2003 FORD EXPEDITION engine

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.
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
Checking and adding brake fluid
Brake fluid should be checked and
refilled as needed. Refer to the
scheduled maintenance guide for
the service interval schedules.
1. Clean the reservoir cap before
removal to prevent dirt or water
from entering the reservoir.
MAX
MIN
MAX
MIN
Maintenance and Specifications
290

3. With the parking brake engaged and your foot on the brake pedal,
start the engine and move the gearshift lever through all of the gear
ranges. Allow sufficient time for each gear to engage.
4. Latch the gearshift lever in P (Park) and leave the engine running.
5. Remove the dipstick, wiping it clean with a clean, dry lint free rag. If
necessary, refer toIdentifying components in the engine compartment
in this chapter for the location of the dipstick.
6. Install the dipstick making sure it is fully seated in the filler tube.
7. Remove the dipstick and inspect the fluid level. The fluid should be in
the designated area for normal operating temperature or ambient
temperature.
Low fluid level
Do not drive the vehicle if the fluid
level is at the bottom of the dipstick
and the ambient temperature is
above 10°C (50°F).
Correct fluid level
The transmission fluid should be checked at normal operating
temperature 66°C-77°C (150°F-170°F) on a level surface. The normal
operating temperature can be reached after approximately 30 km (20
miles) of driving.
You can check the fluid without driving if the ambient temperature is
above 10°C (50°F). However, if fluid is added at this time, an overfill
condition could result when the vehicle reaches normal operating
temperature.
The transmission fluid should be in
this range if at normal operating
temperature (66°C-77°C
[150°F-170°F]).
The transmission fluid should be in
this range if at ambient temperature
(10°C-35°C [50°F-95°F]).
ADD COLD HOT DO NOT ADD
ADD COLD HOT DO NOT ADD
ADD COLD HOT DO NOT ADD
Maintenance and Specifications
292

High fluid level
Fluid levels above the safe range
may result in transmission failure.
An overfill condition of transmission
fluid may cause shift and/or
engagement concerns and/or possible damage.
High fluid levels can be caused by an overheating condition.
Adjusting automatic transmission fluid levels
Before adding any fluid, make sure the correct type is used. The type of
fluid used is normally indicated on the dipstick and also in the
Lubricant specificationssection in this chapter.
Use of a non-approved automatic transmission fluid may cause
internal transmission component damage.
If necessary, add fluid in 250 mL (1/2 pint) increments through the filler
tube until the level is correct.
If an overfill occurs, excess fluid
should be removed by a qualified
technician.
An overfill condition of
transmission fluid may cause shift and/or engagement concerns
and/or possible damage.
Do not use supplemental transmission fluid additives, treatments or
cleaning agents. The use of these materials may affect transmission
operation and result in damage to internal transmission components.
DRIVELINE UNIVERSAL JOINT AND SLIP YOKE
Your vehicle may be equipped with universal joints that require
lubrication. Refer to the scheduled maintenance guide for maintenance
intervals. If the original universal joints are replaced with universal joints
equipped with grease fittings, lubrication will also be necessary.
AIR FILTER MAINTENANCE
Refer to the scheduled maintenance guide for the appropriate intervals
for changing the air filter element.
When changing the air filter element, use only the Motorcraft air filter
element listed. Refer toMotorcraft Part Numbers.
Note:Do not start your engine with the air cleaner removed and do not
remove it while the engine is running.
ADD COLD HOT DO NOT ADD
ADD COLD HOT DO NOT ADD
Maintenance and Specifications
293

Changing the air filter element
1. Loosen the clamp that secures
the air inlet tube to the engine air
filter cover and disconnect the tube
from the cover.
2. Loosen the clamp that secures
the air filter cover to the air filter
housing and carefully separate the
cover from housing.
3. Remove the air filter element
from the air filter housing.
4. Install a new air filter element. Be careful not to crimp the filter
element edges between the air filter housing and cover. This could cause
filter damage and allow unmetered air to enter the engine if not properly
seated.
5. Replace the air filter cover and secure the clamp.
6. Replace the air inlet tube and secure the clamp.
Maintenance and Specifications
294

•Do not exceed 48 km/h (30 mph) with tire chains on your vehicle.
MOTORCRAFT PART NUMBERS
Component 4.6L V8 engine 5.4L V8 engine
Air filter element FA-1634 FA-1634
Battery BTX-65-650 BTX-65-650
Fuel filter FG-986B FG-986B
Oil filter FL-820-S FL-820-S
PCV valve EV-233 EV-238
Spark plugs* AWSF-32P AGSF-22WM
* Refer to Vehicle Emissions Control Information (VECI) decal for spark
plug gap information.
REFILL CAPACITIES
Fluid Ford Part Name Application Capacity
Brake fluid Motorcraft High
Performance DOT 3
Motor Vehicle Brake
FluidAll Fill to line on
reservoir
Engine oil
(includes filter
change)Motorcraft SAE
5W—20 Premium
Synthetic Blend
Motor OilAll 5.7L (6.0
quarts)
Fuel tank N/A All 106L (28.0
gallons)
Power steering
fluidMotorcraft MERCON
AT FAll Fill to line on
reservoir
Transmission
fluid
1Motorcraft
MERCONVATF4R70W 13.1L (13.9
quarts)2
Transfer case
fluidMotorcraft
MERCONAT F4x4 vehicles 1.9L (2.0
quarts)
Engine coolant
3Motorcraft Premium
Engine Coolant
(green-colored) or
Motorcraft Premium
Gold Engine Coolant
(yellow-colored)4.6L V8 engine
with 1 row
radiator21.8L (23.0
quarts)
Maintenance and Specifications
300

Fluid Ford Part Name Application Capacity
5.4L V8 engine
with 1 row
radiator24.1L (25.5
quarts)
4.6L V8 engine
with 1 row
radiator and
aux rear heat23.5L (24.8
quarts)
5.4L V8 engine
with 1 row
radiator and
aux rear heat26.4L (27.9
quarts)
Front axle
lubricantMotorcraft SAE
75W-90 Premium 4x4
Front Axle Lubricant4x4 vehicles 1.8-2.0L
(3.5-3.7 pints)
Rear axle
lubricant
4Motorcraft SAE
75W-90 Fuel
Efficient High
Performance
Synthetic Rear Axle
LubricantConventional
differential
(8.8 inch axle)1.66L (3.5
pints)
Conventional
differential
(9.75 inch
axle)1.90L (4.0
pints)
Motorcraft SAE
75W-140 High
Performance
Synthetic Rear Axle
LubricantLimited-slip
differential
(8.8 inch
axle)
5
1.77L (3.75
pints)5
Limited-slip
differential
(9.75 inch
axle)
5
1.77L (3.75
pints)5
Windshield
washer fluidMotorcraft
Ultra-Clear
Windshield Washer
ConcentrateAll 4.1L (4.5
quarts)
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 your scheduled maintenance guide to determine
the correct service interval.
Maintenance and Specifications
301

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
F5AZ-19G209-AAESR-M1C159-A
Lock cylinders,
swing-away
spare tire carrier
padlockPenetrating and
Lock LubricantMotorcaft XL-1 none
Brake fluid Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
FluidPM-1 ESA-M6C25-A
and DOT 3
Driveshaft, slip
spline, double
Cardan joint
center ballPremium Long
Life GreaseXG-1-K or
XG-1-C or
XG-1-TESA-M1C75-B
Engine coolant Motorcraft
Premium Engine
Coolant
(green-colored)VC-4–A (US) or
CXC-10
(Canada)ESE-M97B44-A
Motorcraft
Premium Gold
Engine Coolant
(yellow-colored)VC-7–A WSS-M97B51-A1
Engine oil Motorcraft SAE
5W20 Premium
Synthetic Blend
Motor OilXO-5W20-QSP WSS-M2C153-H
with API
Certification
Mark
Maintenance and Specifications
303

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 your scheduled maintenance guide to 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.
ENGINE DATA
Engine 4.6L V8 engine 5.4L V8 engine
Cubic inches 281 330
Required fuel 87 octane 87 octane
Firing order 1-3-7-2-6-5-4-8 1-3-7-2-6-5-4-8
Spark plug gap 1.3-1.4 mm
(0.052-0.056 inch)1.3-1.4 mm
(0.052-0.056 inch)
Ignition system Coil on plug Coil on plug
Compression ratio 9.37:1 9.0:1
VEHICLE DIMENSIONS
Vehicle dimensions 4x2 mm (in) 4x4 mm (in)
(1) Overall length 5228
(205.8)5228
(205.8)
(2) Vehicle width
(Body)2000
(78.7)2000
(78.7)
(2) Vehicle width
including mirrors2390
(94.1)2390
(94.1)
Maintenance and Specifications
305