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2003-2006 Ford Expedition Repair Manual

Ford Expedition repair manualsThe second generation Ford Expedition was introduced in 2003 in a four-door sport utility vehicle body style (2WD and 4WD submodels). Two trim levels were available: standard trim XLT and two-tone trim Eddie Bauer. In 2005 Ford Expedition was facelifted (the base 4.6L Triton V8 engine was dropped as the 5.4L Triton V8 was made standard on all Expeditions and updated with 24-valve technology and variable valve timing. The new four-speed automatic 4R75E transmission was added).
General information: Class: full-size SUV; Body style: 4-door SUV; Layout: front engine, rear-wheel drive or four-wheel drive; Wheelbase: 119.0 in (3,023 mm); Length: 205.8 in (5,227 mm); Width: 78.7 in (1,999 mm); Height: 77.6 in (1,971 mm) 2003-2004; 76.7 in (1,948 mm) [2WD], 76.6 in (1,946 mm) [4WD] 2005-2006.
Engines:
4.6L Triton 16V SOHC V8 produced 232 hp (173 kW) and 291 lb·ft (395 N·m)
General information: Configuration: V8; Displacement: 4,601 cc (280.8 cu in); Cylinder bore: 3.552 in (90.2 mm); Piston stroke: 3.543 in (90.0 mm); Valvetrain: OHC with Roller finger followers.
5.4L Triton 16V SOHC V8 produced 260 hp (194 kW) and 350 lb·ft (475 N·m) [2003-2004]
General information: Configuration: V8; Displacement: 4,951 cc (302.1 cu in); Cylinder bore: 3.629 in (92.2 mm); Piston stroke: 3.649 in (92.7 mm); Valvetrain: OHC with Roller finger followers.
5.4L Triton 24V SOHC VCT V8 produced 300 hp (224 kW) and 365 lb·ft (495 N·m) [2005-2006]
General information: Configuration: V8; Displacement: 4,951 cc (302.1 cu in); Cylinder bore: 3.629 in (92.2 mm); Piston stroke: 3.649 in (92.7 mm); Valvetrain: OHC with Roller finger followers.
Repair operations: repair operations possible with the engine in the vehicle; intake manifold: removal and installation; exhaust manifold: removal and installation; valve covers: removal and installation; cylinder head: removal, inspection and installation; engine: removal and installation; engine block: cleaning and inspection; spark plug thread repair; timing chain wear: check; timing cover and timing chain: removal and installation; oil pump: removal, inspection and installation; oil pan: removal, inspection and installation; camshaft and lifters: removal, inspection and installation; crankshaft: inspection, removal and installation etc.
Transmissions:
4-speed Ford 4R70W automatic transmission
Gear ratios (overall): I – 2.84:1; II – 1.55:1; III – 1.0:1; IV – 0.70:1; R – 2.32:1
4-speed Ford 4R75E automatic transmission
Gear ratios (overall): I – 2.84:1; II – 1.55:1; III – 1.0:1; IV – 0.70:1; R – 2.23:1
Repair operations: manual shift linkage: inspection, removal, installation and adjustment; throttle valve mechanisms: removal, installation and adjustment; kickdown mechanisms: removal, installation and adjustment; vacuum modulator: check and replacement; band adjustment; automatic transmission: removal and installation; electronic shift transmission: general information; manual lever position sensor: adjustment; neutral start switch: adjustment.
Transfer case:
Borg Warner BW 44-16 transfer case
General information: Low-range ratio: 2.64:1; Low-range: helical planetary design; Fluid type: ATF; Shift pattern: 2H-4WD-4H-4L; Shift control: electrical
Repair operations: transfer case: removal and installation; transfer case: overhaul; front output shaft oil seal: removal and replacement; rear output shaft oil seal: removal and replacement; rear extension housing bushing: removal and replacement; manual shift lever assembly: removal and installation; electronic shift: removal and installation.
Other manuals: cooling, heating and air conditioning systems; fuel and exhaust systems; engine electrical systems; emissions and engine control systems; driveline; brakes; suspension and steering systems; body; chassis electrical system; wiring diagrams. All 2003-2006 Ford Expedition repair manuals are written specifically for the do-it-yourselfer.