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
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
1744812/01/200310008301Remote oil filter adaptor replacement - new service part. *tt07/27/2004
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
1486404/01/2001619335Subject regarding certain vehicles with 4.6l romeo engines exhibiting an oil leak from the cylinder head gasket area. *tt05/23/2001
1482104/01/2001619315Some vehicles equipped with 4.6l romeo engine may exhibit an oil leak from the cylinder head gasket area. *tt05/23/2001
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
98308402/26/1998607377Information on adding or installing a pulley. *tt09/21/1999
98B3305/01/1999607294Owner notification for replacement of engine cylinder heads. *tt09/17/1999
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
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
01211010/29/2001627768Some vehicles equipped with the romeo built 4.6l 2v engine may exhibit an engine oil leak or oil weepage from the cylinder head gasket at the right hand rear or the left hand front of the engine. *tt02/22/2002
014703/05/2001619424Subject regarding engine oil recommendations for use in 2001 vehicles - sae 5w-20 motor oil. *tt05/30/2001
014203/05/2001619419Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. *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
719410/01/19996092086Subject regarding ford quality renewal (fqr) assembly launch of 4.6l 2v engine. *tt11/24/2000
98-473809/01/1998607152Cold engine knock 5.4l action. *ak11/03/2000
1276705/01/1999607088Exhibiting a vibration that may be interpreted as an nvh condition. *tt11/03/2000
0012306/12/2000613859Some vehicles may experience spark knock during light-to-moderate accelerations. *tt09/20/2000
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
98506211/01/1998613198Subject regarding idle vibration (repeat message). *tt06/19/2000
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
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
816302/01/2000612337Some vehicles with 4.6l, or 6.8l engines may exhibit a roller finger follower coming off during engine cranking in cold temperatures below zero degrees f. a one-time noise from the engine may be heard, followed by rough running / misses06/07/2000
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
981126402/01/1998607489Concerns with ticking noise on initial cold start-up in park and neutral position. *tt09/24/1999
98331602/03/1998607481Some customer may complain of a ticking noise on initial cold start-up in park position and neutral position. *tt09/23/1999
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
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
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
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
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE)
0541703/07/200510014666Intermittent rough idle - non-commanded egr (exhaust gas recirculation valve) flow. *tt05/05/2005
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
02/25/2012175000
 Coil and spark plug blow out of engine when truck was started (1998). the expedition has been known to have this issues as well as other issues. why is ford not taking responsibility; so far accident avoided. i had to replace one coil pack each year so far but this was the worse. i needed the cinder retreaded to fit the spark plug in.
02/25/2012175000
 Coil and spark plug blow out of engine when truck was started (1998). the expedition has been known to have this issues as well as other issues. why is ford not taking responsibility; so far accident avoided. i had to replace one coil pack each year so far but this was the worse. i needed the cinder retreaded to fit the spark plug in.
02/25/2012175000
 Coil and spark plug blow out of engine when truck was started (1998). the expedition has been known to have this issues as well as other issues. why is ford not taking responsibility; so far accident avoided. i had to replace one coil pack each year so far but this was the worse. i needed the cinder retreaded to fit the spark plug in.
02/25/2012175000
 Coil and spark plug blow out of engine when truck was started (1998). the expedition has been known to have this issues as well as other issues. why is ford not taking responsibility; so far accident avoided. i had to replace one coil pack each year so far but this was the worse. i needed the cinder retreaded to fit the spark plug in.
02/25/2012175000
 Coil and spark plug blow out of engine when truck was started (1998). the expedition has been known to have this issues as well as other issues. why is ford not taking responsibility; so far accident avoided. i had to replace one coil pack each year so far but this was the worse. i needed the cinder retreaded to fit the spark plug in.
10/21/2011241252
 Plastic intake manifold failure resulting in repairs in excess of $1500
10/21/2011241252
 Plastic intake manifold failure resulting in repairs in excess of $1500
10/21/2011241252
 Plastic intake manifold failure resulting in repairs in excess of $1500
10/21/2011241252
 Plastic intake manifold failure resulting in repairs in excess of $1500
04/07/201180638
 April 2011 ford 5.4 liter triton blew out yet another spark plug.
04/07/201180638
 April 2011 ford 5.4 liter triton blew out yet another spark plug.
04/07/201180638
 April 2011 ford 5.4 liter triton blew out yet another spark plug.
04/07/201180638
 April 2011 ford 5.4 liter triton blew out yet another spark plug.
04/07/201180638
 April 2011 ford 5.4 liter triton blew out yet another spark plug.
04/08/2011185467
 Tl* the contact owns a 1998 ford expedition. the contact stated that the vehicle caught on fire while parked in the driveway overnight. the contact was awakened by a loud explosion when she discovered the vehicle in flames. the fire department arrived to assist and advised that the fire originated from the engine. the vehicle was destroyed and a fire report was filed. the contact referenced nhtsa campaign id number: 05v388000 (vehicle speed control) and stated that she was advised by the manufacturer that the vehicle was included with the recall but had not received recall repairs. the failure and current mileage was 185,467.
04/08/2011185467
 Tl* the contact owns a 1998 ford expedition. the contact stated that the vehicle caught on fire while parked in the driveway overnight. the contact was awakened by a loud explosion when she discovered the vehicle in flames. the fire department arrived to assist and advised that the fire originated from the engine. the vehicle was destroyed and a fire report was filed. the contact referenced nhtsa campaign id number: 05v388000 (vehicle speed control) and stated that she was advised by the manufacturer that the vehicle was included with the recall but had not received recall repairs. the failure and current mileage was 185,467.
04/08/2011185467
 Tl-the contact owns a 1998 ford expedition. while the vehicle was parked at night the contact stated they heard a loud noise and looked out and noticed the vehicle was on fire. her husband ran outside and she called the fire department. they were informed by the fire department that the fire started from the engine. the vehicle was destroyed and the fire department filed a report. the police were on the scene but she was not sure if they filed a report. the contact referenced recall nhtsa campaign id number: 05v388000(vehicle speed control) and stated she called the manufacturer and was advised that the vehicle was part of the recall. the vehicle was purchased used in 2006. the contact was not sure if the recall work was performed on the vehicle by the previous owner. the failure and current mileages were 185,467. vwb
04/08/2011185467
 Tl-the contact owns a 1998 ford expedition. while the vehicle was parked at night the contact stated they heard a loud noise and looked out and noticed the vehicle was on fire. her husband ran outside and she called the fire department. they were informed by the fire department that the fire started from the engine. the vehicle was destroyed and the fire department filed a report. the police were on the scene but she was not sure if they filed a report. the contact referenced recall nhtsa campaign id number: 05v388000(vehicle speed control) and stated she called the manufacturer and was advised that the vehicle was part of the recall. the vehicle was purchased used in 2006. the contact was not sure if the recall work was performed on the vehicle by the previous owner. the failure and current mileages were 185,467. vwb
02/04/2011120000
 3rd time we have had a spark plug ejection from the passenger engine head of our 1998 ford expedition with a triton 5.4 litre engine. i owned a ford f150 and had this same problem twice. i did research and called a few ase master mechanics that are rated as america's #1 and #4 mechanics in the nation, and was told it is the most common problem fords triton engines have ever had, and they see these problems on a daily basis, yet ford does not acknowledge the problem. ford desperately needs to recall these engines, they are a hazard, and the spark plug ejects with explosive power damaging nearby components on it's way out of the engine. ford refuses to acknowledge this common manufacture defect. to fix this problem new heads need to be installed on the engine. the quick helicoil style sleeve into the stripped spark plug threads has a failure rate of 100%. again this is a major problem and the magnitude can be seen all over the internet by searching fords spark plug blowouts. literally 10's of thousands of forums, and insight in this problem is available online, except support from ford motor company.
02/04/2011120000
 3rd time we have had a spark plug ejection from the passenger engine head of our 1998 ford expedition with a triton 5.4 litre engine. i owned a ford f150 and had this same problem twice. i did research and called a few ase master mechanics that are rated as america's #1 and #4 mechanics in the nation, and was told it is the most common problem fords triton engines have ever had, and they see these problems on a daily basis, yet ford does not acknowledge the problem. ford desperately needs to recall these engines, they are a hazard, and the spark plug ejects with explosive power damaging nearby components on it's way out of the engine. ford refuses to acknowledge this common manufacture defect. to fix this problem new heads need to be installed on the engine. the quick helicoil style sleeve into the stripped spark plug threads has a failure rate of 100%. again this is a major problem and the magnitude can be seen all over the internet by searching fords spark plug blowouts. literally 10's of thousands of forums, and insight in this problem is available online, except support from ford motor company.
02/04/2011120000
 3rd time we have had a spark plug ejection from the passenger engine head of our 1998 ford expedition with a triton 5.4 litre engine. i owned a ford f150 and had this same problem twice. i did research and called a few ase master mechanics that are rated as america's #1 and #4 mechanics in the nation, and was told it is the most common problem fords triton engines have ever had, and they see these problems on a daily basis, yet ford does not acknowledge the problem. ford desperately needs to recall these engines, they are a hazard, and the spark plug ejects with explosive power damaging nearby components on it's way out of the engine. ford refuses to acknowledge this common manufacture defect. to fix this problem new heads need to be installed on the engine. the quick helicoil style sleeve into the stripped spark plug threads has a failure rate of 100%. again this is a major problem and the magnitude can be seen all over the internet by searching fords spark plug blowouts. literally 10's of thousands of forums, and insight in this problem is available online, except support from ford motor company.
02/04/2011120000
 3rd time we have had a spark plug ejection from the passenger engine head of our 1998 ford expedition with a triton 5.4 litre engine. i owned a ford f150 and had this same problem twice. i did research and called a few ase master mechanics that are rated as america's #1 and #4 mechanics in the nation, and was told it is the most common problem fords triton engines have ever had, and they see these problems on a daily basis, yet ford does not acknowledge the problem. ford desperately needs to recall these engines, they are a hazard, and the spark plug ejects with explosive power damaging nearby components on it's way out of the engine. ford refuses to acknowledge this common manufacture defect. to fix this problem new heads need to be installed on the engine. the quick helicoil style sleeve into the stripped spark plug threads has a failure rate of 100%. again this is a major problem and the magnitude can be seen all over the internet by searching fords spark plug blowouts. literally 10's of thousands of forums, and insight in this problem is available online, except support from ford motor company.
02/04/2011120000
 3rd time we have had a spark plug ejection from the passenger engine head of our 1998 ford expedition with a triton 5.4 litre engine. i owned a ford f150 and had this same problem twice. i did research and called a few ase master mechanics that are rated as america's #1 and #4 mechanics in the nation, and was told it is the most common problem fords triton engines have ever had, and they see these problems on a daily basis, yet ford does not acknowledge the problem. ford desperately needs to recall these engines, they are a hazard, and the spark plug ejects with explosive power damaging nearby components on it's way out of the engine. ford refuses to acknowledge this common manufacture defect. to fix this problem new heads need to be installed on the engine. the quick helicoil style sleeve into the stripped spark plug threads has a failure rate of 100%. again this is a major problem and the magnitude can be seen all over the internet by searching fords spark plug blowouts. literally 10's of thousands of forums, and insight in this problem is available online, except support from ford motor company.
11/15/2010145000
 I was driving @ 70mph down interstate 10 in seguine texas when the sparkplug on my 1998 ford expedition blew out of the head, destroying the coil, plug and wire. the vehicle interior filled with gas fumes and the vehicle started to knock very loudly. i was able to stop the vehicle prior to the fuel vapors igniting, however this was extremely dangerous as my wife and children were in the vehicle with me. after researching i have found that this problem is common with the ford 5.4 triton engines. the mechanic i took the cehicle to explained that the aluminum heads do not mesh with the steel spark plugs and eventually tear all the threads out of the head and shoot the plug out of the hole. the head of the vehicle had to be removed and machined at a cost of 1400$.
11/15/2010145000
 I was driving @ 70mph down interstate 10 in seguine texas when the sparkplug on my 1998 ford expedition blew out of the head, destroying the coil, plug and wire. the vehicle interior filled with gas fumes and the vehicle started to knock very loudly. i was able to stop the vehicle prior to the fuel vapors igniting, however this was extremely dangerous as my wife and children were in the vehicle with me. after researching i have found that this problem is common with the ford 5.4 triton engines. the mechanic i took the cehicle to explained that the aluminum heads do not mesh with the steel spark plugs and eventually tear all the threads out of the head and shoot the plug out of the hole. the head of the vehicle had to be removed and machined at a cost of 1400$.
11/15/2010145000
 I was driving @ 70mph down interstate 10 in seguine texas when the sparkplug on my 1998 ford expedition blew out of the head, destroying the coil, plug and wire. the vehicle interior filled with gas fumes and the vehicle started to knock very loudly. i was able to stop the vehicle prior to the fuel vapors igniting, however this was extremely dangerous as my wife and children were in the vehicle with me. after researching i have found that this problem is common with the ford 5.4 triton engines. the mechanic i took the cehicle to explained that the aluminum heads do not mesh with the steel spark plugs and eventually tear all the threads out of the head and shoot the plug out of the hole. the head of the vehicle had to be removed and machined at a cost of 1400$.
11/15/2010145000
 I was driving @ 70mph down interstate 10 in seguine texas when the sparkplug on my 1998 ford expedition blew out of the head, destroying the coil, plug and wire. the vehicle interior filled with gas fumes and the vehicle started to knock very loudly. i was able to stop the vehicle prior to the fuel vapors igniting, however this was extremely dangerous as my wife and children were in the vehicle with me. after researching i have found that this problem is common with the ford 5.4 triton engines. the mechanic i took the cehicle to explained that the aluminum heads do not mesh with the steel spark plugs and eventually tear all the threads out of the head and shoot the plug out of the hole. the head of the vehicle had to be removed and machined at a cost of 1400$.
08/16/2010150000
 Tl- the contact owns a 1998 ford expedition. the contact stated that the spark plugs blew out of the engine while traveling 65 mph. there was no warning prior to the spark plugs blowing out. the contact started to smell something burning coming from under the hood. in march of 2009 only one spark plug blowout, but in august of this year 2 more spark plugs blew out. the vehicle has not been repaired. the dealer stated that this has been a problem with this vehicle. the failure mileage was 150000 and current mileage was 160000.rl
08/16/2010150000
 Tl- the contact owns a 1998 ford expedition. the contact stated that the spark plugs blew out of the engine while traveling 65 mph. there was no warning prior to the spark plugs blowing out. the contact started to smell something burning coming from under the hood. in march of 2009 only one spark plug blowout, but in august of this year 2 more spark plugs blew out. the vehicle has not been repaired. the dealer stated that this has been a problem with this vehicle. the failure mileage was 150000 and current mileage was 160000.rl
08/16/2010150000
 Tl- the contact owns a 1998 ford expedition. the contact stated that the spark plugs blew out of the engine while traveling 65 mph. there was no warning prior to the spark plugs blowing out. the contact started to smell something burning coming from under the hood. in march of 2009 only one spark plug blowout, but in august of this year 2 more spark plugs blew out. the vehicle has not been repaired. the dealer stated that this has been a problem with this vehicle. the failure mileage was 150000 and current mileage was 160000.rl
08/16/2010150000
 Tl- the contact owns a 1998 ford expedition. the contact stated that the spark plugs blew out of the engine while traveling 65 mph. there was no warning prior to the spark plugs blowing out. the contact started to smell something burning coming from under the hood. in march of 2009 only one spark plug blowout, but in august of this year 2 more spark plugs blew out. the vehicle has not been repaired. the dealer stated that this has been a problem with this vehicle. the failure mileage was 150000 and current mileage was 160000.rl
01/28/2010169000
 First, the interior lights and running lights would not power off while all doors were closed, door ajar indicator was on. took to dealer problem resolved for a month or so. now need to spray wd40 on latches religiously. dealer also replaced cruise control harness at this time. then came the radio and heater running with the key out of the ignition. beeps and clicks and bad smells coming from under dash. again to the dealer, no codes found for the issues i was having. battery draining occurring frequently now and no resolution. i now have to disconnect the battery everynight. now when i drive down the road i get the many failure lights flashing on the dash, the windows won't work, speedometer fails, truck loses power and the transmisson shifts strangely. i was hours from home and doing 70mph on the highway when evidencing decided to not work at the same time. then i realize that this is occurring only when it rains or is very wet out. and i was truly afraid for my life and the others that were on the road with me. i had to drift across a lane of traffic with no power to get to the side of the road. i put the truck in park and put my head down, whew, and the motor powered back up and all the failure lights were off. only after investigating on the internet today do i find out this is a common problem. and the fix... replace the windshield seal! and possible damaged fuse box and gem! now why didn't the ford dealer help remedy this problem one of the many times i was in? this problem has been occurring for several years. new windshield $165 and they come to the house. i paid big money for no codes match your issues, miss. tw*
05/10/2004895001
 1998 ford expedition sparkplug ejection. *tr
10/11/20091510001
 Driving our 1998 ford expedition with a triton 5.4l v-8 home from a weekend camping trip, the engine blew a spark plug. we were on a very busy 5 lane highway with our three children under 6 years old. we spent nearly two hours on the side of the interstate waiting for a tow truck. i understand this is a fairly common malady; one in which the nhtsa has investigated before. i understand that many outside ford motor corp feel this is a design flaw and creates unnecessary emergency events on the side of the road. *tr
05/20/20091130001
 1998 ford expedition with 5.4 l engine. #3 spark plug blew out of engine suddenly, causing severe noise, rough running, and loss of power. mileage: 113,000 miles. repair: $400 for retaping head, placing insert, replacing plug and coil. *tr
06/15/2003850001
 1998 ford expedition blew spark plug out of the head with just a little over 85,000 miles. i was told by the dealer i bought it from that the factory recommends to replace the head at $2300.00. and they said this was the only fix. i traded the vehicle in for a huge loss. i only had it for less than a year. because i found that this is a big problem with fords and no-one will do anything to stop this problem, i have vowed never to by another ford and will make as many people aware of this problem as possible. i now own an escalade and have put on over 90,000 miles without any problems, not like the fords expensive repairs. this happened to me a number of years ago and i didn't know there was a place to enter my gripe besides the ford motor company, and this was like talking to a wall. my family had bought fords since the 40's, when my grandfather owned dealerships. he would turn over in his grave to find out that ford is turning it's back on so many longtime faithful customers. *tr
01/29/20091633451
 My 1998 ford expedition has blown out two spark plugs in the past 4 months. after doing research this is a common problem which ford does not repair on their warranty. ford needs to be held responsible for their mistake! *tr
09/10/20081170001
 I was driving on the freeway at 10pm, and heard a loud pop, then what sounded like i had no muffler from the engine. i looked in the engine, and could not really see anything because it was dark. i had to the vehicle towed because i thought i blew a rod, or a head. once at the mechanic's, they saw that i shot out 2 spark plugs- the no. 3 and 4 still attached to the wires, and that there were no threads left. i am having them pull the head, and have plugs put in, so far the cost to date is $1200. if the plugs do not hold, or other ones blow- which could happen at any time, i will have to replace the entire engine . this will about $3000 this is a very common problem with ford engines. please do something about. ford needs to take responsibility!!!!! *tr
09/17/20081290001
 The engine in my 1998 ford expedition continues to have spark plug problems. the engine misfires, runs poorly, and is a hazard to have on the road. i have had several spark plugs blow out and have had to spend $4000 to have one of the heads replaced because ford did not include enough threads in their original design. they later changed the design in 2003 i am told. if someone there would visit the following site [http://www.consumeraffairs.com/automotive/ford_spark.html], they would see that these engines continue to blow out spark plugs as recently as yesterday, 9/16/08. when are you going to issue a recall? these engines have been dangerous and defective for years. i am not sure what it takes, but ford needs to step up an resolve this problem. *tr
07/28/20081192541
 Ford exp eddie b. blew out #3 spark plug. striped the threads in the head. cost is about 2 grand to repair and correct the 7 other plug holes to ensure it does not happen to others. *tr
03/02/2008127000111/01/2003
 Tl*the contact owns a 1998 ford expedition. when the vehicle was started, the spark plugs literally shot out and burned a whole right through the engine. she has not taken the vehicle to the dealer, but the manufacturer sells a toolkit to repair the failure. the contact believes that a recall should be available. the current and failure mileages were 127,000.
04/21/2007125319102/10/2007
 I was driving my 98 expedition through our cul-de-sac when we heard a loud noise from the engine compartment. my wife and i had to push the truck back to our driveway and immediately began to check the spark plugs.(i am a mechanic by trade) we soon discovered that it was the #3 spark plug. it had blown out, stripping all threads. ford is no help at all. they want $4000 to replace the heads, (and claim to have no knowledge of this defect)but can't guarantee that this won't happen again. since yesterday,i've discovered that i'm one of the many thousands who've had this problem. when is someone going to step up and take responsibility? *tr
10/18/2004880006
 The engine shut off while being drive. the dealer stated that the isc valve was defective. *jb
08/16/2003780001
 After parking in the driveway, went to a neighbors house, and consumer heard the alarm going off. rushed to see what was going on . consumer noticed the vehicle was on fire. the fire completely consumed the vehicle. also, the house caught on fire. the fire investigators report determined part failure in the engine department. the vehicle was totaled.*ak
12/29/2004140000111/15/2001
 I own a 1998 ford expedition with a 5.4l v8 engine. i have it serviced at diers ford in fremont, ne. the vehicle had been driven 2 hours at normal highway speeds when a loud pop was heard followed by rough engine operation. upon inspection, one of the spark plugs had blown out of the passenger side cylinder head stripping the threads out of the head as it went. upon towing the vehicle to my dealer, i was given an estimate of $3,000 to replace the head. i have given the dealer permission to have the head replaced but have been told it will not be until late february until they can even get a head to replace the damaged one. to this point they have let me use a loaner vehicle but have now told me they will no longer provide me one. thus, i am out of a vehicle for at least 8 weeks. *jb
01/11/2005900001
 Vehicle caught fire while parked in the driveway. owner contacted the fire department. owner says that there was no modifications made to the engine. vehicle was perfectly fine prior to the fire. provide further details. *nm
08/21/20041400001
 While parked vehicle caught on fire in the engine compartment. *ak
06/02/200491200110/01/1999
 Without warning vehicle stalled. consumer had to coast off the road. consumer had the vehicle towed to the dealer, and mechanic determined that engine head gasket failed, causing the engine to malfunction. *ak both head gasket blew and needed to be replaced. *ts
07/15/2002
 Consumer states the spark plugs pops out of engine causing the vehicle to lose power. dealer has been notified.
10/26/1999308/28/1998
 Consumer states the engine has been replaced with a remanufactured engine 3 times once being due to a faulty connection rod, and an out of balance crankshaft, the serpentine belt, thermostat and gasket have also been replaced, also, the engine light was illuminating, dealer replaced spark plugs.*jb *yh
05/16/1998411/13/1997
 Engine loses power. also, oil gauge anf temporature gauge activate.
ENGINE AND ENGINE COOLING - COOLING SYSTEM
05/31/20091430001
 Number #4 coil pack, once air condition is turned on dripping water from lines into spark plug area, the #4 coil pack will through a code for a miss-fire. i have replaced the coil packs through out the entire engine recently again. i ran the air conditioning for about one hour and the next day i started the vehicle up and it had a rough idle. i drove approximately 6 miles when the check engine light came on. i hooked up my obd2 to see the problem found out the new #4 coil had misfired once again. i had the single coil pack replaced with 45,000 the first time then i replaced them all at 135,000. and now i had to replace the #4 coil pack again by itself at 143,000. it only throws a mis-fire once i have the air condition on. *tr
01/30/2003920001
 The vehicle experienced a coolant leak.*jb
03/09/2000304/01/1998
 Constantly brought to dealership who continually says nothing is wrong with vehicle. no safety defect listed within summary. *ak
03/09/2000304/01/1998
 Constantly brought to dealership who continually says nothing is wrong with vehicle. no safety defect listed within summary. *ak
03/09/2000304/01/1998
 Constantly brought to dealership who continually says nothing is wrong with vehicle. no safety defect listed within summary. *ak
03/26/199903/01/1999
 Steering has play and dealer has tried to fix three times. steering has feeling of no control. cooling system needed one gallon of coolant five days after taking ownership on 3/26/99. vehicle was a demo model and was still considered new even though it was a 1998 model.
03/26/1999
 The engine loses coolant with no visible signs of leak found, the steering pulls to right and is loose, feels like you can easily loose control. drove other new vehicle and did not have this problem, similar to odi id# 702318.
ENGINE AND ENGINE COOLING - COOLING SYSTEM - HOSE
03/19/2001
 Fluid from the cooling system leaked from hoses and dripped on #4 spark plug, causing plug not to function. please provide any additional information/attachments.*ak
ENGINE AND ENGINE COOLING - ENGINE
07/13/2011144000
 Our 1998 ford expedition with the 5.4 v8 triton engine had another spark plug blow out of the cylinder head. the last time this happened was about 3 years ago, it was the #3 cylinder plug then and last week it was the #6 cylinder plug, i searched the internet concerning this problem and found hundreds if not more of the same issues, and no one is making ford do anything about this, just thought my voice in this matter might help. please if there was ever an instance of a recall this is surely one. this is getting very expensive for the auto owner, the first time we had it fixed by ford and it was $250 and this time it was over $1,000. thank you for addressing this issue,
07/13/2011144000
 Our 1998 ford expedition with the 5.4 v8 triton engine had another spark plug blow out of the cylinder head. the last time this happened was about 3 years ago, it was the #3 cylinder plug then and last week it was the #6 cylinder plug, i searched the internet concerning this problem and found hundreds if not more of the same issues, and no one is making ford do anything about this, just thought my voice in this matter might help. please if there was ever an instance of a recall this is surely one. this is getting very expensive for the auto owner, the first time we had it fixed by ford and it was $250 and this time it was over $1,000. thank you for addressing this issue,
07/13/2011144000
 Our 1998 ford expedition with the 5.4 v8 triton engine had another spark plug blow out of the cylinder head. the last time this happened was about 3 years ago, it was the #3 cylinder plug then and last week it was the #6 cylinder plug, i searched the internet concerning this problem and found hundreds if not more of the same issues, and no one is making ford do anything about this, just thought my voice in this matter might help. please if there was ever an instance of a recall this is surely one. this is getting very expensive for the auto owner, the first time we had it fixed by ford and it was $250 and this time it was over $1,000. thank you for addressing this issue,
07/13/2011144000
 Our 1998 ford expedition with the 5.4 v8 triton engine had another spark plug blow out of the cylinder head. the last time this happened was about 3 years ago, it was the #3 cylinder plug then and last week it was the #6 cylinder plug, i searched the internet concerning this problem and found hundreds if not more of the same issues, and no one is making ford do anything about this, just thought my voice in this matter might help. please if there was ever an instance of a recall this is surely one. this is getting very expensive for the auto owner, the first time we had it fixed by ford and it was $250 and this time it was over $1,000. thank you for addressing this issue,
10/08/2010120000
 1998 ford exoedition the sparg plug blow out.
10/08/2010120000
 1998 ford exoedition the sparg plug blow out.
10/08/2010120000
 1998 ford exoedition the sparg plug blow out.
10/08/2010120000
 1998 ford exoedition the sparg plug blow out.
06/11/2010163200
 Tl- the contact owns a 1998 ford expedition. while the vehicle was parked she stated that a witness saw a fire ignite underneath the drivers side wheel. there was a loud noise where the vehicle went up in flames. the whole front end of the vehicle was destroyed. the dealer has not yet been contacted. there have been no diagnosis or repairs. the failure and current mileage was 163200.cv
12/24/20082001001
 The #4 spark plug ejected from the engine. this is the second time this has occurred within two years. *tr
12/15/20081630001
 Plug blew out of head. had someone look at the truck and they said that it's common for that truck to do that so i checked with another garage to see what they had to say and they told me the same thing .so why is there not a recall on this? *tr
06/17/20081373441
 Ford 5.4l engine spark plugs blowing out of engine. *tr
05/12/20081350001
 Spark plug blowout in a ford expedition 5.4l v8. *tr
03/06/20081100001
 My 1998 ford expedition blew out a spark plug on the highway while i had my baby daughter in the truck. i lost power and had to swerve into the slow lane almost causing multiple accidents . this is the 2nd time this has happened and still no recall. *tr
01/19/2008205000112/10/1997
 As i was driving i heard a loud clattering noise. in a few seconds it became louder. i shut the engine off. my husband came and drove the expedition approx 1/4 mile home. the # 4 spark plug blew out of the head. it slammed the coil pack into the fuel rail and cut the fuel line. as of this time, we have not repaired the vehicle yet. *tr
09/12/20071400001
 Tl*the contact owns a 1998 ford expedition. the contact stated that the engine caught fire while the vehicle was parked. the vehicle was destroyed. the purchase date was unknown. the current and failure mileages were 140,000.
07/18/20072200001
 Tl*the contact owns a 1998 ford expedition. the contact stated that the vehicle caught fire while parked in the driveway. the fire spread from the instrument panel to the radiator and finally to the rear of the vehicle. the vehicle was destroyed. the fire department stated that the fire may have been caused by an electrical source from the engine. the police and fire departments filed a report. the dealer and manufacturer have not been notified. the purchase date was unknown. the current and failure mileages were 220,000.
05/21/2007125000211/10/1997
 Under normal driving condition spark plug blew out @ 1250000. previously a different spark plug had blown out @ 40000 and was repaired with a helicoil. repairs were underway. this appeared to be a very common problem with these 5.4l engines! *ak
08/12/2006204/10/2000
 Back in 2005 my 1998 ford expedition had a spark plug blow out of the cylinder head. had it fixed the first time with a heli-coil. in 2006 it blew out again had to replace the cylinder heads. *nm
01/26/2007128000108/10/2006
 1998 ford expedition, triton engine, forcible ejection of spark plug. threading stripped from cylinder head will not allow reinsertion of spark plug. cost to repair per ford service $4000. ford refuses to acknowledge this as a manufacturing defect and issue recall. no guarantee if repaired that same failure will not occur again. probable cause: poorly designed aluminum cylinder heads with insufficient threading to retain spark plugs. *nm
01/05/2007104880110/01/2006
 1998 ford expedition triton motor-spark plug blowout #2 cylinder. *jb
11/18/200698000106/02/1998
 Dt*: the contact stated while driving 35 mph, a spark plug popped out of place without warning. the vehicle was towed to the residence. the dealer was contacted, and determined the cylinder head needed to be replaced. updated 12/28/2006 - *nm
10/06/2006962131
 A spark blew out the engine leading to major engine damage. to further hurt the ford reputation they said it would cost my life savings to repair it when i had it towed to a reputable mechanic my findings is that it would only cost half of my life savings not only was i told this but then i find evidence that there is a huge cover up .please lord don't let my government be caught up in this mess this corporation has a lot of influence but the american people have a right to live in a just society we the people are what this nation is made from and corporations come and go. *nm duplicate of odi #10170656. no injuries per consumer call by c. rose on 1/16/07
10/06/200696449108/20/2005
 Engine shot a spark plug out dealer advised to replace whole engine for 5000 instead of 4000 to replace defective cylinder head dealer charged almost 300 to change out spark plugs couldn't finish job because threads in hole were stripped out requiring major engine work vehicle has only 96000 miles found mechanic that is doing work to hopefully fix for about 2000. *jb duplicate of odi #10170816. no injuries per consumer call by c. rose on 1/16/07
01/12/2006108/15/2001
 I own a 1998 ford expedition xlt. my check engine light has been on for the past 8 months. when truck is connected to computer for trouble shoot egr code is detected. i have changed egr,solenoid,computer and to this date light is still on. i have been doing research and a large amount of people with ford expeditions are having this problem. please help. *nm
02/13/2006105700210/01/1999
 Dt*: the contact stated while driving 35 mph a spark plug blew out of the cylinder head due to the thread holding the spark plug into place and the engine stalled. the vehicle was taken to the dealership for inspection. upon inspection, the dealership put a heli coil in the cylinder head and replaced the spark plug, which remedied the problem. updated 3/9/2006 - the first failure occurred at 48000 miles on the #2 cylinder. the plug was blown out of the cylinder head. the latest failure was on the #7 plug. *nm
12/28/20042
 Driving down to bakersfield, following a severe skiing injury, my 1998 ford expedition blew a spark plug out the aluminum head, shearing off the coil, and incapacitating the car. *nm
11/25/20052
 While driving on the northbound 405 in la, my 1998 expedition shot a spark plug from the aluminum head. i was trapped in 70mph traffic in the dark waiting a tow truck. *nm
10/03/2005118000208/26/2003
 I was accelerating near my home when the plug blew in the engine of my ford expedition. no accident was caused. this is the second plug to blow on this vehicle in 3 years. *nm
07/02/200384000304/20/1998
 On july 1, 2003 while driving on freeway i heard a loud pop followed by a loss of power. i had the vehicle towed to galpin ford. i was told the #2 spark plug blew through the head gasket. total repairs paid were $4059.99. approx. 1 month later spark plug #4 on the other head blew. not wanting another 4 grand bill i towed the vehicle to dodge brothers where i was charged $402.95 to insert a heli-coil for the one spark plug hole. on 11/10 a 3rd plug bew. knowing that i still had two more plugs that could blow my wife towed vehicle back to galpin. when told repairs would be in excess of $2500.00 she broke down and got them to reduce the cost to $874.00. total costs with tow and rental 5,736.94. *nm
12/01/200493000111/01/2000
 Dt: contact stated while wife was driving a 1998 ford expedition a spark plug blew out from engine. the consumer states wife heard a loud noise coming from the engine and the vehicle kept running, but it lost power and was misfiring. a certified mechanic stated the number four spark blew out on the passenger side due to a defective cylinder head. and stated there is not enough thread on the block to hold the spark plug in. the consumer states this has never happened to his vehicle before. the vehicle has now been repaired by having metal jackets put into the cylinders and also had the cylinders rethreaded. the service dealer stated it would cost approximately $2,000 to repair the vehicle.
07/22/20057700004/16/2004
 My wife and i were going down to so. calif. when we heard a loud pop. i checked under the hood and found that the second spark plug back on the drivers side had blown out. we had to set out in the desert for 4 hours before we could be towed. the ford dealer in carson city, nevada told us that this a common problem and ford would not cover these repairs. what is going on here, where is the recall, ford should have to replace all of these defective parts at their expence, they are the ones made the defective parts.
07/01/200584000310/14/1998
 My 1998 ford expedition eddie bauer with 84k miles on it has had two spark plug coils go bad and have been replaced for $425 each time. on july 1, while driving on the highway, the car made a loud pop and we had to pull over, luckily without causing an accident. we were able to get to the ford dealer in ojai, who looked at the car and determined that the a spark plug had blown out of the head and cost to repair was going to be $3800. many people with the 5.4l triton engine report the same problem and ford needs to address this. the engine should be recalled since it has a fatal deisgn flaw. there are only 4 threads in each spark plug hole instead of 8. we could have been killed if the car had stalled at the wrong time. please get ford to address this problem.
10/22/2004119000108/09/2002
 Engine failure. in my research of the type of engine in my vehicle, a 4.6l made in the romeo plant, have found that there has been numerous people that had their motors fail(blown). i have a ford expedition 1998 with a 4.6l engine and the 8th digit of the vin # being a w for romeo plant. when i called in excess of 20+ auto salvage yards, i had gotten the same response. that particular engine from that particular plant was a problem. i was also told 1997 was the same occurrence. unfortunately, i owe almost $7000.00 on this vehicle that i now can not drive with out replacing or rebuilding the engine, which will be more than a couple thousand. i have been told by these many salvage yards and my local ford dealer the problem occurs when antifreeze makes its way into the oil and burns out the main bearings. *jb
06/14/200498000204/01/1998
 The vehicle started to make a noise, when the consumer was driving. the dealer stated the upper camshaft sensor had broken. then a month later the lower camshaft sensor broke. the manufacture stated the warranty does not apply after mileage has become to high. *nm *nm
12/28/20041200001
 I had a skiing accident and severely damaged my knee. as i was being taken to the hospital in my 1998 expedition, it blew a spark plug out of the engine. i was told by the dealer today that this is a common problem with all ford triton aluminum engines, however, there would be no compensation for this known defect. *nm
12/10/2003900001
 While the vehicle was parked, a fire started in the engine. the fire was put out and the vehicle was towed. please provide more information. *jb
10/06/2004
 The plug blew out of the head on my 1998 ford expedition 5.4 liter v8. has to go to ford, approx 2700 to fix, my extended 3rd party warranty refuses to cover because they say it is a manufacturer defect. ford disagrees. i will have to pay this. too many people have this same thing happen to them . there are several web sites that deal with it. even the 3rd party extended warranty company said they see it all the time on these engines. *nm
06/23/2004113428111/15/1999
 On june 23, 2004 my 1998 ford expedition was towed to a dealer because i blew a spark plug. i was told that it would cost over $2700.00 to get it fixed. they said it was because the spark plug would only blow out again and i needed a new head covering. the service manager said that this was a common occurrence on the aluminum heads. my question or rather my complaint is that i am angry about the response from the service manager and from the ford front office. if ford knows that this is a common occurrence then why should the consumer be liable for something that ford knows is a problem. am pretty upset about this as ford knows this happens and there hasn't been a recall. why isn't there a recall if there is a problem with the head coverings?? am i expected to pay an additional $2700.00 when the other head goes bad? this isn't right and if they have a problem then fix it and don't just rob the consumer. *jb
06/27/200480450109/15/2003
 Engine at idle for a period of time heard a pop and found that spark plug had blown out of the head upon further investigation found out that this is a common problem with the ford triton v8 engine. *jb
05/31/2004117000108/19/2002
 While driving consumer heard a loud knocking noise coming from the front. the consumer was able to pull over and inspected the vehicle. the consumer noticed that the spark plug from the passenger side blew out. the consumer contacted the dealer, and was informed that the cylinder head needed to be replaced due to a blow out. *ak the consumer found that many others experienced this same problem with the 5.4 and the 4.6 ford engines. the problem was found to be a defect in the heads not having enough threads to hold the plugs in. ford would not assist in the repair, even though they recently redesigned the heads to prevent the problem. *sc
04/27/200488000008/07/2000
 Driving one day and heard a loud pop then no response or power from the engine.a certified mechanic said that the 3rd spark plug was blown out of the head and the acknowledged that this is a common thing in these type of engines. i also talked to the dealer that i bought this joke of a vehicle from and they said that they get these kind of repairs in all the time - domino ford in midlothian il. i talked to ford motor co. consumer complaints and all they said was sir there is no recall on your'e vehicle and they said have a nice day. the mechanic said they would put in a insert or heli coil and that it might work but after scanning the internet there is all kinds of complaints out there with this exact kind of problem with the ford pickups , vans and suv's that have this triton engine. ford won't acknowledge this because they know that under a recall it will cost them a lot to fix this obvious manufacturer defect. of the complaints that i read and talking to my mechanic they all mention that the threads that hold the spark plugs are not long or deep enough to contain the spark plug for good. for 40k price tag ford motor co. should replace the engines in these vehicles. do we have to wait for someone to sacrifice their life for this to get rectified? just like the tire issues. if someone does die due to this defect i will be the first to come forward on this on when i complained and that nothing was done. peoples lives should not be risked to line fords pockets. if you sue them they will drag it out so long because they made 40k a vehicle on this model alone and they will drag it out until you can't pay for help anymore.
04/01/200493300107/07/2001
 When accelerating from a traffic light, i heard a pop and then my 5.4l engine on my 1998 ford expedition started making a loud continous popping/ticking sound. we had it towed to the local ford dealer and they diagnosed it as a blown spark plug caused by the cylinder head threads giving way and causing the spark plug to be blown out of the spark plug hole. they are charging us almost $3300 to fix the defect in their cylinder heads. they deny there is any type of recall, but i did see a tsb# 98b33 which relates to cylinder head replacement. if you go to these websites, http://www.f150online.com/forums/showthread.php?s=90a1a25c42dbffde23d53146381e3e78&threadid=88853&perpage=15&pagenumber=2 and http://forums.pickuptruck.com/showflat.php?cat=&board=ubb10&number=155196 you will see that this has happened to alot of other ford owners with 5.4 and 6.7l v-8's and v-10's. i have never heard of a spark plug blowing up and cracking a head before in my life and to me this is obviously a manufaturer defect and ford should recall these engines and fix this problem at no cost to the consumer. we have done all of our scheduled maintenance at ford dealers and spent considerable amounts of money doing so and we were never warned or told of this problem with these engines. ford should at the very least recommend more frequent maintenance specifically addressing this issue. *ak
02/04/20041070002
 While driving consumer heard a loud rattling noise coming from engine. dealership was notified, but did not resolve the problem.
12/20/2003111/26/2002
 Ford spark plug blowout problem. *jb
01/10/2004960001
 Spark plug blown out of cylinder head.
10/23/20031200001
 While driving consumer heard a tapping sound coming from the engine. consumer continued driving when the check engine light appeared on the dashboard. afterwards, vehicle lost power. consumer had vehicle towed to the dealership. *ak
10/15/2003110000111/23/1997
 I have a 1998 ford expedition 5.4l. the sparkplug threads on cylinder #3 are damaged even though the sparkplugs are original. the ford mechanic claims this is due to insufficient threads on the original cylinder head. my plug loosened part way but did not blow out like many others have reported. *la
10/17/2003730001
 While driving 50 mph the vehicle stalled. the driver pulled over onto the shoulder and attempted to restart the vehicle but it wouldn't turn over. the vehicle was towed to the dealership but the mechanic could not duplicate the problem. *ak *nlm *ph
09/28/2003131000109/10/2000
 Traveling on the freeway in stop and go traffic at approximately 40-50 mph when one of the spark plugs in the motor exploded out of the head. i spoke to ford, and they expressed that this is a common problem with the ford expedition, that it is probably a casting flaw with the heads, and that a replacement is typical and will cost approximately $3,000.00 for repair. aside from being stranded on the side of the road, there was no indicator that this would happen. research has led me to find that there are hundreds, if not thousands, of other ford owners that have experienced this same problem. where is the recall? *la
10/02/2003125000109/21/1999
 Spark plug was 'blown' out of cylinder head on 1998 ford expedition. ford enthusiast website showed this occurring to several people. the expense is $4100 and it seems to me that this is a defect in manufacturer. there was no warning, nor any recent service performed other than oil change. *jb
08/15/200375000009/01/2001
 While driving on i-75 in michigan, i heard a loud pop and the truck began to shake. after driving to the nearest ford dealership i learned that the 3rd spar kplug on the driver side had blown out of the head, and the coil had melted. i'm being quoted $2100 on the repair right now, and trying to trade it in, after looking at the other problems that have been posted through here. hopefully this will get seriously considered for recall. *ak
01/27/200047917209/15/1999
 Incident 1 (dated 01/27/00): spark plug blew out of driver-side cyclinder head. dealer retapped treads, replaced spark plug, reassembled engine ($1216.79) incident 2 (dated 08/29/02): spark plug blew out of driver-side cyclinder head. dealer replaced cyclinder head, reassembled engine ($2035.61)
07/18/199884000112/04/1999
 Vehicle had a cylinder head failure blowing spark plug out of the #4 cylinder causing gas to pump out over engine. estimated cost to repair by green valley ford $4100.00. *ak
05/07/200369000102/02/1998
 The spark plug blew out of the cylinder head on the passenger side, and stripped all of the threads out. *ak *ts *jb
02/03/2003815881
 Number three spark plug and assembly blown out of head. i have found this to be common with many 5.4 litre motors since experiencing this. local ford dealer towne ford in redwood city wanted $2,000.00 to inspect and then start to talk about repair costs. towed vehicle to mission valley ford in santa clara where service advisor obtained an extended warranty from ford to have head replaced due to numerous similar problems. repair cost $1900.00 for wich i had to pay $750.00. the motor must be pulled from truck to replace the head. i had been informed by one fleet owner of trucks with several of these motors that had experienced the same problem with the same motors as mine, that one vehicle blew out a spark plug on the driver side after replacing the head on the passenger side. i had both heads replaced at the same time and was told by the service advisor that ford had changed the part numbers of the heads indicating that a change had been made to the new heads supplied for replacement. the total cost was $2,500.00 for both heads replaced. the problem is that the heads do not have enough surface area in them to properly hold the spark plug securely.
02/01/200358300109/01/1997
 At 58,000 miles one of the spark plugs was blown out of the cylinder head on the drivers side. the repair required a replacement head assembly; however, no heads are available in the entire country. only option from ford was to replace the engine! the engine had already been replaced at 33,900 miles due to a piston slap problem. the cylinder head only had 25,000 miles on it when the spark plug blew out. ford would not provide any assistance due to the fact that the engine warranty ran out at 24,000 miles.
08/13/2002
 While traveling on highway vehicle stalls. dealership is aware of problem.*ak
04/28/200207/01/2000
 While at idle the #3 sparkplug blew out of the cylinder stripping the threads. the repair facility estimates $2000 to repair. this is exactly like odi #743868. there is a defect in the heads. this engine was replaced twice at about 30,000 miles because of leaks in the headgasket. the current engine only has 34000 miles. when the spakplug blew out it spewed gas over the engine creating a potential fire hazard.*ak
 Head gaskets are leaking coolant onto the ground. a recall has been issued on vehicle's make and model; however, this vehicle was not included due to vin. please provide additional information.*ak
12/31/2001
 While driving on freeway consumer heard a loud pop in vehcile, and then vehicle started to shake. consumer took vehicle to the dealer, and dealer noted that head gasket had blowen out. *ak
09/03/20011
 While driving crankshaft/ pulley snapped off the motor. lost all power to vehicle. after towing vehicle to mechanic, there was not a reason for crankshaft to snap.*ak
07/17/2001111/01/1997
 We purchased a brand new 1998 ford expedition in november of 1997. the car came standard with a 3 year bumper-to-bumber warrenty. our 3 year warranty expired in november of 2000. on july 19, 2001, we experienced a mechanical problem with our vehicle and had it towed to theodore robins-ford in costa mesa, ca. they,theodore robins informed us that one of the engines cylinders was not working. now, our car is a little less than 4 years old and has only 21,000 miles on it. theodore robins-ford is refusing to fix the car free of charge. the total cost of repairs is about $1900. theodore robins-ford maintains the point-of-view that the warrenty has expired. they are willing to charge us $495 that would extend our warrenty from november of 2000 until november of 2002. this $495 amount will cover the cost of fixing the car.*ak
04/07/2001109/01/1998
 While sitting at idle, the engine blew a sparkplug from the cylinder, completely stripping the threads and requiring an entire new header assembly ($1800 repair). i had never heard of such a failure but the dealer has seen it on other expeditions/navigators and f-150 pickups. this suv is used as my wife's mini van and does not pull trailers or go off-road. there has to be a manufacturing defect with the aluminum head.*ak
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
02/15/200897662109/07/1997
 1998 ford expedition with 97,000 miles blew out the #4 spark plug during normal operation. this was the factory original spark plug. *tr
11/04/2007106/01/2002
 1998 ford expedition 5.4l v8 engine, spark plug from cylinder#3 blew out of head causing damage to cylinder head and ignition coil. cleaned out threads with tap of same size, which are impossible to see in tight area of engine compartment and installed new spark plug but it blew out again two days later. *tr
01/07/2006110000103/13/2002
 Spark plug blow out ford 5.4 v8. *nm
07/16/200349486101/20/1998
 I have a 1998 ford expedition 5.4l engine. at under 50000 miles a spark plug blew right out of the cylinder. head and stripped the threads. repairs included a new cylinder head. ford recommends spark plug change at about 100000 miles. the issue is a defective design of the aluminum cylinder head only having a few turns of thread to hold in a spark plug under compression.*ak
08/13/20031
 Consumer stated head gasket was leaking oil. dealer emphasized the need to replace head gasket as soon as possible. *ak
01/19/200392102009/17/1997
 Spark plug blown out of stripped socket
09/01/2001
 While driving at any speed the vehicles engine shuts off. consumer states' vehicle will not restart for several days. ford has replaced the computer module and the theft system and problem keeps reoccurring. please provide any further information. mr
12/23/19971009/01/2097
 Repeated problem that has escalated to a suggested engine replacement. the #4 coil has been repaired 10 times. the vehicle warranty and extended warranty have been exhausted. ford has repeatly failed to find the real problem. the customer service department representatives and supervisor have said that there's nothing ford can do about my problem. it's the ford policy.*ak
03/27/200203/01/1999
 Dealership says oil leak due to engine block being mis-cast. dealership recommends new engine to fix the problem. heads could be replaced but problem would reoccur again. this problem has occurred in many engines and ford is aware of this but is offering no help with the cost of replacement or recall on the engine to anyone but those who have ford extended warranties. this is the original engine that was put in the truck. the defect has always been there and is not something that has occurred over time. cost of new engine approximately $4,500.*ak
 When starting the vehicle it would shut off and could not be restarted, the vehicle was taken to the dealer but the problem could not be found. nlm
11/15/200110005/01/2001
 The engine consistently cuts out when placing the transmission into reverse. its been back twice, but no trouble found. it happens when in traffic and has nearly caused rear end collisions. no particular action causes this, just come to a stop and put it in reverse.*ak
 When vehicle is parked down hill after starting and letting the vehicle warm up engine completely shutsdown, cause unknown. please give any further details.*ak
10/01/1999
 Parts of rubber kept coming off, engine kept loosing to much oil but claimed they could not find why. has done this since i bought it now find the problem the intake is busted can not pay to fix it . never get recall notices. no safety defect. *ak
11/01/19980
 Dealer said it was normal to put in a quart of oil every thousand miles. consumer does not agree, none of prior vehicles needed that much oil.*ak
110/01/1998
 While driving engine died, engine replaced at owner's expense. cj
12/14/19992
 While driving,the vehicle is stalling, once it stalled while making a right hand turn. *slc
1
 Windows- all power windows occassionally will not let up if down or down if up. engine- when stopped, gives an intermitten vibration. child locks- engages when unlock power locks. turn signal- if steering wheel not straight, can't engage turn signal. tires- making sound as if they will peel off at any moment. (tiresize: p255/70r16)( dot number: tire size: p255/70r16 )
06/02/20000
 Vehicle had been leaking oil since it was bought. but, dealer couldn't find where the leak was coming from. *ak
11/02/1998105/01/1998
 Engine failed. yh
01/06/1999107/23/1998
 Computer malfunction causing vehicle stalling after fixing computer incidents of stalling still continuing.
06/17/1998
 Vehicle stalls when leaving stop light or stop sign. very dangerious problem as vehicle stalls in front of on comming traffic, that either has to panic brake or swerve to avoid striking the stalled vehicle.
09/01/1998
 Speed sensitive power steering: at the time of purchase the vehicle pulled right. the vehicle also exhibited a problem i call steering burst or hang. when turning either left or right the power assist steering would continue to apply pressure to the steering wheel. this continued pressure could only be stoped by jerking hard, back in the opposite direction on the steering wheel. another issue experienced is when accelerating hard from a stop or passing etc. the vehicle moves to the right of the lane of travel. this occurs in a surprisingly quick and unusual manner as if the vehicle where dog tracking to the right.?. the vehicle was aligned by the dearler 4 times in the first weak of ownership. also the frame and the tires were checked. after the forth alignment i noticed the vehicle wondering left & right on the road. suspecting somthing fishy, i took the vehicle to an independent auto shop. the mechanic ther pointed out visually the caster and camber adjustment slots and how they were maxed out. the caster and camber had been intentionally set to 3 degrees and 6 degrees out of manufactors specifications so as to pull left. left so as to bury the pull right problem. this steering system is either mal-engineered, mal-assembled or has defective parts. a problem which the dealer nor manufacturer can resolve or don't want to resolve it. ford had two of thier reps look at the problem. both times they stated the vehicle operates as per design. the last time they (ford & dealer) had the vehicle they deactivated the speed sensitve feature which makes the problem feel less apparent but is non the less still there. the power steering is now stiffer and tighter i can only surmise to further attemp to cover -up the problem. other expeditions i test drove had the same problem. and on theford expedition enthusiest web site there are many of the same complaints. the a/c failure was catastrophic the vehicle had to be towed, late at night i might add. more details please call.
02/13/1998
 While driving the vehicle hesitates which may cause an accident. been to dealer several times and put a recorder to help determine the problem. dealer cannot determine problem. please provide further information. *ak
10/05/199708/01/1997
 The engine makes a pinging noise after vehicle has time to warm up(about 1/2 hr). i've been to three (3) different dealers. the first one said to just put in higher octane gas (it should run on 87 octane according to the owners manual) and that was all they did. they didn't even write it up. the second dealer did the same. the third dealer kept the truck over night and wrote they reprogrammed the computer however this did not solve the problem. i called ford and they told me they would get in touch with the third dealer and i would be hearing from them soon. it's been over two weeks now and i've had enough. i don't know if i'm polluting the air with this truck or not. it is not suppose to make pinging sounds even though at the third dealership, one of their mechanics told me that all fords ping. i don't know if this is considered a safety problem or not but i want you to be aware of this because i have spoken to other expedition owners and quite a few of them are having the same problem. thanks, al krause
06/22/19981
 While driving the vehicle stalls at any speed. the dealer is aware of the problem. dealer not able to solve the problem. *ak *slc
12/09/19975
 Engine continuously loses coolant and overheats, repair attempts, however probmem continues.
07/22/1998
 While driving the vehicle stalls. the dealer has not been able to duplicate the problem. *ak
05/16/1998411/13/1997
 Engine loses power. also, oil gauge anf temporature gauge activate.
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS
06/29/1998
 The air conditioning compressor broke. due a defective bolt the belt slipped off, and the car stopped in the middle of the freeway. also, the engine check light kept coming on. upon notification of dealer, the mechanic stated that the light was on because of the belt slipping off. repair work was done. the bolts were replaced, and the light still came on. the dealer cannot duplicate the problem.
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
11/12/2008860001
 1998 ford expedition 4x4 4.6l, the poor quality steel used for the exhaust manifolds and bolts rust very fast. mine resulted in the driverside bolts rusting away causing exhaust coming directly out of the engine, also the egr tube rusted off the drivers manifold causing hot exhaust to blow toward the top of the engine. on the passenger side the manifold bolts/studs also rusted away causing exhaust to disperse in the engine bay. also on the passenger side the manifold cracked about 3 inches long on the top of the manifold causing hot exhaust to blow upward to the upper engine bay. i corrected this problem by replacing the bad manifolds/studs with pacesetter shorty headers and bolts, it was the cheapest fix. the pacesetter shorty header kit was $150 from www.summitracing.com . the truck was extremely loud before i fixed this problem and i was pulled over for it by the police 4 times, they let me go if i promised to fix the problem. since i fixed the problem the truck is very quiet and i don't get threatened with $75 tickets anymore plus i have the peace of mind the truck wont burn to the ground with my family in it from hot leaking exhaust manifolds or rusty failed studs/bolts. *tr
11/18/2006760005
 On the underside of the vehicle there is an audible, high frequency rattle or vibration that is increased when the vehicle is in gear, stopped and in idle. the noise reduces and often goes away when the engine rpms are increased above 600 per minute. the vehicle has been examined by the dealer three times, has had all of the exhaust brackets tightened or replaced to no avail. owner was informed that it was a backed out bolt in the exhaust heat shield, this bolt was changed by dealer on the 3rd trip, with no change, in fat, that made it worse. two different muffler shops have looked at and notice nothing else loose or missing. on the last visit to the dealer, owner was told that the reason for the noise is that the exhaust pipe is torqued and twisted a little bit from heat contraction and expansion. *nm
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
08/30/2002
 Coolant system vapor form inside of heater compartment, and fumes are coming inside of vehicle . dealership is aware of problem.*ak
04/26/2002105/15/1998
 While driving, heard a noise under the truck as if vehicle ran over something. took vehicle to dealership, mechanic stated it was sway bar link that broke off. *ak check engine light is illuminated; dealer found hego sensors were not responding; bank 1 and 2 hego sensors were replaced. *tt
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
07/11/200650000102/09/1998
 Dt*: the contact stated the vehicle was leaking antifreeze onto the intake manifold behind the engine. an independent mechanic determined the upper part of the engine needed to be removed to repair the leak.
12/12/20041040001
 The car was under normal city driving conditions when the #3 spark plug was violently ejected from the engine. although there was not a fire, with fuel air vapors being expelled from the empty spark plug hole and the plug and wire visible arcing in the engine compartment, there certainly was a possibility of a fire. i have contacted ford motors customer relations directly to report this as a potentially dangerous design flaw, they flatly deny that there is any problem. unfortunately, the cost of this repair can run between $3000 and $6000, which is probably why ford has chosen to take the coarse of denial. at the same time they are denying that this is a hazardous design flaw, the have corrected the problem in replacement parts and in later model years. *jb
12/22/2003700009
 1998 ford expedition eddy bauer losses power when accelerated over 3000 rpms, on what seems to be a misfire, i've taken it to different mechanics, i've had the coils and spark plugs replaced, i've spent over $2000 and problem still persists. i went to two different ford dealers just to encountered the worst dealer serviced i've ever received in my life...they are no help. i am stuck with a car that i paid over $30,000 for that has defect problems that ford is aware of but is completety unwilling to accept. this is definitely the worst investment i've ever made in my life, can anybody help me?...please.*ak