Accepted Answer

Most service bulletins are for information only and not considered a recall ,so ford is unlikely to cover the costs.
The door ajar concern is not likely related to the Programming issue.The door ajar swiitches tend to stick on and can often be lubricated through the latches. If this doesn't help,your dealer can use the same scan tool to test the switches while they are checking for updates.

TSB 04-14-9

FORD:	2003-2004 Expedition
LINCOLN:	2003-2004 Navigator

 

ISSUE:

Some 2003-2004 Expedition/Navigator vehicles may exhibit the following symptoms in any combination:

• Intermittent Driveability Concerns
• Intermittent Flickering Of The Charging System Warning Indicator
• Malfunction Indicator Lamp (MIL) On With DTC's P0620 And/Or P0320 In Memory

These conditions may be caused either by chafing or corrosion of the 14305 harness, or an interaction of the PCM with the charging system.

ACTION:

Check the vehicle build date to select the appropriate Service Procedure.

SERVICE PROCEDURE

 

Vehicles built before 4/2/04: Reprogram PCM to the latest calibration using WDS release B32.2 or higher, and replace the 14305 harness. Apply a very light coat of electrical grease (F8AZ-19G208-AA) on the male pins of the alternator/regulator (C102A connection), and the pins of C192A on the 14305 harness (see Note).

Replace the 14305 harness as follows:

• Expedition built 3/18/02 - 1/31/03: 2L1Z-14305-AB
• Expedition built after 2/1/03: 3L1Z-14305-AB
• Navigator built 3/18/02 - 1/31/03: 2L7Z-14305-AB
• Navigator built after 2/1/03: 3L7Y-14305-AB

  NOTE:

  BEFORE APPLYING GREASE TO A NEW SERVICE HARNESS, CHECK THE ENGINEERING PART NUMBER. HARNESSES WITH ENGINEERING PART NUMBER 2L1T-AL, 2L7T-AL, 4L1T-AC, OR 4L7T-AC (OR WITH HIGHER SUFFIXES) ALREADY CONTAIN ELECTRICAL GREASE AND NO ADDITIONAL ELECTRICAL GREASE IS NECESSARY. DO NOT OVERAPPLY GREASE, AS TERMINAL DAMAGE MAY RESULT.

   

Vehicles built from 4/2/04 to 6/14/04: Reprogram PCM to the latest calibration using WDS release B32.2 or higher, and apply a very light coat of electrical grease on the male pins of the alternator/regulator (C102A connection), and the pins of C192A on the 14305 harness (see prior Note).

Vehicles built from 6/15/04 to 7/19/04: Only reprogram PCM to the latest calibration using WDS release B32.2 or higher.

NOTE:

VEHICLES BUILT AFTER 4/2/04 HAVE A PROTECTIVE SLEEVE ON THE 14305 HARNESS. VEHICLES BUILT AFTER 6/14/04 ALREADY HAVE GREASE IN THE 14305 HARNESS CONNECTORS.

 

NOTE:

DO NOT REPLACE THE ALTERNATOR UNLESS INDICATED BY WORKSHOP MANUAL DIAGNOSTICS.

LABOR OPERATION CLAIMING CHART
Operation	Labor Description	Application	Time
041409A	Vehicles Built Before 6/15/04: Check for codes, update the PCM calibration, and replace the 14305 harness if necessary. Apply a very light coat of electrical grease on the male pins of the alternator/regulator (C102A connection), and the pins of C192A on the 14305 harness.	Expedition Navigator	0.6 Hr. 1.4 Hrs.
041409B	Vehicles Built From 6/15/04 To 7/19/04: Check for codes update the PCM calibration only.	Expedition Navigator	0.4 Hr. 0.4 Hr.

PART NUMBER	PART NAME
2L1Z-14305-AB	Harness
2L7Z-14305-AB	Harness
3L1Z-14305-AB	Harness
3L7Y-14305-AB	Harness
F8AZ-19G208-AA	Electrical Grease

 

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage

Edited by Scottdagoalie on 7/20/2009 at 8:58 PM

Expert:	Scottdagoalie
Pos. Feedback:	98.6 %
Accepts:
Answered:	7/20/2009

Senior Master Tech.

30 years with Ford dealers