A few problems with an 03 Expedition

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I have an early production 2003 Ford Expedition Eddie Bauer 4.6 (A VIN build code/4/02 manufacture date) that has been to the dealer for any and every TSB and other malfunction. I thought everything was fixed but two new possible problems seem to have emerged.

1) A/C: Ever since the vehicle was new, when starting the vehicle cold, with the A/C engaged, the compressor would make a loud clashing sound. Dealer has checked the unit and said that the compressor and clutch are within factory specs. The noise disappears when the vehicle has warmed up. Last week in 90 degree weather the automatic temperature control started blowing warm air for about a minute or so. Thought the refrigerant might have been low, but after messing with the temperature setting (set at 72) and turning the unit on and off, I got the A/C back. Long ago I saw a post on a TSB for A/C problems but could not find it. Would anyone have a number?

2) Drivetrain: After about 5,000 miles on the odometer, I noticed that during low speed turns and light acceleration and slowing down and light acceleration that the truck will jolt. This problem tends to be occassional, but more frequent with about 23,000 miles now. Dealer said they could not replicate the problem, and tried flashing the PCM, saying that it may have been out of date. My brother tends to think it may be a problem with the differential (it's the 3.55 limited slip)?

So far, my local Ford dealer has been great about fixing problems, but I have my regrets about buying a vehicle during its introduction.

Any thoughts or answers would be greatly appreciated!
 

bnvus

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Hey jsoko1,

I have the same exact problem with the AC. The whole engine shakes when I kick it in in the morning. Dealer has been unable to replicate the problem because as you said it goes away after warm up. The differential problem you mention might be the front clutch pack problem that has been mentioned here before. The problem has been assciated with the 3.73 limited slips which is what you should have in your Bauer. As you guessed it there is a TSB out there for repairing the clutch packs. Do asearch on the forum for it. Good luck.
 
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