service FORD EXPEDITION 2005 2.G Repair Manual

When refueling always shut the engine off and never allow
sparks or open flames near the filler neck. Never smoke while
refueling. Fuel vapor is extremely hazardous under certain conditions.
Care should be taken to avoid inhaling excess fumes.
The flow of fuel through a fuel pump nozzle can produce static
electricity, which can cause a fire if fuel is pumped into an
ungrounded fuel container.
Use the following guidelines to avoid static build-up when filling an
ungrounded fuel container:
•Place approved fuel container on the ground.
•DO NOT fill a fuel container while it is in the vehicle (including the
cargo area).
•Keep the fuel pump nozzle in contact with the fuel container while
filling.
•DO NOT use a device that would hold the fuel pump handle in the fill
position.
Fuel Filler Cap
Your fuel tank filler cap has an indexed design with a 1/4 turn turn on/off
feature.
When fueling your vehicle:
1. Turn the engine off.
2. Carefully turn the filler cap counterclockwise 1/4 turn of a turn until it
stops.
3. Pull to remove the cap from the fuel filler pipe.
4. To install the cap, align the tabs on the cap with the notches on the
filler pipe.
5. Turn the filler cap clockwise 1/4 turn of a turn until at least one click
is heard.
If ”Check fuel cap” displays in the message center or the ”Service Engine
Soon” indicator (vehicle without message center) comes on and stays on
after you start the engine, the fuel filler cap may not be properly
installed. Turn off the engine, remove the fuel filler cap, align the cap
properly and reinstall it.
If you must replace the fuel filler cap, replace it with a fuel filler
cap that is designed for your vehicle. The customer warranty may
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be void for any damage to the fuel tank or fuel system if the
correct genuine Ford or Motorcraft fuel filler cap is not used.
The fuel system may be under pressure. If the fuel filler cap is
venting vapor or if you hear a hissing sound, wait until it stops
before completely removing the fuel filler cap. Otherwise, fuel may
spray out and injure you or others.
If you do not use the proper fuel filler cap, excessive pressure or
vacuum in the fuel tank may damage the fuel system or cause
the fuel cap to disengage in a collision, which may result in possible
personal injury.
Choosing the right fuel
Use only UNLEADED FUEL. The use of leaded fuel is prohibited by law
and could damage your vehicle.
Your vehicle was not designed to use fuel or fuel additives with metallic
compounds, including manganese-based additives. Studies indicate that
these additives can cause your vehicle’s emission control system to
deteriorate more rapidly. In Canada, premium grade fuel generally
contains more metallic additives than regular fuel. We recommend using
regular grade fuel. In Canada, many fuels contain metallic additives, but
fuels free of such additives may be available; check with your local fuel
dealer.
Do not use fuel containing methanol. It can damage critical fuel system
components.
Repairs to correct the effects of using a fuel for which your vehicle was
not designed may not be covered by your warranty.
Octane recommendations
Your vehicle is designed to use
“Regular” unleaded gasoline with
pump (R+M)/2 octane rating of 87.
We do not recommend the use of
gasolines labeled as “Regular” that
are sold with octane ratings of 86 or lower in high altitude areas.
Do not be concerned if your engine sometimes knocks lightly. However, if
it knocks heavily under most driving conditions while you are using fuel
with the recommended octane rating, see your dealer or a qualified
service technician to prevent any engine damage.
87(R+M)/2 METHOD
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Fuel quality
If you are experiencing starting, rough idle or hesitation driveability
problems during a cold start, try a different brand of gasoline. If the
problems persist, see your dealer or a qualified service technician.
It should not be necessary to add any aftermarket products to your fuel
tank if you continue to use high quality fuel of the recommended octane
rating. Aftermarket products could cause damage to the fuel system.
Repairs to correct the effects of using an aftermarket product in your
fuel may not be covered by your warranty.
Many of the world’s automakers approved the World-wide Fuel Charter
that recommends gasoline specifications to provide improved
performance and emission control system protection for your vehicle.
Gasolines that meet the World-wide Fuel Charter should be used when
available. Ask your fuel supplier about gasolines that meet the
World-wide Fuel Charter.
Cleaner air
Ford endorses the use of reformulated “cleaner-burning” gasolines to
improve air quality.
Running out of fuel
Avoid running out of fuel because this situation may have an adverse
affect on powertrain components.
If you have run out of fuel:
•You may need to cycle the ignition from OFF to ON several times after
refueling, to allow the fuel system to pump the fuel from the tank to
the engine.
•YourService engine soonindicator may come on. For more
information on theService engine soonindicator, refer to the
Instrument clusterchapter.
Fuel Filter
For fuel filter replacement, see your dealer or a qualified service
technician. Refer to the scheduled maintenance guide for the appropriate
intervals for changing the fuel filter.
Replace the fuel filter with an authorized Motorcraft part. The
customer warranty may be void for any damage to the fuel system
if an authorized Motorcraft fuel filter is not used.
ESSENTIALS OF GOOD FUEL ECONOMY
Measuring techniques
Your best source of information about actual fuel economy is you, the
driver. You must gather information as accurately and consistently as
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It is important to note the box in the lower left corner of the window
sticker. These numbers represent the range of fuel economy expected on
the vehicle under optimum conditions. Your fuel economy may vary
depending upon the method of operation and conditions.
EMISSION CONTROL SYSTEM
Your vehicle is equipped with various emission control components and a
catalytic converter which will enable your vehicle to comply with
applicable exhaust emission standards. To make sure that the catalytic
converter and other emission control components continue to work
properly:
•Use only the specified fuel listed.
•Avoid running out of fuel.
•Do not turn off the ignition while your vehicle is moving, especially at
high speeds.
•Have the items listed in yourScheduled Maintenance Guide
performed according to the specified schedule.
The scheduled maintenance items listed in theScheduled Maintenance
Guideare essential to the life and performance of your vehicle and to its
emissions system.
If other than Ford, Motorcraft or Ford-authorized parts are used for
maintenance replacements or for service of components affecting
emission control, such non-Ford parts should be equivalent to genuine
Ford Motor Company parts in performance and durability.
Do not park, idle, or drive your vehicle in dry grass or other dry
ground cover. The emission system heats up the engine
compartment and exhaust system, which can start a fire.
Illumination of theService engine soonlight, charging system warning
light or the temperature warning light, fluid leaks, strange odors, smoke
or loss of engine power, could indicate that the emission control system
is not working properly.
Exhaust leaks may result in entry of harmful and potentially
lethal fumes into the passenger compartment.
Do not make any unauthorized changes to your vehicle or engine. By
law, vehicle owners and anyone who manufactures, repairs, services,
sells, leases, trades vehicles, or supervises a fleet of vehicles are not
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permitted to intentionally remove an emission control device or prevent
it from working. Information about your vehicle’s emission system is on
the Vehicle Emission Control Information Decal located on or near the
engine. This decal identifies engine displacement and gives some tune up
specifications.
Please consult yourWarranty Guidefor complete emission warranty
information.
On board diagnostics (OBD-II)
Your vehicle is equipped with a computer that monitors the engine’s
emission control system. This system is commonly known as the On
Board Diagnostics System (OBD-II). This OBD-II system protects the
environment by ensuring that your vehicle continues to meet
government emission standards. The OBD-II system also assists the
service technician in properly servicing your vehicle. When theCheck
engine/Service engine soonlight illuminates, the OBD-II system has
detected a malfunction. Temporary malfunctions may cause yourCheck
engine/Service engine soonlight to illuminate. Examples are:
1. The vehicle has run out of fuel. (The engine may misfire or run
poorly.)
2. Poor fuel quality or water in the fuel.
3. The fuel cap may not have been securely tightened.
These temporary malfunctions can be corrected by filling the fuel tank
with good quality fuel and/or properly tightening the fuel cap. After three
driving cycles without these or any other temporary malfunctions
present, theCheck engine/Service engine soonlight should turn off. (A
driving cycle consists of a cold engine startup followed by mixed
city/highway driving.) No additional vehicle service is required.
If theCheck engine/Service engine soonlight remains on, have your
vehicle serviced at the first available opportunity.
Readiness for Inspection/Maintenance (I/M) testing
In some localities, it may be a legal requirement to pass an I/M test of
the on-board diagnostics system. If yourCheck engine/Service engine
soonlight is on, refer to the description in theWarning lights and
chimessection of theInstrument Clusterchapter. Your vehicle may not
pass the I/M test with theCheck engine/Service engine soonlight on.
If the vehicle’s powertrain system or its battery has just been serviced,
the on-board diagnostics system is reset to a “not ready for I/M test”
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condition. To ready the on-board diagnostics system for I/M testing, a
minimum of 30 minutes of city and highway driving is necessary as
described below:
•First, at least 10 minutes of driving on an expressway or highway.
•Next, at least 20 minutes driving in stop-and-go, city-type traffic with
at least four idle periods.
Allow the vehicle to sit for at least eight hours without starting the
engine. Then, start the engine and complete the above driving cycle. The
engine must warm up to its normal operating temperature. Once started,
do not turn off the engine until the above driving cycle is complete.
CHECKING AND ADDING POWER STEERING FLUID
Check the power steering fluid. Refer to the scheduled maintenance
guide for the service interval schedules. If adding fluid is necessary, use
only Ford Premium Power Steering Fluid or MERCONAT F.
1. Start the engine and let it run
until it reaches normal operating
temperature (the engine coolant
temperature gauge indicator will be
near the center of the normal area
between H and C).
2. While the engine idles, turn the
steering wheel left and right several
times.
3. Turn the engine off.
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4. Check the fluid level in the
reservoir. It should be between the
MIN and MAX lines. Do not add
fluid if the level is in this range.
5. If the fluid is low, add fluid in
small amounts, continuously
checking the level until it reaches
the range between the MIN and
MAX lines. Be sure to put the cap
back on the reservoir.
BRAKE FLUID RESERVOIR
The fluid level will drop slowly as
the brakes wear, and will rise when
the brake components are replaced.
Fluid levels between the “MIN” and
“MAX” lines are within the normal
operating range; there is no need to
add fluid. If the fluid levels are
outside of the normal operating
range the performance of your
brake system could be
compromised; seek service from
your dealer immediately.
TRANSMISSION FLUID
Checking automatic transmission fluid
Refer to yourScheduled Maintenance Guidefor scheduled intervals for
fluid checks and changes. Your transmission does not consume fluid.
However, the fluid level should be checked if the transmission is not
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3. Install a new air filter element
into the tray assembly.
4. Return air filter tray to original
position by pressing firmly on the
handle until all rearward movement
stops and secure the two clamps.
MOTORCRAFT PART NUMBERS
Component 5.4L 3V V8 engine
Air filter element FA-1754
Battery BXT-65-650
Fuel filter FG-986B
Oil filter FL-820-S
PCV valve
1
Spark plugs2
1
The PCV valve is a critical emission component. It is one of the items
listed in theScheduled Maintenance Guideand is essential to the life
and performance of your vehicle and to its emissions system.
For PCV valve replacement, see your dealer or a qualified service
technician. Refer to theScheduled Maintenance Guidefor the
appropriate intervals for changing the PCV valve.
Replace the PCV valve with one that meets Ford material and
design specifications for your vehicle, such as a Motorcraft or
equivalent replacement part. The customer warranty may be void
for any damage to the emissions system if such a PCV valve is not
used.
2For spark plug replacement, see your dealer or a qualified service
technician. Refer to theScheduled Maintenance Guidefor the
appropriate intervals for changing the spark plugs.
Replace the spark plugs with ones that meet Ford material and
design specifications for your vehicle, such as Motorcraft or
equivalent replacement parts. The customer warranty may be
void for any damage to the engine if such spark plugs are not
used.
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Fluid Ford Part
NameApplication Capacity
Front axle
lubricantMotorcraft SAE
75W-90 Fuel
Efficient High
Performance
Synthetic Rear
Axle Lubricant4x4 vehicles 3.5-3.7 pints
(1.8-2.0L)
Rear axle
lubricant
4Motorcraft SAE
75W-140
Synthetic Rear
Axle LubricantConventional
differential
(8.8 inch axle)4.0 pints (1.90L)
Conventional
differential
(9.75 inch axle)4.5 pints (2.13L)
Limited-slip
differential
(8.8 inch axle)
5
3.75 pints
(1.77L)5
Limited-slip
differential
(9.75 inch axle)
5
4.25 pints
(2.01L)5
Windshield
washer fluidMotorcraft
Premium
Windshield
Washer
ConcentrateAll 4.5 quarts
(4.1L)
1Ensure the correct automatic transmission fluid is used. Transmission
fluid requirements are indicated on the dipstick or on the dipstick
handle. Check the container to verify the fluid being added is of the
correct type. Refer to yourScheduled Maintenance Guideto determine
the correct service interval.
Some transmission fluids may be labeled as dual usage, such as
MERCONand MERCONV. These dual usage fluids are not to be used
in an automatic transmission that requires use of the MERCONtype
fluid. However, these dual usage fluids may be used in transmissions that
require the MERCONV type fluid.
MERCONand MERCONV type fluids are not interchangeable.
DO NOT mix MERCONand MERCONV. Use of a transmission
fluid that indicates dual usage (MERCONand MERCONV) in
an automatic transmission application requiring MERCONmay
cause transmission damage. Use of any fluid other than the
recommended fluid may cause transmission damage.
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2Indicates only approximate dry-fill capacity. Some applications may vary
based on cooler size and if equipped with an in-tank cooler. The amount
of transmission fluid and fluid level should be set by the indication on
the dipstick’s normal operating range.
3Add the coolant type originally equipped in your vehicle.
4Your vehicle’s rear axle is filled with a synthetic rear axle lubricant and
is considered lubricated for life. These lubricants are not to be checked
or changed unless a leak is suspected, service is required or the axle has
been submerged in water. The axle lubricant should be changed any time
the axle has been submerged in water.
Service refill capacities are determined by filling the rear axle 0.9 inch
(23mm) below the bottom of the filler hole.
5Add 4 oz. (118 ml) of Additive Friction Modifier XL-3 (or equivalent)
for complete refill of Limited Slip axles. For complete refills, fill using the
Additive Friction Modifier first.
6Use of synthetic or synthetic blend motor oil is not mandatory. Engine
oil need only meet the requirements of Ford specification
WSS-M2C930-A and the API Certification mark.
LUBRICANT SPECIFICATIONS
ItemFord part
nameFord part
numberFord
specification
Hinges, latches,
striker plates
and rotors, seat
tracks, fuel filler
door hinge and
springMulti-Purpose
GreaseXG-4 or XL-5 ESR-M1C159-A
or ESB-M1C93-B
Lock cylinders,
swing-away
spare tire carrier
padlockPenetrating and
Lock LubricantMotorcraft XL-1 none
Brake fluid Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
FluidPM-1 ESA-M6C25-A
and DOT 3
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