and was wondering if the half shafts traveling at different speeds could have caused this. After it has been fixed they say there is a clunk when going into AWD. They think the noise is coming from the transfer case.
Any thoughts on what is going on. Is there anything Ford should stand behind.
I don't believe the S clip has been installed and was wondering if the half shafts traveling at different speeds could have caused this. After it has been fixed they say there is a clunk when going into AWD. They think the noise is coming from the transfer case.
Any thoughts on what is going on. Is there anything Ford should stand behind.
Sit. Stay.
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From: Washington State
I had that noise...well...if the noise sounded like yer grindin' up half your wheel bearings and then a big crackin' thud...
They replaced the whole hub assembly and now no noise but a small thump when the everything engages. It shouldn't be more than a small thump.
Did you ask them if they perform the S-clip TSB procedures?
They replaced the whole hub assembly and now no noise but a small thump when the everything engages. It shouldn't be more than a small thump.
Did you ask them if they perform the S-clip TSB procedures?
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I just picked it up and there is a terrible noise going fron 2WD to AWD. They think it is the syncros in the transfer case. They haven't found out if the s clip was installed.
Anyone know if not having the S-clip would cause the hub and actauter to go?
Anyone know if not having the S-clip would cause the hub and actauter to go?
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Get the TSP done to the front, that will fix all your problems. I had it to the dealer three times telling them something was wrong. That grinding and clunking is screwing up your hub!!! They just kept blowing me off, then I did some research on this site and others and found out there was a problem with the front end. You should not feel a thing when going from 2WD to AWD!!!!!
Sit. Stay.
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From: Washington State
Originally Posted by peterwarren
You should not feel a thing when going from 2WD to AWD!!!!!
I tried it today (again) and no noise. There is a small thump when the front axle actually engages in 4AWD. Not when I switch it but when it is working as designed (engaging when there is a loss of rear traction).
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From: Oregon
I've always felt the claims by manufacture's that you can switch on the fly were mostly for marketing purposes. I always wait till I am at a very slow speed to switch to AWD.(less than 2-3MPH). I guess I am just lucky the weather or driving conditions don't change that fast here to require me to go to AWD at 50MPH. 
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Still not fixed
They opened up the transfer case and found a shift collar that was cracked so they replaced that and it did not help the noise at all. The noise is really alot worse than just a thug almost as if something is grinding. I will stop out tomorrow and remind them again of the s-clip.
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Dealerships are money making IDIOTS!!!!!! I had it to them THREE TIMES before I had to argue to have the DAMN MF TSB done!!! Mine had approx 18,000 miles when the TSB finally got accomplished. Mine was clunking and grinding just like yours prior to the TSB. I drove mine in AWD most of the time because I knew the clunking and grinding was BAD..... I did not switch between 2WD and AWD very much. It drove fine in AWD 70-80 MPH. Yours probably also has a kind of howl in 2WD right? IT's like the hub does not fully disengage. The TSB mentions half shaif speed or something... So anyway, argue for them to do the TSB and have them look at those hubs and make sure they are ok, if not, have them replaced and get it in WRITING if they say the hubs are OK!!!! If you still have your warranty it should not cost a thing, just time. Anyone want to take bets on "If that shift collar was even cracked???"
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It's Fixed
They ended up calling Ford and they recomended installing the s-clip. And it didn't make noise anymore !!
The shift collar was cracked. Not sure if it was caused from not having the s-clip or something else. The dealership offered to pay the entire repair bill themselves as Ford had turned them down being that the truck has 59,000 miles in it.
Hats off to Luther Family Ford in Fargo ND
The shift collar was cracked. Not sure if it was caused from not having the s-clip or something else. The dealership offered to pay the entire repair bill themselves as Ford had turned them down being that the truck has 59,000 miles in it.
Hats off to Luther Family Ford in Fargo ND
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