Bulletins

BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ENGINE AND ENGINE COOLING
04160111/14/20050522810018745Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running. *tt01/12/2006
ENGINE AND ENGINE COOLING - COOLING SYSTEM
1272005/01/19996091697Some vehicles may develop a coolant leak at the worm gear clamp located at the joint between the metal intake coolant tube and the flexible rubber coolant hose. *tt11/09/2000
623205/01/1999607031Some vehicles may develop a coolant leak at the worm gear clamp located at the joint between the metal intake coolant tube and the coil resulting in engine misfire with diagnostic trouble code p0304 and / or rough idle. *tt11/03/2000
BC101109702001/02/199751174Overheating on 4.6/5.4l vehicles may be caused by possible water pump concern due to free spinning water pump impeller.06/27/1997
BC019797020101/02/199751067Engine overheating- water pump concern due to free spinning water pump impeller. *jd06/27/1997
ENGINE AND ENGINE COOLING - ENGINE
0721210/01/200710023943Some 1997-2008 vehicles equipped with a 4.6l 2v, 5.4l 2v, or 6.8l 2v engine--spark plug thread repair procedure--not covered under new vehicle limited warranty. *nj this includes f-53 motorhome chassis. updated 2/23/10. *pe02/20/2008
03140408/23/20040416110011162Engine misfire or running - coil on plug (cop) ignition systems - wds cop kit diagnostic tips. to include various 2005 models. * ar this article 04161 supersedes tsb 03-14-04.01/06/2005
0314407/21/200310003744Engine misfire or rough running condition with coil on plug (cop) ignition systems may be more accurately diagnosed using the optional worldwide diagnostic system (wds) coil on plug (cop) kit. 2003 super duty f series included. *tt10/29/2003
1668303/01/200310001937False failure of the vapor management valve (vmv). *tt *jb07/28/2003
805802/01/2000612269Some vehicles with 4.6l fqr engine assemblies may have a smaller knock sensor threaded hole than that in original equipped engine assemblies. *tt06/07/2000
98B3305/01/1999607294Owner notification for replacement of engine cylinder heads. *tt09/17/1999
97600707/01/1997605786Brief information regarding cylinder head temperature (cht) and fail safe cooling. *tt07/26/1999
98232511/23/1998603931The malfucntion indicator lamp ( mil ) may illuminate and diagnostic trouble code (dtc) p0455 may be stored in memory. *yc03/11/1999
987404/13/1998601343A new silicone gasket and sealant. *yc07/24/1998
97090297181109/02/199754077Concerns with squeaking and/or rattling noises may occur during different driving characteristics and from varying points on the vehicle. *yc03/30/1998
BC103439702002/01/199751812Illumination of the check engine light. *jd07/17/1997
BC005697020101/02/199751024Some expeditions may experience some belt chirp at cold start up in ambient temperatures of 30-50 degrees f. *jd06/27/1997
BC031597020101/02/199751114Fead belt squeal, cold only. revised belt released. *jd06/27/1997
BC032597230101/23/199751435Some 5.4l front end serpetntine belts may make some noise between temperatures fo 30 f-50 f. *jd06/27/1997
BC309097022502/25/199751690Vehicles with a rough running/miss symptom with a misfire dtc on a particular cylinder where normal diagnosis does not pinpoint a cause - check for damage to camshaft. *tw06/27/1997
BC101479702001/02/199751207Belt chirp at cold start up in ambient temperatures of 30-50 degrees f. *jd06/27/1997
BC101769723001/23/199751531Check engine light on with dtc p0455 in continuous memory on vehicle applications. *jd06/27/1997
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
1590105/01/2002637787This bulletin states that some 4.6l fqr engine assemblies may have a smaller or larger knock sensor threaded hold than the one in the original engine assembly. *tt12/06/2002
0124612/10/2001630515Engine oil system priming procedures, service tips for reports of premature engine failure. *tt04/18/2002
1551701/01/2002630043Subject regarding exaggerated engine braking on deceleration. *yd04/12/2002
021401/21/2002630001Some engine assemblies with aluminum cylinder heads repaired in-vehile have been found to leak coolant and/or oil from the cylinder head gasket area. *tt04/11/2002
0120510/15/2001627927Some vehicles may exhibit vacuum or air leaks in the intake manifold and / or engine system causing diagnostic trouble codes p0171 and or p0174. *tt02/26/2002
014703/05/2001619424Subject regarding engine oil recommendations for use in 2001 vehicles - sae 5w-20 motor oil. *tt05/30/2001
1437209/01/2001618640Information on idle vibration or engine droan on acceleration. *jb04/18/2001
1460901/01/2001617992Subject regarding high idle and/or check engine light condition. *jb04/03/2001
98518511/01/1998613316Cold start engine noise01/29/2001
498112/01/1998615321Some vehicles equipped with 5.4l engines may exhibit a cold start engine knock concern until warmed up. *tt01/13/2001
525712/01/1998615374Information on vehicles exhibiting cold engine knock. *tt01/13/2001
1279805/01/1999607112Some vehicles equipped with engines produced by windsor engine plant may exhibit an engine knock at initial cold startup. *tt01/05/2001
463808/01/1998615176Malfunction indicator lamp on, with p0300 - p0308 misfire diagnostic trouble codes with a 4.6l engine. *tt01/03/2001
466408/01/1998615200This bulletin states that for certain vehicles it is not possible to set the check engine light and set diagnostic trouble code p0455 (evaporative emissions gross leak) if a customer refuels the vehicle with the engine running. *01/03/2001
1333110/01/19996092152Some vehicles equipped with engines produced by windsor engine plant may exhibit an engine knock at initial cold startup. *tt11/27/2000
1276705/01/1999607088Exhibiting a vibration that may be interpreted as an nvh condition. *tt11/03/2000
98-473809/01/1998607152Cold engine knock 5.4l action. *ak11/03/2000
1153004/01/1998613794When diagnosing crank / no start on certain vehicles equipped with passive anti-theft (pats) check the customers key ring for any magnetic objects like the mobile speedpass key which may affect the signal transmission between the pats key a08/03/2000
805804/01/2000613617Some vehicles with 4.6l fqr engine assemblies may have a smaller knock sensor threaded hole than that in original equipped engine assemblies. **mr07/26/2000
1217011/01/1998613218Information concerning the octane shorting bar located on the passenger side of engine compartment near the bulkhead is not intended to be functional in reducing detonation/spark knock. *mjs06/19/2000
98505911/01/1998613196Experiencing cold engine knock (repeat / revised message). *tt06/19/2000
1213911/01/1998613160Some vehicles equipped with 4.6l or 6.8l engines may exhibit a cold start engine noise until warmed up. *mjs06/19/2000
98506211/01/1998613198Subject regarding idle vibration (repeat message). *tt06/19/2000
1217411/01/1998613224Some vehicles may exhibit a hard start/long crank, cold start stall, cold rough idle concern. *mjs06/19/2000
1383202/01/2000612426Some vehicles with 4.6l fqr engine assemblies may have a smaller knock sensor threaded hole than that in original equipped engine assemblies. *tt06/08/2000
635007/01/1999610653Some vehicles equipped with engines produced by windsor engine plant may exhibit an engine knock at initial cold startup. *tt05/10/2000
1332210/01/1999609613Some vehicles may exhibit an engine knock at initial cold startup. *tt04/04/2000
715510/01/19996090791Vehicles equipped with windsor engines only may exhibit an engine knock at initial cold startup. *tt03/30/2000
1328509/01/19996090709Experiencing engine knock at initial cold startup. *tt03/23/2000
98357001/01/1998607838Some engines may exhibit oil leakage. *tt10/13/1999
99603405/01/1999606947Experiencing a engine knock at cold start-up. *tt09/08/1999
9981605/03/1999606420Ford motor company now recommends sae 5w-30 viscosity grade for servicing any ford gasoline-powered vehicle regardless of model year. *tt08/19/1999
98211011/01/1998603673During high idle speeds throttle sticks after steady state driving in cold ambient temperatures. *yc03/01/1999
98031704/01/1998603510Symptoms regarding p0300-p0308 misfire dtcs with 4.6l engines. *yc02/23/1999
BC078296101410/14/199650408Concerns of check engine light 'on'. *tt04/24/1997
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS
1436509/01/2000618636This bulletin addresses concerns a noise at intial engine startup when cold from the accessory drive belt. *jb04/18/2001
BC101469702001/02/199751206Belt chirp at cold start up in ambient temperatures of 30-50 degrees f. *jd06/27/1997
BC005697230101/23/199751407Some vehicles with air conditioning can exhibit a cold start accessory drive belt noise (chirp) concern. *jd06/27/1997
BC032596112911/29/199650733Some front end serpentine belts may make noise when between 30 and 50 degrees fahrenheit. *tw06/17/1997
BC031596110111/01/199650723Fead belt squeal, cold only. *tw06/17/1997
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
98201010/12/1998603695Experiencing a buzzing or rattling noise from the exhaust system. *yc03/02/1999
98252112/21/1998603658Concerns of breakage of the exhaust system between the muffler and tailpipe may occur on some vehicles. *yc03/01/1999
BC306297022802/28/199751674Illumination of check engine light with dtc p0446 may be due to contaminated cannister, evap lines or vent solenoid. *tw06/27/1997
BC967196100110/01/199650531Push connection between the flexible fuel vapor line at the carbon canister & the metal fuel vapor line may not seat fully on the fuel vapor line. *tt05/27/1997
BC966896100110/01/199650529Concern for vehicles exhibiting lean codes p0171 & p0174 (vacuum leak). *tt05/27/1997
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
98151208/03/1998609551A direct replacement part for the evaporative emission canister and bracket assembly. ak04/03/2000
98231011/23/1998603724Mass air flow (maf)- sensor contamination- service tip. *ak03/03/1999
BC327097020702/07/199751868Check engine light - dtc p0446 - check for mold flashing in the 90 degree elbow evap line conming out of the cannister. *tw07/17/1997
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE)
BC351097230101/23/199751494Check engine light on with dtc p0455 in continuous memory on 1997 5.4l vehicle applications. *jd06/27/1997
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
055403/21/200510014685Use of stainless steel exhaust studs in service for 5.4l 2v engine. *tt05/05/2005
1732011/01/200310008169Broken exhaust manifold studs. *tt07/22/2004

Investigations

NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
ENGINE AND ENGINE COOLING
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK PLUG EJECTION FROM CYLINDER HEAD
 On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi
ENGINE AND ENGINE COOLING - ENGINE
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK PLUG EJECTION FROM CYLINDER HEAD
 On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
DP05005FORD MOTOR COMPANY09/22/200501/04/2006SPARK PLUG EJECTION FROM CYLINDER HEAD
 On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi

Consumer Complaints

Fail datemilesoccurencesPurchase date
ENGINE AND ENGINE COOLING
10/18/2007150000
 Tl-the contact owns a 1997 ford expedition. the contact stated that while driving 30 mph, a loud banging noise was heard and the vehicle began to shake. the vehicle was towed home and the contact noticed that one of the spark plugs fractured and destroyed the motor. the motor and spark plugs were replaced. the failure had since recurred three times. the manufacturer was made aware of the failure, but offered no assistance. the failure mileage was 150,000. kmj
10/18/2007150000
 Tl-the contact owns a 1997 ford expedition. the contact stated that while driving 30 mph, a loud banging noise was heard and the vehicle began to shake. the vehicle was towed home and the contact noticed that one of the spark plugs fractured and destroyed the motor. the motor and spark plugs were replaced. the failure had since recurred three times. the manufacturer was made aware of the failure, but offered no assistance. the failure mileage was 150,000. sm.
05/07/2011232936
 Tl* the contact owns a 1997 ford expedition. the contact stated that the vehicle caught on fire, which originated from under the hood. the police and the fire department were called and a police report was filed. the vehicle was not taken to the dealer for inspection and the manufacturer was not made aware of the failure. the vehicle was not repaired. the failure and current mileage was 232,936.
06/06/2005120000
 Tl*the contact owns a 1997 ford expedition. the contact stated that the vehicle attempted to stall while driving 10 mph and there was a leak in the fuel tank. the vehicle was taken to midas for an oil change and the vehicle began to stall immediately after it was serviced. the contact took the vehicle back to midas three times after it stalled. the mechanic stated that the vehicle needed a coil pack. the mechanic performed a tune up and that the spark plugs were damaged. the cylinder head also needed to be replaced. the failure mileage was approximately 120,000. the contact was told by ford a representative that the ford expedition spark plugs recall was closed. the current mileage was approximately 132,000.
09/11/20091316291
 Fire center of hood drivers side vehicle sitting not running. *tr
07/04/20071550001
 Our 1997 ford expedition ejected a sparkplug, multiple times in the past year. was helicoiled and still damaged motor to the point of rebuild or replacing motor. happened during a holiday towing our boat, very lucky it didn't hurt anyone. we had to have boat and ford towed, ruined our vacation, thanks to having a class a driver behind the wheel minimized a major accident. *tr
04/12/2009960001
 Engine making a load noise after traveling to my inlaws which was 216 miles pulled over noticed number 8 cylinder had blown the spark plug out of the block 2 months prior number 3 cylinder blew out and in 2008 number 1 cylinder blew out plug from the block. i have been in touch with ford motor company they there was nothing they could do. *tr
04/01/20091060001
 Spark plug blew out of motor. *tr
01/26/20091794211
 As i was driving my ford the sparkplug blew out of my cylinder head and took out my coil. *tr
11/07/20081758961
 I have a 1997 ford exp with a 5.4 engine, i was driving along and i heard this loud pop sound and then lost power! i open the hood and found that the spark plug ejected out the engine and blew the ign coil apart. i have had three set of spark plugs installed from 1998-2007 and never had a problem(175896 miles on my truck). im a auto tech by trade and have worked for western auto for 11years, and pep boys auto for 14 years. over the last several years i have seen alot of fords trucks come in with this problem ! with so many people having the same problem when will ford be held accountable or some type of recall put in place ?it has not been fix yet , but i have look into buying a online insert kit that drills out the spark plug hole and install new threads to repair the damage threads. the cost of the kit is $367.95 and im doing the work myself but im sure it would be between 900 to 3000 thousand dollar if i have gone to a shop for repairs. please contact me with a response ? thank you for your time! *tr
09/22/20081650001
 1997 ford expedition with a 5.4 l v-8. spark plug blew out of cylinder head. have read this is common problem but to this date ford hasn't had to recall to repair the defective cylinder heads. *tr
06/30/20081275021
 1997 ford expedition, 5.4 v8. driving about 25 mph when a spark plug blue out. this is the second time this has happened. the first time it happened when my wife was driving. my mechanic is going to use a helicoil kit to repair the threads. i was out of town for the first incident and do not know what was done to repair the problem the first time. *tr
05/18/20071600003
 Tl*the contact owns a 1997 ford expedition. while driving 55 mph, a spark plug ejected from the cylinder. the vehicle then make a loud noise and shut down completely. the contact was able to restart the vehicle, but it would only advance approximately five miles afterwards. the contact took the vehicle to the dealer and they wanted to replace the head at the cost of $2,000. he consulted ford motor company, but has not yet received a response. the current mileage is 172,000 and failure mileage was 160,000. updated 6/2/08 *cn updated
11/03/2007110000111/04/2000
 Tl*the contact owns a 1997 ford expedition. the contact stated that his vehicle caught fire. the engine and hood burning were able to control the fire. a fire report was filed. the manufacturer is aware of the failure, but there are no recalls available. they advised the contact to have the insurance company perform an investigation. the current and failure mileages were 110,000.
07/25/200785050309/21/1997
 Spark plug blew out of cyl. # 3 due to lack of threads in cylinder head, or lack of material in that location. the triton v series engines have an inherent problem with blowing the plugs out, it will cost between 2500- 4000 to fix one plug blow out, putting in inserts only causes the repair again at a later date. when is the government going to step in and say enough, the public has already. *tr
05/09/20061540001
 I had a ingnitor blow completely out of the head on my expedition. . it immediately smelled of gas and sounded like a tractor. the ingnitor then kept hitting the fuel rail. we were lucky that the vehicle did not start on fire because of the two hitting and starting a fire with a spark. when i talked to a ford dealer they said that yes it does happen quite a bit because of the on the head...they only put 2 threads in to thread the ingnitor in. i think there needs to be a recall on this if this happens. some one could be working on the vehicle when this happened and could start a fire due to the gas. it will now cost me $3000 to fix this design default only to get replaced by the same issue!!! *jb
10/30/20051180001
 Traveling @ 65 mph and loud bang. engine lost power and was extremely loud. was told by authorized ford dealer that the spark plug had blow out of the cylinder. the truck was not fixed. ford wanted $5000 for new engine or $4200 to rebuild mine. 1997 eddie bauer expedition. *jb
04/17/2005105000107/18/2000
 The consumer stated vehicle was parked with the engine off in the yard when it caught fire and burned. flames came from the front of the vehicle. just had it serviced twice since december.
02/15/20051780001
 The consumer was driving on the highway at approximately 65 mph and at that speed the engine began to eject the spark plugs out of the seventh cylinder. the ignition coil sits under the fuel rail. the consumer feels, this could ignite and cause a big fire to the engine. provide further details.
05/13/200265000902/17/1999
 Paint and finish on roof of vehicle peeling, cracking, flaking off - oxidation from rust, ruining entire outer car surface - have been advised that primer coat was either missed or skimped during the production process... ford will not address this issue - one male rep from ford stated: the paint job is only supposed to last 2 years not an acceptable answer...also, child safety locks engage themselves, thus preventing occupants in rear seats to exit vehicle, can cause injury or death in an emergency situation... also, vehicle rear wheels and or axels chatter at low speed turns... also, an audible hum in vehicle at normal highway speeds...also, audible squeaking from interior side panels...ford dealer states: cause cannot be located...also, leather seats have cracked and show signs of abnormal wear - this is apparant in all leather seat coverings but especially in the front bucket or captain seats...ford states warranty for vehicle no longer covers -engine has had several episodes of misfiring of revving on it's own - has been explained away as a computer problem or a sensor problem - always at cost to consumer...check engine light has come on on numerous occasions, using previous explanations as stated previously. have numerous invoices for replacements of sensors, computer chips, etc.*ak
06/15/200491000106/01/1998
 Spark plug suddenly blew out of the passenger side cylinder head while driving 65 miles an hour on the freeway. had the car towed to the dealer and they wanted $3100 to put on a new cylinder head. did some checking on the internet and found it was a common problem with that engine that has not been recalled. took the car to another shop and had inserts put in for all 4 spark plugs on that head for $2000. *ak
06/15/2003155000
 Spark plug blows out of aluminum head. this car has one of the most extensive service records paso robles ford has on record; these are their words. in other words this vehicle has been maintained very very well and to have the plug blow out in the first place is uncalled for. secondly we paid to have a remanufactered engine installed and a few weeks later the plug blows out again. this is supposed to be on what ford calls a revised part to take care of plugs blowing out of the aluminum head. ford will not give us a straight answer on what the revision is; this could be anything-possibly not even related to the problem. my understanding is the problem is that there are only three threads going into the aluminum head. apparently the revision does not take this problem into account because it only took a few weeks for the exact same thing to happen.
06/29/2003710001
 While driving at 65 mph vehicle lost engine compression. dealer notified.
ENGINE AND ENGINE COOLING - COOLING SYSTEM
12/19/2000105/01/1997
 The firewall heater hose connectors in the area of the #4 coil pack on many expedition with the 5.4l v-8 will leak hot coolant on the #4 cylinder coil pack. this will lead to the failure of this coil pack. failure of this coil pack causes a severve engine miss and loss of performance. failure on highway can make vehicle unsafe. ford is aware of the problem but is not provding a permanent fix.
12/01/1997109/01/1997
 The complete engine failure occured gradually..the dealer never was able to diagnosis it until coolant in cylinders 1 and 4 caused the vehicle to not start. the control-trac is very disconcerting since the traction control system will not stay in 4 wheel drive when it has been selected to do so. i have turned this vehicle in for servicing for this problem on 8 occasions with no resolution....
ENGINE AND ENGINE COOLING - ENGINE
09/03/2010
 I own a 1997 eddie bauer ford expedition that i bought in 1998 as a demo model it has run great until it started to blow the spark plug from the heads the first time was last year while my family and i were driving back form texas we were in a remote part of the country when it blew and spent over 500.00 for towing not to mention the 1200.00 dollar bill that the dealership tagged on. i was never informed that this was a problem that could re-occur we have taken other trips but did not have issue until just recently it blew another plug and of course the bill in in the thousands. ford needs to take some ownership for the product that they build if they want to keep some of as customers...
06/16/2010128000
 Tl- the contact owns a 1997 ford expedition. while traveling 60 mph the contact noticed that the dashboard had stopped functioning, seconds later the vehicle had suddenly shut off without warning. the contact called the dealership and was informed that the failure was due to liquid leaking into the engine. the vehicle has not been diagnosed and there were no prior warnings. the current and failure mileages was 128000. bml
02/08/20102420001
 #4 spark plug blew thru head. *tr
03/24/20081850001
 While driving my 1997 ford expedition xlt 5.4l v8 truck a spark plug blew out of the head of the engine. this is the second time that is happened, the first being in august, 2007. this same problem occurred on 2 different spark plugs. each time, the plug blew out and the engine made a popping sounds like a badly tuned lawnmower. i was able to get to a dealer the second time, the first time i had to be towed. throughout the time i had to drive the car this way, gas vapors were coming out of the cylinder at each turn of the piston. this sounds to be a common problem with the 5.4l engines from ford. *tr
10/16/20081
 Was driving home from work, heard a loud noise and truck got really loud. got it home checked it out. the spark plug blew out. had to take it to a dealer and get a new insert put in cause it was stripped. *tr
01/15/20081310001
 Spark plug blew out of cylinder #6 while traveling at highway speed. this resulted in a loud noise and a check engine light, strong smell of gasoline. due to outside temperatures of -10 deg f car was driven to nearest exit, lucky there was no fire. *tr
10/22/20081870001
 I have a 1997 ford expedition with a 5.4l v-8 engine. within the past 2 months, on 2 separate occasions, the same spark plug blew off the engine. the 2nd incident occurred on oct 22, 2008 when i started the truck in a parking lot. i needed a tow to get the truck and my family home. now, a new spark plug can't be screwed in because the threads are stripped. i have not taken it to a mechanic but based on the numerous complaints in the consumeraffairs.com website, it seems this problem could cost me thousands of dollars. depending on the cost, i may not repair this since this could happen again with the other 7 spark plugs. i will not buy a ford truck again and will advise my family and friends to get rid of theirs. *tr
08/17/20081
 1997 ford expedition--aluminum heads are engineered incorrectly. the problem is the spark plug recess bore is to thin, the spark plug does not have enough material to properly seat in the head and after awhile the plug will back out. the pressure from the combustion will eventually blow the plug out. this will lead to costly damage to fuel injection damage, piston, intake manifold, etc. the problem is ranging from 96' to 2005 triton engines. ford will not help you nor will the engine manufacturer until someone dies! repairing this problem...... low cost-heili coil insert $100 to $1000 depending on your service tech. or a complete head replacement (steel heads) $3000 to $5000. *tr
09/11/200796000
 Tl*the contact owns a 1997 ford expedition. while driving approximately 10 mph, the contact heard a loud noise underneath the vehicle. she pulled to the side of the road and inspected underneath the vehicle and hood. the contact smelled a burning odor underneath the hood. there were no warning indicators illuminated on the instrument panel. the vehicle was taken to an independent mechanic and they stated that the failure was related to a disconnected spark plug in the engine. the vehicle was repaired for the malfunction. on two separate occasions, the vehicle was taken to an independent mechanic for identical failures, but there were no resolutions. the vin was unknown. the failure mileage was 96,000.
12/01/2007230000
 Tl*the contact owns a 1997 ford expedition. the contact stated that the spark plugs are being blown out of the engine head. the spark plugs have been replaced twice. all the repairs to the vehicle have been performed by the contact because the dealer could not guarantee successful results. the current mileage was 239,000 and failure mileage was 230,000.
01/15/20081000001
 In a matter of 9 months, my 1997 ford expedition has misfired and blown out spark plug 4 times now. has cost me over $3,000 in repairs. the last time it happened my truck smelled like fire, but never ignited. my check engine light is now on for a 5th time, the truck is misfiring again and it is only a matter of time before another blowout occurs. *tr
12/29/20071220001
 Spark plug failure and damage on 97 expedition.*cn
01/01/2007110000201/01/2001
 Tl*the contact owns a 1997 ford expedition. the contact stated that the vehicle fails to start when he turns the ignition and the power locks fail to operate. the vehicle has been jump-started and tested and all of the components appeared to be working normally. the contact stated that the four wheel drive feature fails to engage, although the indicator on the instrument panel illuminates. he has not notified a local dealer or the manufacturer because the failures are intermittent. the engine size was unknown. the current mileage is 114,000 and failure mileage was 110,000.
06/11/2006128000101/10/2002
 While driving at approximately 65 mph # 2 spark plug pops out of the head. *jb
12/10/2003112683101/13/2003
 #3 spark plug ejected from the engine, which resulted in significant power loss. i nearly was rear-ended by a gas truck, but was eventually able to pull off the freeway. the spark plug threads were stripped from the head, the spark plug boot was split and the coil mount was broken off. *nm
01/25/2006132980112/27/1996
 Spark plug blown out of head by force of the engine, loss of power an major damage. *jb
10/05/20051
 Dt: the contact stated that the 1997 ford expedition blew out plug a spark plug in the engine and stripped the head and the coil. this happened while driving at 35 mph. the contact has been in contact with ford, and they told him to take the truck to the dealer and call them back. the dealership did a diagnostic testing , and said that it would take $4,850.00 to repair the engine. when the contact called ford back the person to whom the contact talked to did not understand why he was calling them back. the contact spoke to two different people and they did not know what he was talking about. the contact said that he planned to fix the truck when he has the money available.*ak
07/15/2005151000203/15/2004
 On june 17, 2005 our 1997 expedition blew its first spark plug. we at the time that it was an uncommon occurence so we had a local mechanic fix the problem at the cost of $388. not even a month later on july 15, 2005 our expediton blew another spark plug different cylinder but on the same side. we are looking into options to see which is the best option for us to go with. while researching we found that this problem is not so umcommon with a 5.4 liter engine whether in a expedition, f-150, etc and does not matter how many miles either. i saw the numerous compliants on consumer affairs.com which is where i found your number and called today. i think that ford motor company needs to start accepting responsibility for their defects in their engines. as of right now we are not sure how much it will cost to repair our truck. an estimate given to my husband was for $3600.00 to redo the heads or $4700.00 to replace the engine but if they replace with the same defected engine even with a warranty it will do us no good considering the warranty will not cover for this specific repair. this has also caused our family vacation to be put in limbo and trying to figure out how to pay for the repairs. my family does not have that type of money just lying around waiting to be used. me and my husband both work to support our six children, and it seems like ford motor company needs to pick up the pace and help us considering they are not willing to come out and recall their defected engine.
12/26/2003117000108/01/1998
 1997 expedition 5.l triton. blew #3 plug 18000 miles after having it replaced. research shows that this is a common failure though ford does not acknowledge any design flaw. *ak
06/16/200315600006/06/1997
 Spark-plug blew out of aluminum head on a 97' ford expedition with 155,000 mi. paid $4500.00 for a new improvedre-built engine. spark-plug blew out again with 1,000 mi. on new engine. ford will not talk to us; we would like some answers as we were told the improved design addressed the problem of the spark-plugs only having three(3) threads holding it onto the aluminum head. *nlm
08/28/20021
 When i take off the gas is sticky and takes alot to get it going, when turning from stop my rear end vibrates like it's going to fall off. aready had the transmission replaced by the dealer ship i got the car from. driver side window clunks when rolling down, motor makes a knocking noise when cold. i just don't expect this kind of problems when you pay alot of money for a nice car.*ak
11/22/19991
 The head gasket failed, dealership completed repair without charge. *mjs
03/03/1998101/01/1997
 Aluminum head failure, again (dot number: 0 tiresize: 0)
02/21/1997
 Would hear noises in the engine. front drive serpentine belt keeps breaking. has taken vehicle to dealer's at least 12 times for problem. also, the crankshaft/ pulley tensioner would loosen & the vaccum to the brakes. would not have any brakes due to lack of pressure. *ak
12/01/1998111/01/1996
 Oil seal/grease retainer--oil leaked.
 While driving vehicle engine shut down . cause of problem defective crankshaft seal. also tie rod end was never connected to vehicle at the factory. *ak
110/01/1996
 Serpentine belt failure.
05/28/1997
 Engine push rod failure. *ak
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
07/19/2006760001
 Driving my 97 ford expedition home from work it blew a spark plug and the vehicle only has 76k. brought it to crowley ford in plainville, ct. and the plug was repaired for $750.00. it did not correct the problem. was told that the engine needed replacing for the price of $5200.00. this problem is related to poor design. i did my homework. there are several other individuals who have reported the same problem across the country. at this time ford is not taking any responsibility for this. *nm
07/20/200212/01/2000
 Cold engine knock continues after ten minute warm up and ten minute drive time. contacted ford, no help. dt
06/20/2000
 Around 60 mph vehicle feels like it's shifting/ jerks, then stalls. dealer cannot find problem, stated that water was getting in the engine. *ak
12/01/2001
 Vehicle stalled at 55 mph. after inspecting vehicle dealer determined there was no oil in engine and one rod had blown. dash indicator did not show low oil prior to this incident. engine needed to be replaced.*ak
06/01/20011
 When making right hand turns vehicle intermittently acts like back is independent from front. when coming to a stop, vehicle bucks and drags. dealer informed consumer that motor, rear sway bar link, forward drive shaft and speed sensor needed to be replaced. *ak
02/08/20015
 While driving vehicle engine check light comes on and remains on. this causes vehicle to act as if it's going to stall out when its idling too long at stop lights or stop signs. has happened so far 5 times. had taken to dealership 4 times, each time mechanic replaced a coil pack. light would go out, but after 2 weeks would return again. *ak *slc
02/01/2001
 While traveling with cruise control engaged cruise control unit would not disengage to slow down for an exit. consumer has replaced motor three times.*ak
01/20/2001
 Consumer was staying in below freezing weather conditions and part of engine failed. engine skips/shakes, and runs hard. vehicle is driveable. ford says it's because vehicle has 4.5 tectron engine, all expeditions have this model. *ak
01/26/2001106/01/1997
 Engine began making noise; slowed to pull off road; engine stopped and was able to coast to side of road. oil pressure went to zero despite recent oil change and full reading on the oil. dealer said engine seized and needs to be replaced. unknown orgin or cause of seizure. all mileage on vehicle is highway.*ak
06/18/1997511/06/1997
 Repair attempts on several occasions due to engine noise, however not able to be rectified. mjs
09/21/1999
 While making a turn vehicle stalls unexpectedly which may cause a crash. dealer replaced 2 iac valves. there is a back order on this part. please provide further information. *ak
102/01/1998
 Rear sway bar fell out of bushing, making difficult to control. engine has rough idle.roof rack fell off due to screws that hold rack to roof were not installed.exterior moldings and glass trim discolored.passenger power window sticks and squeaks.serpentine belt noisy upon cold morning starts.
02/01/1998
 Brakes were squeaky and felt spongy, addressed twice, rotors were out by -0.05. engine exihibit 'piston slap' documented from day one, dealer stated it may be attributed to octane level, informed by second dealer to downshift, that it will not harm engine, road test by technician diagnosed the pcm was adjusting to load!!nowhere to secure child seat in third row.heater replaced twice with windows fogging creating poor visibility.second row single seat fell back upon acceleration,knocking passenger's head back, was stuck and would not reset until pushed very, very hard. interior dash and headliner squeaks, horseshoe molding tabs around stereo wore through and rattles
07/15/19991003/25/1997
 On many occasions vehicle experienced vibration which resulted in loss of idle strength, causing failure. *yc
02/25/1999204/01/1997
 In two weeks time, i have had my engine completely fail while exiting
09/15/1998
 While parked for short period of time the vehicle exploded and caused a fire without prior warning. cause unknown. dealer cannot determine problem . *ak
06/29/19981
 While driving slowly in the rain, the vehicle suddenly went into a skid. during the skid, the vehicle shutdown with no power steering or abs, giving owner no indication. the engine check light came on after vehicle shutdown and remained on for a couple of days. manufacturer will be notified. *ak *slc
08/01/1997
 Engine: driving approximately 45mph and attempting to slow down to make a turn and the vehicle just cuts off without any warning. took to dealer and was told they were aware of the problem, but have no way of correcting it at this time. *ak
01/15/1997101/15/1997
 After the check engine light came on, the vehicle suddenly stopped, causing accident.
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS
 While driving the sway bar broke causing the vehicle to pull to the right. please provide any additional information. ph
02/21/1997
 Would hear noises in the engine. front drive serpentine belt keeps breaking. has taken vehicle to dealer's at least 12 times for problem. also, the crankshaft/ pulley tensioner would loosen & the vaccum to the brakes. would not have any brakes due to lack of pressure. *ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
06/25/20081776481
 I have a 1997 ford expedition, engine coils were replaced , check engine light went off and there was no jump in acceleration. 2 weeks later check engine light back on. *tr
11/01/200003/01/1999
 While driving front differential crank case started to leak fluid. wheel well was being coated with fluid. had contacted manufacturer and informed consumer that he knew the problem. had a fix for problem, but no recall issued. *ak the crankcase bleed valve was moved from the bottom of the differntial to the top. *slc
11/01/1996
 Buzzing or vibrating noise at idle in exhaust system emminating from underneath front seat area. i've been to two dealerships multiple times and have not been able to get the problem corrected.
101/01/1997
 Exhaust system experiencing noise. *yc
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
03/15/200647200103/03/1997
 Passenger side exhaust manifold studs corroded and broke on 4.6l engine, causing exhaust leak with emission control catalytic converter. replaced studs with stainless studs, but not acknowledged on 4.6l. *ak
10/15/1998811/01/1996
 Charcoal cannister on fuel tank clogs w/ dirt from gravel road, causes engine light to come on. i paid to replaced it with a re-designed part & dealer still repeatedly has to clean new 1 out. he says this happens to 97s & 98s. this is a pressure relief valve. now i'm told to buy another new one with no guarantee it won't clog. i'm driving with it clogged. who knows if pressure will build in the tank. complaints to ford have been useless. i live in the country. cannot avoid gravel road. this suv is advertised to handle this kind of driving. our ford pickup and jeep cherokee don't do this. i want ford to come up a part that works.*ak
01/30/2000101/01/1997
 We were informed by ritar ford that the reason the engine check light came on ,was caused by water dripping from the air conditioner line onto the oxygen sensor. we were also informed that t.s.b.# 00-1-7 would alleviate the problem by re-routing the line so the water would not drip on the oxygen sensor . however even though we purchased e.s.p. (extended warranty protection) this repair was not covered because we exceeded 36,000 miles. i feel as we were ripped-off being asked to pay for a obvious engineering shortfall by ford motor company . aside from the engineering problem, a pontental enviromental problem is possible due to the failure of the oxygen sensor. *ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE)
12/01/199911/01/1999
 In idle the engine can not hold a smooth idle at 1400 rpm. the dealer service dept. claims it's the egr valve opening and closing. when driving, this problem does not allow the engine to run smooth and affects power at a range of 1400-1700 rpm depending on loading on the engine (i.e. towing a trailer, driving up hill...). this is occurs constantly and affects the performance of the vehicle in all driving conditions. the dealer has attempted six times to correct the problem without success. the korum ford service manager mike powers admitted it being a defect since they weren't able to correct it. ford has chosen not to take any action to commit to fixing it or providing a fair replacement of the vehicle. i have found one other documented case of this problem on the web.*ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
08/08/2007960001
 Spark plug on my 97 ford expedition blow out. the engine is a triton 5.4l. it happened while i was driving on residential street at 30 miles per hour. *tr
05/31/2007188000112/28/1996
 Tl*the contact owns a 1997 ford expedition. the dealer informed the contact that the manifold bolts have rusted out and need to be rebuilt and re-drilled. the vehicle was not included in any recalls. the contact heard a ticking sound coming from the passenger side of the motor due to the manifold rusting. the noise ceases when the vehicle heats up. the current mileage is 190,000 and failure mileage was 188,000.
11/26/2005132000110/04/1998
 Towing trailer and exhaust manifold studs broke. this caused a loss of power climbing a steep grade. car behind almost hit us. *jb
11/10/1998
 The tail pipe separated from the muffler & fell off. dealer referred owner to muffler shop. they welded pipe on & it fell off sometimes later again. *ak

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