Just wondering how they work... My 03 Ex is outta warranty, but I see there is one or more TSB's on some things (rattling cladding for example; still looking for the rattling door TSB). Anyhow, will / should Ford still honor the TSB even if the truck is beyond warranty?

Thanks.

 

Technical Service Bulletins (TSBs) are simply field instructions to dealer technicians to provide additional technical data, service updates, diagnostic nfo, changes to service documentation, corrections, clarifications, etc. They are not recalls so there is nothing to be "honored" as would a recall or warranty.

TSBs often do address as to whether recommended repairs are covered and tell the dealer how to make the correct warranty claim for reimbursement from Ford. If a vehicle is out of the manufacturer's warranty, then obviously these provisions do not apply.

Recalls and Owner Notification Programs (ONPs) often do provide additional coverage for vehicle owners. Each one has its own rules and allowances, so it is necessary to carefully read each program's rules.

Steve

Steve

 

I just looked thru the list of TSBs for your truck as of '05, and I didn't notice anything about door rattles, other than this.

Article No. 03-23-3 NOISE FROM DOOR CLADDING
Publication Date: November 7, 2003
FORD: 2003 EXPEDITION
LINCOLN: 2003 NAVIGATOR

ISSUE: Some 2003 Expedition vehicles built before June 16, 2003, and 2003 Navigator vehicles built before August 4, 2003 may exhibit a flapping, fluttering, vibrating, or rattling noise from the cladding at the bottom of the front and/or rear doors at highway speeds. Navigator vehicles may also exhibit a squeak noise at highway speeds from the same area.

ACTION: For Expedition vehicles, install adhesive-backed foam blocks between the cladding and the door exterior skin. This will eliminate movement between the cladding and the door, and eliminate contact between the closeout flange and the door. For Navigator vehicles, remove the cladding from the door and replace the original attachment clips with new. Install foam blocks on the back side of the cladding on vehicles that were not originally equipped with some or all of them.

EXPEDITION PROCEDURE
Using a Bondo spreader or similar wide, flat, plastic tool, insert tool at the corner between the cladding and the door exterior skin. Slide tool to the area of the cladding where foam block will be inserted, and use tool to gently pry cladding away from the door.

NOTE: DO NOT FLEX THE CLADDING EXCESSIVELY, OR CLIP BREAKAGE AND/OR CLADDING DAMAGE WILL RESULT. DO NOT USE A NARROW OR THICK TOOL, SUCH AS A BODY "BONE", AS THIS MAY LEAVE WHITE WITNESS MARKS IN THE CLADDING.

Clean the inside cladding surface where the foam block will be applied and allow surface to dry before installing. Remove adhesive backing from the foam block, and place block between the cladding and door with the adhesive side facing the cladding, against the closeout flange. Continue placing foam blocks in this manner on the affected door. Two foam blocks are required for any affected front door, and one foam block is required for any affected rear door.

NAVIGATOR PROCEDURE
Cover a minimum of 101mm (4") of the door surface along and above the top edge of the cladding with body tape to protect the paint surface.

NOTE: THIS STEP MUST BE PERFORMED OR DAMAGE TO THE SHEET METAL AND PAINT MAY OCCUR DURING CLADDING REMOVAL.

Wrap the metal parts of clip removal tools (Snap-On A177A and Snap-On YA331), including the flange on the handle of tool YA331, in masking tape to protect the paint from damage during tool use. Place vehicle on a hoist and adjust to a good working height. Gently flex the vertical rear closeout of the front door cladding to expose the rear lower clip. Insert the clip removal tool (Snap-On A177A) through the flexed closeout, locate the clip, and insert the fork of the tool between the clip and the door. Push on the clip while applying twisting force on the tool until the clip pops out of the door. Repeat Steps 5 and 6 for the remainder of the clips (6 total for front door, 5 total for rear door) on the bottom and sides of the door panel.
Using a Bondo spreader or similar wide, flat, plastic tool, gently bend the top edge of the cladding away from the door skin to allow tool access to the top row of clips.

NOTE: DO NOT FLEX THE CLADDING EXCESSIVELY, OR CLIP BREAKAGE AND/OR CLADDING DAMAGE WILL RESULT. DO NOT USE A NARROW OR THICK TOOL, SUCH AS A BODY "BONE", AS THIS MAY LEAVE WHITE WITNESS MARKS IN THE CLADDING.

Insert tool (Snap-On YA331) between the top edge of the cladding and the door, beginning at the rearmost clip. Make sure metal parts of tool are wrapped with tape before using, see Step 2. Squeeze the handle of the tool to pop the clip out of the door. Continue in this manner to remove all the clips from the door (9 clips along the top edge of the front door cladding and 7 clips along the top edge of the rear door cladding). Lay the cladding on a clean, covered work bench, outward side down. Remove all attachment clips (15 for the front door piece, 12 for the rear door piece) from their mounting locations and discard.
NOTE: DO NOT REUSE ATTACHMENT CLIPS, AS THEIR RETENTION PROPERTIES CANNOT BE GUARANTEED ONCE THEY HAVE BEEN REMOVED FROM THE SHEET METAL.

Install new clips and foam blocks from service kit(s) as appropriate. Directions for installation are contained in the instruction sheets, included with the kits.
Reinstall cladding to door skin by aligning the cladding with the door and pushing the clips into the holes in the door skin.

3L7Z-78465K00-AA Kit - Front Door (Navigator)
3L7Z-78465K00-BA Kit - Rear Door (Navigator)
3L1Z-78465K00-AA Kit - Front & Rear Door (Expedition)

 

NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by "do-it-yourselfers". Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle.

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