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
1640311/01/200210008334Engine-light tick or rattle type noise from engine after cold start. *mj07/28/2004
0222711/11/200210008310Engine-cylinder head deck leak-4.6 and 5.4l engines-new service-only gasket and cylinder head kits availability. *mj07/27/2004
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
1384603/01/2001620275Some vehicles built 7/1998 to 6/1999 equipped with a 4.6 / 5.4l winsor built engines may exhibit an oil leak from the cylinder heat gasket area. *tt07/23/2001
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
1384602/01/2000612444Some vehicles built 7/1998 to 6/1999 equipped with a 4.6 / 5.4l windsor built engines may exhibit an oil leak from the cylinder head gasket area. *tt06/08/2000
809302/01/2000612291Some vehicles built 7/1998 to 6/1999 equipped with a 4.6 / 5.4l windsor built engine may exhibit an oil leak from the cylinder head gasket area. *tt06/07/2000
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
1585105/01/2002637696Some 5.4l windsor power improved engines may exhibit a slight oil leak or weep at the cylinder head to block joint. *tt12/04/2002
0210805/27/2002636083Some vehicles equipped with the 5.4l 2v engine may exhibit a whistling noise fromthe formed nylon tube inthe idle-air bypass flow circuit. *tt11/05/2002
0124612/10/2001630515Engine oil system priming procedures, service tips for reports of premature engine failure. *tt04/18/2002
1543111/01/2001630452Exhibiting lack of power condition when vehicle is operated in ambient temperatures. *tt04/17/2002
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
1525909/01/2001625807Concerns with the lower power in high ambient temepratures. *tt12/03/2001
0112206/25/2001622661On some vehicles there may be an oil leak from the right hand head gasket at the rear of the block / head joint. *tt10/22/2001
014203/05/2001619419Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. *tt05/30/2001
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
525712/01/1998615374Information on vehicles exhibiting cold engine knock. *tt01/13/2001
498112/01/1998615321Some vehicles equipped with 5.4l engines may exhibit a cold start engine knock concern until warmed up. *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
1340910/01/1999614613Some vehicles equipped with a 4.6l engine may exhibit a hesitation / stumble after initial vehicle start-up during accelerator tip-in, with a cold engine. *tt11/28/2000
1333110/01/19996092152Some vehicles equipped with engines produced by windsor engine plant may exhibit an engine knock at initial cold startup. *tt11/27/2000
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
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
732110/01/1999609606Exhibiting a hesitation / stumble after initial vehicle start-up during accelerator tip-in, with a cold engine. *tt04/04/2000
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
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
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
802104/01/2000613615Exhibiting a crackling / popping noise from the exhaust. **mr07/26/2000
802101/01/2000612686Some vehicles may exhibit a crackling/popping noise from the exhaust, vehicles built between 11/1/97 and 12/8/99. *mjs06/12/2000
1380601/01/2000612823Some vehicles built between 11/1/97 and 12/8/99 may exhibit a crackling/popping noise from the exhaust. *mjs06/12/2000
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
98231011/23/1998603724Mass air flow (maf)- sensor contamination- service tip. *ak03/03/1999
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
08/16/20101600001
 Cranked the truck to drive and motor began to knock and white smoke began to pour out. engine locked up. *tr
08/16/20101600001
 Cranked the truck to drive and motor began to knock and white smoke began to pour out. engine locked up. *tr
08/16/20101600001
 Cranked the truck to drive and motor began to knock and white smoke began to pour out. engine locked up. *tr
08/16/2010160000
 Cranked the truck to drive and motor began to knock and white smoke began to pour out. engine locked up
07/10/20121260001
 Truck parked, not drove for three days, alarm went off and truck burst into flames in motor area, truck total loss, found out after fire they had recall on cruise control switch, would've been nice to know, so i'm sure several people unaware.car company need to realize cars is how they make there money and our cars are the way we pay them. *tr
07/10/20121260001
 Truck parked, not drove for three days, alarm went off and truck burst into flames in motor area, truck total loss, found out after fire they had recall on cruise control switch, would've been nice to know, so i'm sure several people unaware.car company need to realize cars is how they make there money and our cars are the way we pay them. *tr
07/10/2012126000
 Truck parked, not drove for three days, alarm went off and truck burst into flames in motor area, truck total loss, found out after fire they had recall on cruise control switch, would've been nice to know, so i'm sure several people unaware.car company need to realize cars is how they make there money and our cars are the way we pay them
07/10/2012126000
 Truck parked, not drove for three days, alarm went off and truck burst into flames in motor area, truck total loss, found out after fire they had recall on cruise control switch, would've been nice to know, so i'm sure several people unaware.car company need to realize cars is how they make there money and our cars are the way we pay them
07/10/2012126000
 Truck parked, not drove for three days, alarm went off and truck burst into flames in motor area, truck total loss, found out after fire they had recall on cruise control switch, would've been nice to know, so i'm sure several people unaware.car company need to realize cars is how they make there money and our cars are the way we pay them
08/04/20111230001
 While driving down the road maintain steady speed on level road number 3 sparkplug blew out breaking coil and dropping sparkplug on the road. original sparkplugs had never been changed. *tr
08/04/20111230001
 While driving down the road maintain steady speed on level road number 3 sparkplug blew out breaking coil and dropping sparkplug on the road. original sparkplugs had never been changed. *tr
08/04/20111230001
 While driving down the road maintain steady speed on level road number 3 sparkplug blew out breaking coil and dropping sparkplug on the road. original sparkplugs had never been changed. *tr
08/04/2011123000
 While driving down the road maintain steady speed on level road number 3 sparkplug blowed out breaking coil and dropping sparkplug on the road. original sparkplugs had never been changed.
08/04/2011123000
 While driving down the road maintain steady speed on level road number 3 sparkplug blowed out breaking coil and dropping sparkplug on the road. original sparkplugs had never been changed.
ENGINE AND ENGINE COOLING
09/01/2011134500
 Tl- the contact owns a 1999 ford expedition. the contact stated that there was an abnormal vibration from the motor which was stripping the spark plugs. the dealer advised the contact that the vehicle was operating as designed and also advised that she purchase a spark plug kit. the manufacturer was made aware of the failure however, did not offer any assistance. no repairs were performed. the current mileage was 135,000 and the approximate failure mileage was 134,500. kmj
09/01/2011134500
 Tl- the contact owns a 1999 ford expedition. the contact stated that there was an abnormal vibration from the motor which was stripping the spark plugs. the dealer advised the contact that the vehicle was operating as designed and also advised that she purchase a spark plug kit. the manufacturer was made aware of the failure however, did not offer any assistance. no repairs were performed. the current mileage was 135,000 and the approximate failure mileage was 134,500. kmj
09/01/2011134500
 Tl- the contact owns a 1999 ford expedition. the contact stated that there was an abnormal vibration from the motor which was stripping the spark plugs. the dealer advised the contact that the vehicle was operating as designed and also advised that she purchase a spark plug kit. the manufacturer was made aware of the failure however, did not offer any assistance. no repairs were performed. the current mileage was 135,000 and the approximate failure mileage was 134,500. kmj
09/01/2011134500
 Tl-the contact owns a 1999 ford expedition. the contact stated that vibration from the motor strips the spark plug. the dealer advised the contact that the vehicle was operating as designed. they also advised her to purchase a kit spark plug kit. the manufacturer was aware of the failure; however, did not offer any assistance. no repairs were performed. the current mileage was 135,000. the approximate failure mileage was 134,500. bw
06/25/2011155000
 While moving accross country my 1999 ford expedition ejected the number 3 spark plug. this situation placed my family in harm's way as it occured on the interstate and was quite startling. the service rep was able to tell me what was wrong with my vehicle as soon as told him the make and model. the repair cost is significant, but the potential for an under hood fire caused by the fuel vapors being ignited by the ejected plug is of grave concern. ford is keenly aware of the problem and has designed a replacement head for the vehicle, but refuses to do the honorable thing and replace it at their expense. they instead choose to profit from their customers by charging them for the repair or replacement of the cylinder heads. i find it predatorial that a car company would make a faulty product and then profit from the repair of said product. this could start a new precident by signaling to other car companies that if you sell a defective vehicle, you can make money on the backside by charging for the repair or replacement of that part. the safety concerns that are associated with this failure are related to the loud and sudden popping sound when the plug ejects, this could easily distract a driver and could potentially lead to a fatal accident. the fuel vapors could be ignited shortly after the plug ejects and could also cause the driver to lose control of the vehicle. considering the expedition carries up to 9 people the risk of a trafic fatality is increased greatly. please hold ford accountable for their error and lets hope no one gets hurt or killed until then.
06/25/2011155000
 While moving accross country my 1999 ford expedition ejected the number 3 spark plug. this situation placed my family in harm's way as it occured on the interstate and was quite startling. the service rep was able to tell me what was wrong with my vehicle as soon as told him the make and model. the repair cost is significant, but the potential for an under hood fire caused by the fuel vapors being ignited by the ejected plug is of grave concern. ford is keenly aware of the problem and has designed a replacement head for the vehicle, but refuses to do the honorable thing and replace it at their expense. they instead choose to profit from their customers by charging them for the repair or replacement of the cylinder heads. i find it predatorial that a car company would make a faulty product and then profit from the repair of said product. this could start a new precident by signaling to other car companies that if you sell a defective vehicle, you can make money on the backside by charging for the repair or replacement of that part. the safety concerns that are associated with this failure are related to the loud and sudden popping sound when the plug ejects, this could easily distract a driver and could potentially lead to a fatal accident. the fuel vapors could be ignited shortly after the plug ejects and could also cause the driver to lose control of the vehicle. considering the expedition carries up to 9 people the risk of a trafic fatality is increased greatly. please hold ford accountable for their error and lets hope no one gets hurt or killed until then.
06/25/2011155000
 While moving accross country my 1999 ford expedition ejected the number 3 spark plug. this situation placed my family in harm's way as it occured on the interstate and was quite startling. the service rep was able to tell me what was wrong with my vehicle as soon as told him the make and model. the repair cost is significant, but the potential for an under hood fire caused by the fuel vapors being ignited by the ejected plug is of grave concern. ford is keenly aware of the problem and has designed a replacement head for the vehicle, but refuses to do the honorable thing and replace it at their expense. they instead choose to profit from their customers by charging them for the repair or replacement of the cylinder heads. i find it predatorial that a car company would make a faulty product and then profit from the repair of said product. this could start a new precident by signaling to other car companies that if you sell a defective vehicle, you can make money on the backside by charging for the repair or replacement of that part. the safety concerns that are associated with this failure are related to the loud and sudden popping sound when the plug ejects, this could easily distract a driver and could potentially lead to a fatal accident. the fuel vapors could be ignited shortly after the plug ejects and could also cause the driver to lose control of the vehicle. considering the expedition carries up to 9 people the risk of a trafic fatality is increased greatly. please hold ford accountable for their error and lets hope no one gets hurt or killed until then.
06/25/2011155000
 While moving accross country my 1999 ford expedition ejected the number 3 spark plug. this situation placed my family in harm's way as it occured on the interstate and was quite startling. the service rep was able to tell me what was wrong with my vehicle as soon as told him the make and model. the repair cost is significant, but the potential for an under hood fire caused by the fuel vapors being ignited by the ejected plug is of grave concern. ford is keenly aware of the problem and has designed a replacement head for the vehicle, but refuses to do the honorable thing and replace it at their expense. they instead choose to profit from their customers by charging them for the repair or replacement of the cylinder heads. i find it predatorial that a car company would make a faulty product and then profit from the repair of said product. this could start a new precident by signaling to other car companies that if you sell a defective vehicle, you can make money on the backside by charging for the repair or replacement of that part. the safety concerns that are associated with this failure are related to the loud and sudden popping sound when the plug ejects, this could easily distract a driver and could potentially lead to a fatal accident. the fuel vapors could be ignited shortly after the plug ejects and could also cause the driver to lose control of the vehicle. considering the expedition carries up to 9 people the risk of a trafic fatality is increased greatly. please hold ford accountable for their error and lets hope no one gets hurt or killed until then.
06/25/2011155000
 While moving accross country my 1999 ford expedition ejected the number 3 spark plug. this situation placed my family in harm's way as it occured on the interstate and was quite startling. the service rep was able to tell me what was wrong with my vehicle as soon as told him the make and model. the repair cost is significant, but the potential for an under hood fire caused by the fuel vapors being ignited by the ejected plug is of grave concern. ford is keenly aware of the problem and has designed a replacement head for the vehicle, but refuses to do the honorable thing and replace it at their expense. they instead choose to profit from their customers by charging them for the repair or replacement of the cylinder heads. i find it predatorial that a car company would make a faulty product and then profit from the repair of said product. this could start a new precident by signaling to other car companies that if you sell a defective vehicle, you can make money on the backside by charging for the repair or replacement of that part. the safety concerns that are associated with this failure are related to the loud and sudden popping sound when the plug ejects, this could easily distract a driver and could potentially lead to a fatal accident. the fuel vapors could be ignited shortly after the plug ejects and could also cause the driver to lose control of the vehicle. considering the expedition carries up to 9 people the risk of a trafic fatality is increased greatly. please hold ford accountable for their error and lets hope no one gets hurt or killed until then.
06/25/2011155000
 While moving accross country my 1999 ford expedition ejected the number 3 spark plug. this situation placed my family in harm's way as it occured on the interstate and was quite startling. the service rep was able to tell me what was wrong with my vehicle as soon as told him the make and model. the repair cost is significant, but the potential for an under hood fire caused by the fuel vapors being ignited by the ejected plug is of grave concern. ford is keenly aware of the problem and has designed a replacement head for the vehicle, but refuses to do the honorable thing and replace it at their expense. they instead choose to profit from their customers by charging them for the repair or replacement of the cylinder heads. i find it predatorial that a car company would make a faulty product and then profit from the repair of said product. this could start a new precident by signaling to other car companies that if you sell a defective vehicle, you can make money on the backside by charging for the repair or replacement of that part. the safety concerns that are associated with this failure are related to the loud and sudden popping sound when the plug ejects, this could easily distract a driver and could potentially lead to a fatal accident. the fuel vapors could be ignited shortly after the plug ejects and could also cause the driver to lose control of the vehicle. considering the expedition carries up to 9 people the risk of a trafic fatality is increased greatly. please hold ford accountable for their error and lets hope no one gets hurt or killed until then.
05/24/2011167000
 Tl*the contact owns a 1999 ford expedition. while the vehicle was parked the contact turned on the ignition and saw smoke escaping from the hood and defrost vents. when the contact exit the vehicle looked underneath the hood, the engine was on fire. the fire department filed a report. the vehicle was destroyed. the approximate failure mileage was 167,000.
05/24/2011167000
 Tl- the contact owns a 1999 ford expedition. while parked the contact turned on the ignition and noticed smoke was escaping from the hood and the defroster vents. the contact exited the vehicle and opened the hood and noticed flames. the fire department was called to the scene and a report was filed. the vehicle was destroyed. the approximate failure mileage was 167,000. ds
05/24/2011167000
 Tl- the contact owns a 1999 ford expedition. while parked the contact turned on the ignition and noticed smoke was escaping from the hood and the defroster vents. the contact exited the vehicle and opened the hood and noticed flames. the fire department was called to the scene and a report was filed. the vehicle was destroyed. the approximate failure mileage was 167,000. ds
05/24/2011167000
 Tl- the contact owns a 1999 ford expedition. while parked the contact turned on the ignition and noticed smoke was escaping from the hood and the defroster vents. the contact exited the vehicle and opened the hood and noticed flames. the fire department was called to the scene and a report was filed. the vehicle was destroyed. the approximate failure mileage was 167,000. ds
03/21/2011142000
 Was driving along with my son in my 1999 ford expedition(eddie baur series) when all of a suden heard a pop took it to a macanic and they said spark plug blew and a coil would not fix the problem they said i would need to replace the cylinder head cuz the hole was to big i had this truck for only a month and a half and ive been reading that im not the only one with this problem. something needs to be done about this. please!!!!!!!!
03/21/2011142000
 Was driving along with my son in my 1999 ford expedition(eddie baur series) when all of a suden heard a pop took it to a macanic and they said spark plug blew and a coil would not fix the problem they said i would need to replace the cylinder head cuz the hole was to big i had this truck for only a month and a half and ive been reading that im not the only one with this problem. something needs to be done about this. please!!!!!!!!
03/21/2011142000
 Was driving along with my son in my 1999 ford expedition(eddie baur series) when all of a suden heard a pop took it to a macanic and they said spark plug blew and a coil would not fix the problem they said i would need to replace the cylinder head cuz the hole was to big i had this truck for only a month and a half and ive been reading that im not the only one with this problem. something needs to be done about this. please!!!!!!!!
03/21/2011142000
 Was driving along with my son in my 1999 ford expedition(eddie baur series) when all of a suden heard a pop took it to a macanic and they said spark plug blew and a coil would not fix the problem they said i would need to replace the cylinder head cuz the hole was to big i had this truck for only a month and a half and ive been reading that im not the only one with this problem. something needs to be done about this. please!!!!!!!!
02/12/2011185689
 I own a 1999 eddie bauer expedition. was at a light and turned right going about 20 miles and hour when i heard an exaggerated pop and it seemed like it rattled very loudly. this is the third time spark #3 has popped out. this is ridiculous. worst part is that it happened at 2:00 am on a dark road. had to get it towed to a local mechanic
02/12/2011185689
 I own a 1999 eddie bauer expedition. was at a light and turned right going about 20 miles and hour when i heard an exaggerated pop and it seemed like it rattled very loudly. this is the third time spark #3 has popped out. this is ridiculous. worst part is that it happened at 2:00 am on a dark road. had to get it towed to a local mechanic
02/12/2011185689
 I own a 1999 eddie bauer expedition. was at a light and turned right going about 20 miles and hour when i heard an exaggerated pop and it seemed like it rattled very loudly. this is the third time spark #3 has popped out. this is ridiculous. worst part is that it happened at 2:00 am on a dark road. had to get it towed to a local mechanic
02/12/2011185689
 I own a 1999 eddie bauer expedition. was at a light and turned right going about 20 miles and hour when i heard an exaggerated pop and it seemed like it rattled very loudly. this is the third time spark #3 has popped out. this is ridiculous. worst part is that it happened at 2:00 am on a dark road. had to get it towed to a local mechanic
02/12/2011185689
 I own a 1999 eddie bauer expedition. was at a light and turned right going about 20 miles and hour when i heard an exaggerated pop and it seemed like it rattled very loudly. this is the third time spark #3 has popped out. this is ridiculous. worst part is that it happened at 2:00 am on a dark road. had to get it towed to a local mechanic
05/10/2010100000
 Tl- the contact owns a 1999 ford expedition. the contact stated the spark plugs blew out on the vehicle. the dealer informed the contact that cylinder seven blowout and this has been a major problem. the dealer recommended the contact purchase a new head for the vehicle after the blowout. since cylinder seven blowout, cylinder three has done the same thing. the vehicle had not been repaired at the time of the complaint. the failure mileage 100000 and the current mileage is 122000.rl
05/10/2010100000
 Tl- the contact owns a 1999 ford expedition. the contact stated the spark plugs blew out on the vehicle. the dealer informed the contact that cylinder seven blowout and this has been a major problem. the dealer recommended the contact purchase a new head for the vehicle after the blowout. since cylinder seven blowout, cylinder three has done the same thing. the vehicle had not been repaired at the time of the complaint. the failure mileage 100000 and the current mileage is 122000.rl
05/10/2010100000
 Tl- the contact owns a 1999 ford expedition. the contact stated the spark plugs blew out on the vehicle. the dealer informed the contact that cylinder seven blowout and this has been a major problem. the dealer recommended the contact purchase a new head for the vehicle after the blowout. since cylinder seven blowout, cylinder three has done the same thing. the vehicle had not been repaired at the time of the complaint. the failure mileage 100000 and the current mileage is 122000.rl
05/10/2010100000
 Tl- the contact owns a 1999 ford expedition. the contact stated the spark plugs blew out on the vehicle. the dealer informed the contact that cylinder seven blowout and this has been a major problem. the dealer recommended the contact purchase a new head for the vehicle after the blowout. since cylinder seven blowout, cylinder three has done the same thing. the vehicle had not been repaired at the time of the complaint. the failure mileage 100000 and the current mileage is 122000.rl
08/20/2010122000
 A spark plug blew/popped out the head on our 1999 ford expedition, causing fuel vapor to leak out of the opening, and starting a small fire, which was quickly doused. this is the 2nd time in 3 years that this has occured, resulting in over $2000 in repair costs for each occurence. i am very frustrated as i have read thousands of complaints from other expedition, navigator, f-150, and f-250 owners with this same dangerious situation, and nothing has been done? peoples lives could be at risk with this issue? recall now!
08/20/2010122000
 A spark plug blew/popped out the head on our 1999 ford expedition, causing fuel vapor to leak out of the opening, and starting a small fire, which was quickly doused. this is the 2nd time in 3 years that this has occured, resulting in over $2000 in repair costs for each occurence. i am very frustrated as i have read thousands of complaints from other expedition, navigator, f-150, and f-250 owners with this same dangerious situation, and nothing has been done? peoples lives could be at risk with this issue? recall now!
08/20/2010122000
 A spark plug blew/popped out the head on our 1999 ford expedition, causing fuel vapor to leak out of the opening, and starting a small fire, which was quickly doused. this is the 2nd time in 3 years that this has occured, resulting in over $2000 in repair costs for each occurence. i am very frustrated as i have read thousands of complaints from other expedition, navigator, f-150, and f-250 owners with this same dangerious situation, and nothing has been done? peoples lives could be at risk with this issue? recall now!
08/20/2010122000
 A spark plug blew/popped out the head on our 1999 ford expedition, causing fuel vapor to leak out of the opening, and starting a small fire, which was quickly doused. this is the 2nd time in 3 years that this has occured, resulting in over $2000 in repair costs for each occurence. i am very frustrated as i have read thousands of complaints from other expedition, navigator, f-150, and f-250 owners with this same dangerious situation, and nothing has been done? peoples lives could be at risk with this issue? recall now!
08/20/2010122000
 A spark plug blew/popped out the head on our 1999 ford expedition, causing fuel vapor to leak out of the opening, and starting a small fire, which was quickly doused. this is the 2nd time in 3 years that this has occured, resulting in over $2000 in repair costs for each occurence. i am very frustrated as i have read thousands of complaints from other expedition, navigator, f-150, and f-250 owners with this same dangerious situation, and nothing has been done? peoples lives could be at risk with this issue? recall now!
03/13/2010105000
 1999 expedition 5.4l blowing spark plug from cylinder head.
08/08/200611500
 Engine blew out a sparkplug just like the other reports. cost me around 900.00 get running again. mechanic told me ford knows about this problem because they a repair kit just for this problem.
02/16/20101800001
 Normal daily driving. spark plug blow out. not replaced yet. *tr
02/11/20101340002
 This is the second time i've had a spark plug eject from the cylinder head due to the poor threading in the cylinder head! it cost me $3,000 for the first fix, and now maybe another $3,000!!! this was the second one to have done this in a 3 year span, it damaged the cylinder head and ignition coil along with damaging my fuel rail. the first time this had happened we had to take it into the shop and have the entire cylinder head replaced along with ignition coil gaskets ect. the bill was $3,220. *tr
12/29/20091
 My son exited the publix grocery store where he was working and found that our 1999 ford expedition was on fire with no one in the vehicle with the keys in his pocket. the flames were coming from the engine department. four small fire extinguishers were not able to extinguish the fire, the fire department was called. the vehicle was destroyed, as well as damage to the two vehicles parked on either side. we were having no mechanical trouble with the vehicle at all, in fact, we had just replaced the four tires the day before. there was a recall on the vehicle regarding the cruise control, which we had complied with by immediately taking the vehicle to our local ford dealership for the recall, where it was taken care of. supposedly the problem of unexpected fires was corrected. fortunately there were no injuries or fatalities that occurred as a result of this incident. thank goodness the vehicle was not parked in our garage when this fire occurred. it has caused us a great deal of unneeded aggravation, time and unavailable costs involved in accommodating our son's responsibility to get to and from work, along with our own responsibilities. *tr
12/17/20091300001
 This complaint is in reference to our 1999 ford expedition. my wife started out on her daily drive to work. as usual, she allowed the vehicle to warm up for 10 minutes before leaving. about 1 block from our home, she heard a pop and the vehicle started to shake, run rough, rattled and lose power. she also had trouble steering the vehicle because of the loss in power. she was able to return home without any further incident. i inspected the vehicle later in the day and found that the 2nd spark plug from the front of the engine on the passenger side had blown out of the head and damaged the coil. i am reporting this incident because i have read of many ford owners who have experienced this same failure. this vehicle received a tune-up at approximately 92000 mile in 2006. it currently has around 130000 miles. *tr
11/20/20091370001
 While sitting in traffic in downtown cincinnati, i heard a loud pop under my hood and then my truck sounded like a steam engine. i also began to smell raw gasoline. i pulled to the curb and checked under the hood. drivers side rear spark plug had blown out, breaking off the coil pack. gas had sprayed onto the side of my engine. mechanic advised that it was a common problem with this engine. manufactured with as few as 4 threads to hold in a spark plug. thin walled aluminum cylinder heads are a very poor design. ford advised that they were aware of the problem, but had no intentions of a recall. *tr
10/22/20091000001
 I own a 1999 ford expedition, last year the number 3 plug popped and had to be rethreaded and now we have a different popped plug that needs repair. the first repair cost $800 and i had to rent a car. for this second repair i brought the truck to two repair garages and neither mechanic could repair this plug because it could not be reached. how can i be compensated due to this being a known problem and a second occurrence in my vehicle? *tr
01/01/200598000
 Tl* the contact owns a 1999 ford expedition. the contact stated that the spark plugs thread failed, which caused the spark plugs to eject from the coil. he attempted to repair the vehicle himself. a technician from the dealer stated that he would have to pay $1,900.00 to repair the vehicle. no repairs were made. the failure mileage was 98,000. the current mileage was 135,800.
04/01/200460000
 Tl*- the contact owns a 1999 ford expedition. the contact stated that intermittently the vehicle stalls without any prior warnings. in 2004, a technician concluded that the engine compressor strips the spark plug thread, which causes the plugs to eject. he then replaced the engine head, and ecm at an expense of $2,200.00. the failure resurfaced so he took the vehicle back to a repair facility.a mechanic replaced the spark plug wires with a special thread, at an expense of $1,600.00. the manufacturer was notified. the failure mileage was 60,000. the current mileage was 125,000. the vehicle identification number was unavailable.
06/15/20091650001
 First incident, i was sitting at a red light and when it changed i hit the gas and the spark blew out of the second hole on the passenger side. second incident, i was driving down the road at 60 miles per hr and the plug in hole 3 on the drivers side blew out. third incident, i was at stop sign, and when i hit the gas to go it blew the spark plug in hole 3 on the passenger side almost causing an accident. this was all in a 5 month timeframe. the repairs were made using the timesert kit from timesert.com. the mechanic charged me $350 + parts. *tr
05/13/20091430001
 1. normal driving conditions, and normal operation of the suv. 2. sudden noise from the engine, upon inspection we found that the spark plug had been ejected from the engine block and striped the threads. 3. modification kit (readily available, as the parts store said this is a very common problem) was purchased and installed. *tr
05/12/20091460001
 Parked vehicle at 8:32 am. our security cameras caught the fire on camera at 11:20 pm. vehicle burned out totally. *tr
04/22/20091090001
 I have a 1999 ford expedition, triton v8 engine, it has 100,000 miles, i have taken very good care of this car. change the oil every 3000 and ect. about 6 months ago my spark plug shot out causing severe damage, it cost me 460.00. 2 days ago i was coming home on the expressway when another shot out causing me to go from 60miles to 40 where i almost got hit by a truck! what is going on? i'm told that this has been happening for years. how can there not of been a recall on this engine defect. and now im out 500.00 again and my worry is i still have 6 more plugs to go, the mechanics have to get a special repair kit from ford. i am so upset, this is not fair that ford will not recall this engine and either repair the defects or pony up a new engine? but they will pay 12months of a car payment if you buy a new car and lose your job????? something has to be done about this. i could of been killed by that truck from slowing down so fast. thank god i was in the right lane. any suggestions? it's only 10 years old and in excellent condition! *tr
04/08/20091320001
 I have a 1999 ford expedition eddie bauer with a triton 5.4 liter v-8 and this is the second time that i have had a spark plug blow out of the cylinder head.. i am aware that this is a re-occurring problem with the ford engine, but i like many others am getting tired of shelling out thousands f dollars to fix a design defect i am a laid off auto worker living in michigan and i cannot believe that ford wants us to still buy their mistakes and then bail them and the other manufacturing companies out of what is clearly there own doing.. and as far as my truck i think will be looking into a better kind of car and company!!!!!! *tr
03/20/20091140001
 99 ford expedition blew out #3 spark plug and damaged coil, no forewarning of this , has 114,000miles, cost me $400 for a temp fix,,was told this is a common problem with the 5.4 engine, garage installed a repair sleeve and special plug,,no warranty,,i was 800 miles from home, when the plug blew, i thought somebody took a shot at me...it also ruined the coil. *tr
03/03/2009200000
 Tl*the contact owns a 1999 ford expedition. after the vehicle had been shut off for approximately 15 minutes, it caught fire. the fire department arrived and stated that the fire originated from the front driver's side of the vehicle, underneath the engine. a report was filed. the windshield and windows were all cracked and damaged due to the high flames. the vehicle was destroyed. the contact believes that the vehicle should have been recalled and she should have been notified of any defects. the vin was unknown. the current and failure mileages were over 200,000.
12/22/20081220001
 While driving at 60 mph, the farthest rear spark plug on the driver's side of the ford triton v8 engine ejected from the head. *tr
10/29/20081050001
 Driving home from doctor visit, heard a loud pop, and lost power, very loud engine noise as if i had no exhaust. mechanic looked at it apparently the engine blew out a spark plug making it necessary to replace the cylinder head since it stepped the treads. and also broke the coil. am on disability and fixed income, the repair cost is so high i have to wait and be without a car. do not know what to do. the mechanic told me it is a common problem with this vehicle and ford. and i researched the web and found out that many others experienced the same thing. furthermore when going to ford for repair, they say that the new head is a improved version. so if it is an improved version that mean that they know that there is a problem with the product to begin with. ford should replace the faulty heads at no cost to vehicle owner. *tr
05/06/20081000003
 Tl*the contact owns a 1999 ford expedition. while driving 55 mph, the contact heard a loud noise coming from the engine. he managed to get control of the vehicle and pulled over. the vehicle was towed to a mechanic and they replaced a healy coil. the vehicle was repaired; however, the failure recurred two months later while driving at the same speed. a state trooper stopped to assist. the vehicle was once again towed to the mechanic and they performed the same repair. less than a month later, the failure recurred again. the vehicle is currently at the contact's residence with a blown spark plug. the failure mileage was 100,000 and current mileage was 106,000. updated 09/23/08. *lj the consumer stated 3 sparks plugs had blown out from the engine. updated 09/24/08. 8jb
07/18/20081060001
 I own a 1999 ford expedition and my family has experienced (3) blown spark plugs! the triton engines ford makes have aluminum heads and spark plugs are blowing out. on may 6, 2008 was my first experience (cost $273.03) replaced helie coil. july 18th 2nd blowout with 3 young children late at night. police officer has had 2 blown spark plugs on his ford! (cost $1,502.02) had to remove head. #3 blowout last night pulling into my driveway with family on board. i will not take this vehicle anywhere again as these explosions can cause a car fire and i will not risk that or being stranded in remote camping area. i have wrote a letter to ford board of directors- called ford directly and at this time there is no customer satisfaction programs according to amy my case girl. google ford triton engine blown spark plugs and you will see the many consumers frustrated and experiencing this. if my car catches fire and my family is injured or killed i will hold you and ford personally liable as this is my written notification of this defect. there needs to be a recall and it needs to happen now! *tr
08/20/20031200001
 97 to 99 5.4 fords like to blow plugs out of the cast aluminum cylinder heads. they doubled the threads in 2000. it occurred to my 99 expedition,out of warranty don't expectancy help from ford maybe your dealer. my expedition was 4 years old,at the time. best advice buy gm forget about ford unless you own a tow truck. *tr
06/21/20081090001
 My wife was driving to colorado springs on hwy 24. she pulled away from a stoplight when she heard a loud slapping noise. she was able to get to the side of the road safely, despite heavy traffic. we had the ford expedition towed to the dealer we bought it from. they have called me to tell me the number 7 spark plug blew out of he block ruining the threads that hold it, in addition the coil pack was ruined. i have a warranty on this vehicle (it was bought used), the service manager is telling me they will not cover this under the warranty because it is a maintenance issue. i informed him that i will not pay for this repair and he said he would call ford to see what they are doing, lol. if my wife had been traveling at hwy speeds she could have crashed and the possibility of a fire was real because of the fact fuel was coming out of the spark plug hole and the coil pack was still firing. something must be done. *tr
05/22/20081266611
 Attn: i apologize first submission was incorrect phone number: this contains proper contact phone number 1999 ford expedition #3 spark plug blowout. *tr
05/22/20081266611
 1999 ford expedition #3 spark plug blowout. *tr
04/06/20081030001
 Ford expedition - spark plug was ejected from cylinder. *tr
10/13/200711622208/04/1999
 Tl*the contact owns a 1999 ford expedition. the failure occurred in october 2007 and the again on march 21, 2008. the spark plug came out of the engine while driving 25 mph. he found the spark plug sitting on top of the engine. the service engine soon light was not illuminated until the following day after the failure occurred. the mechanic stated that your number three spark plug blew out the engine block. he also stated that if he were driving faster than 25 mph the spark plug would have gone through the hood and then the windshield. the manufacturer stated that the failure was not covered by the warranty and they are unable to assist him with the repair. the estimated cost to repair the vehicle was $3,000 to $7,000. the contact also filed a complaint with the consumer protection agency and was not given a case number to reference. the vehicle was serviced on a regular basis. there are invoices available to show each time the vehicle was serviced and diagnosed. the failure mileage was 11622 and the current mileage was 13000.
07/17/20071040001
 The #3 spark plug blew completely out of my 1999 ford expedition, ford refuses to repair it saying that it must have been the result of some sort of abuse of the vehicle. after seeing thousands of these type of complaints from this particular engine class, it is reasonable to conclude that this is a serious design flaw, if the fuel rail had been compromised, the end result certainly would have resulted in a fire. i think that you should require ford to either repair the affected defective engines, or compensate the owners for their repairs... *tr
01/19/200870306107/15/2000
 Tl*the contact owns a 1999 ford expedition. while driving 65 mph, the contact heard a loud popping sound under the hood. the vehicle decelerated to 0 and would not accelerate. the vehicle was towed to a dealer. the dealer stated that the spark plug popped out and stripped the engine head. one of the engine heads has to be replaced. the current and failure mileages were 70,306. updated 02/15/08. *lj
12/13/2007142000109/21/2004
 1999 ford expedition 5.4 motor blew spark plug on passenger side-rear plug. *tr
12/05/2007150000103/01/2006
 I own a 1999 ford expedition. yesterday, my fiance and kids were on their way to school when the engine failed. upon inspection, we found that the engine had ejected the #3 spark plug on the passenger side. this caused the coil pack to shatter as well as the plug cable attached to it. i've done extensive searching on the subject, and there have been incidents reported of fires caused by these plug ejections. also, hundreds of consumers have been stuck with repair costs of several thousand dollars. this is a common problem and should be addressed as a recall. lives are at risk. *tr
10/15/2005900002
 Tl*the contact owns a 1999 ford expedition. in 2005, while driving 55 mph, the contact heard a popping sound and stopped the vehicle. he noticed that the spark plug had come through the engine. a month later, the failure recurred. the purchase and incident dates were unknown. the current mileage is 130,000 and failure mileage was 90,000.
06/15/2007131000107/01/2005
 Dear sirs, i own a 1999 ford expedition, the engine seemed to be have operated fine until the # 3 spark plug blew completely out of the cylinder head. if the plug and the destroyed coil would have ruptured the fuel rail the vehicle would have gone up in flames. i hope that something can be done on the part of ford to repair this unbelievingly, amazing , and very common safety problem ford was brushing under the rug. the vehicle was past the waranty period so that won't be of any help, but this problem was incredibly dangerous
02/23/200777000111/22/2001
 5.4 triton engine spark plug blown at 77,000 miles on my 1999 ford expedition. *jb
06/01/2006130000201/10/1999
 1999 ford expedition bought brand new at serramonte ford in colma ca. serviced in strict accordance every 5000 miles per ford owner manual and at the same ford dealership exclusively. lost engine, timing chain at 55,000 miles, lost transmission at 130000 miles. *jb
03/01/2005100000202/11/2005
 I bought a used 1999 ford expedition. i owned it for less than 30 days before the first spark plug ejected. after having the dealer fix it the problem it happened again in less than 30 days. i had to spend 1000 to have the car towed home from ny, the price of the rental car and another 3500 to get a new head. not to mention the 500 i paid the dealer to fix the car. *jb
01/20/2006103000107/20/2003
 #3 spark plug blew out of engine taking the thread insert with it. *ak
11/14/2005114000108/01/2003
 Dt: contact stated while stopping at a stop light heard a loud pop. the vehicle was taken to a local dealership ,where they found the engine head needed to be replaced because the spark plug blew out of the engine. the repairs will be made at the contact's expense. *ak updated 03/20/06. *jb
05/24/2005131000104/03/2003
 1999 ford expedition with 5.4 triton v8. spark plug is ejected from the aluminum cylindar head. immediately upon the plug being blown from the position on the head i could smell fuel and the engine began to violently make a loud popping sound. i have found numerous complaints on the web regarding this but cannot find any resolution measures. bought the truck used with 85k miles but i have read other complaints where the plugs blow out at much lower mileage. had to have it towed because i was advised by the dealer that, it wouldn't be a good idea to drive it if you smell fuel. i had the service rep tell me that, this is pretty common in our lighting models with the v10, but not with our v8 models. he also tells me that the plugs were too short for the engine but i checked with the mechanic that changed my plugs and he says that he put the replacement spec plugs that ford recommended. links to other sites related to this: http://www.f150online.com/forums/showthread.php?s=&threadid=103042 i know these are not filed complaints with the nhtsa but this is a serious issue. when i took it into the ford dealership at dobb's ford, 7925 hwy 64, memphis, tn 38133-4007, they told me originally it would be $2600. i was almost set to have it done then he tells me that labor was not included in that price and the total price would be $3800.
12/27/20041
 Engine tends to stall, and unable to start when it rains. occasionally, engine turns on and off on its own. consumer will contact manufacturer.*ak
11/04/20041080002
 Engine compartment fire after being parked 5 minutes. fire centered in engine compartment on driver's side towards the rear of the engine compartment. brake switch at pedal had been replaced 4 months before fire.*ak
10/08/200483000106/25/2002
 I had a tune up done at roundtree moore ford dealership in lake city florida on 08-11-04. i drove my vehicle on vacation to pennsylvani and while there a spark plug came out and damaged the cylinder head and coil pack. i took the vehicle top a ford dealer in pennsylvania (davies ford connelsville pa)and was advised that it appeared it was the fault of the original dealership. upon contacting my dealership i was advised that this was common with this type of engine. i had the repair done at a local mechanic for $790.00.
10/18/2004730001
 While driving, a loud pop was heard. later there were several pops heard, the owner pulled over to the side of the road and looked inside and saw that the spark plug had blown completely out of the head. the owner had to buy another spark plug and an ignition coil. the new spark plug would not go back in because the previous spark plug stripped the plug area where the new plug would not enter. the owner was told by the dealer that it would cost 3,000.00 to replace the heads to keep this from recurring. provide further details. *jb
05/13/20047273004/30/2000
 In dec of 2003 we had a spark plug foul out, now 6 months later we are informed that we had a right side head gasket blown and a power steering pump leaking.
05/03/200450000110/01/1998
 I own the infamous 1999 ford expedition with the head gasket oil leak. though i loved this car from the day i purchased it new up until the time at 50,000 miles the oil started to leak. it is well maintained and babied, so for something as serious as this to happen to all of us who own these vehicles disappoints me. ford would only pay for half of the repair, but i believe this should be a recall because of the seriousness of the problem.a head gasket blowing? the heads are also defective from what i have read. that is not your average repair. i don't have the money to replace something that was installed defective to begin with. i guess i will continue to stuff a rag up under the leak until ford feels like taking reponsibility for its failures. *ak
04/12/2001290002
 Engine was leaking oil. dealership replaced the head gasket. however, oil leak recurred. currently, dealership indicated that engine head was whopping and causing the oil to leak.*ak
03/14/200446000105/12/1999
 About a year ago the cylinder head gasket on our 1999 ford expedition was replaced due to leaking oil, by the dealership. the mileage was 35,000. now a year later, while traveling at 70 mph. on the freeway, a spark plug blew out of the same right cylinder. the loud noise and clatter caused a knee jerk response,almost causing an accident. the vehicle's mileage is now only 46,000. we feel that ford should do the responsible thing and recall these 5.4 l engines with the aluminum cylinder heads and and replace them with a better design with safety in mind. if you check other consumer compaints, you will see that this is not an isoleted incident.*ak
02/12/200469000203/04/2003
 We bought a 1999 ford expedition eddie bauer almost a year ago. the day we bought it we noticed a burnt oil smell. the dealer replaced the head gasket. now almost a year later, we blew a spark plug and need a new head. dealer says that the head gasket and head are not related???? i was told that this car has these problems because of aluminum heads..i want the dealer to replace it, i am willing to pay more for a new one, but i am not willing to repair it and take a loss! help!!*ak
12/17/2003720001
 Consumer complained about a consistent problem with the engine check light in 1999, ford, expedition. every time engine light was on vehicle hesitated/shook. dealer replaced engine sensor, but problem still occurring. *ak
10/29/200348000104/07/2001
 1999 ford expedition: 4.6 sohc ead gasket leaks oil fixed twice still leaks. multi function switch replaced once,doe's not work again. expedition has rough idle ,never been able to fix. *ak
08/03/2002004/23/1999
 Interior lights malfunctioning, daytime running lights not working correctly, heating/cooling system not working properly; stays on even when key is not in ignition. when ignition is turned on or off, the woofer makes a loud thumping sound. woofer inoperable. right sign wing never worked properly/ will not open or close. braking system is doubtful, it squeaks, and when gas is released engine and braking are not coordinated smoothly . constant squeaking when in motion. dealerships service repair personal neglect and refuse to find the causes, even though vehicle is still under warranty. *nlm
12/19/20023723012/16/2002
 Right cylinder head gasket leaking oil. dealer said no warranty too old and too many miles. it's a 1999 ford expedition with 38,000 miles. ford knows there is a problem see tsb's. but will not do anything about it.
01/21/2003
 Consumer state that while driving without warning the head gasket blew causing fluid to leak out. dealer notified. ts
 Computer system affected temperature gauge. this caused it to run hot and stall. been to dealer 5-6 times for problem. mechanic claimed to have repaired it each time, but problem reappeared. *ak
ENGINE AND ENGINE COOLING - COOLING SYSTEM
03/03/20058900013003/03/2005
 1999 ford expedition eddie bauer 4x4 the emergency brake was removed by the dealer when they sold it to me and never put one on it, also the /c blows out hot air up front and cold in the back, and the odomitter does not work, it goes in and out and the dealer refuses to fix it. several of my friends have the same truck and they have the same problem
12/13/1999111/11/1999
 The heater hose dripped antifreeze on to a coil causing damage. yh
08/01/1999
 Vehicle smells of oil but none visualized on inspection of engine. seems to be worse with colder temperatures. oil gauge in vehicle runs higher end of normal engine temperature is normal. *ak
08/30/1999311/01/1998
 When vehicle had 3,789 miles on it, coolant leaked onto plugs & coils. had it repaired. on 8/30/99, coolant leaked onto plugs & coils. had it repaired again. wrote to zone division with copies to ceo and chairman of ford requesting to be released from my lease. only got form letters back. on 1/2/2000, same thing happened again. left car at dealership, putting envelop with keys and note stating problem in their night service window.. have had other problems with vehicle i.e. rear wiper blade inoperative. adamson ford, where car was leased from kept vehicle from thursday 8/30/99 until monday 9/2/99. dealership very rude and uncooperative, and failed to repair items listed on service order. i believe vehicle is a defective product sent from the factory to the dealership who in turn leased it to me. *ak
ENGINE AND ENGINE COOLING - COOLING SYSTEM - HOSE
01/01/200371000308/18/2002
 Heater hose leaks at the back of the firewall, drips down on top of spark plugs and shorts out spark plug & wire. also see smoke from oil burning from same back area. no oil on the ground. also, smell antifreeze & oil through vents after heater hose was repaired.
02/28/20011
 This is reported because of the common nature of this problem and the expense of repair. this is a faulty design which routes an engine coolant hose such that when the hose connection leaks, it drips onto the #4 coil pack and shorts it out. this defect has been carried over through at least three model years (97,98& 99). the cost of my repair was approx. $400. this is not normal wear nor is it a random component failure. i suspect ford knows about the problem. as a high volume production company, their quality department has surely flagged this defect through some form of failure trend analysis effort.
ENGINE AND ENGINE COOLING - COOLING SYSTEM - RADIATOR ASSEMBLY
06/13/2005200000106/02/2000
 Dt*: the contact stated the engine shut down while driving at 50 mph. the vehicle was taken to a local dealership where the cause was determined, but the dealer was unable to make the necessary repairs. an independent repair shop inspected the vehicle and determined the engine suffered electrolysis problems. the antifreeze leaked onto the engine because the compartment was made of weak aluminum. therefore, the compartment could not sustain the fluid. *ak
ENGINE AND ENGINE COOLING - ENGINE
02/05/2011125428
 I have a 1999 ford expedition that has continuously blown spark plugs, i have had it repaired several times at a local dealership. i keep my vehicles maintained on a regular basis, and i have no warnings leading up to the spark plug blowing. i am afraid that one of these times it will blow and my engine will catch on fire. i am very diappointed with ford, that they have not done anything to resolve this issue, except to keep replacing the coil pack and spark plugs and charging me more money. this problem began in nov 2007, and i have had to have it serviced for the same issure two other times and now as of today i will have to have it repaired again. i have trust in my dealership that they are fully capable of repairing the vehicle as they have serviced my other vehicles with no other problems.
02/05/2011125428
 I have a 1999 ford expedition that has continuously blown spark plugs, i have had it repaired several times at a local dealership. i keep my vehicles maintained on a regular basis, and i have no warnings leading up to the spark plug blowing. i am afraid that one of these times it will blow and my engine will catch on fire. i am very diappointed with ford, that they have not done anything to resolve this issue, except to keep replacing the coil pack and spark plugs and charging me more money. this problem began in nov 2007, and i have had to have it serviced for the same issure two other times and now as of today i will have to have it repaired again. i have trust in my dealership that they are fully capable of repairing the vehicle as they have serviced my other vehicles with no other problems.
02/05/2011125428
 I have a 1999 ford expedition that has continuously blown spark plugs, i have had it repaired several times at a local dealership. i keep my vehicles maintained on a regular basis, and i have no warnings leading up to the spark plug blowing. i am afraid that one of these times it will blow and my engine will catch on fire. i am very diappointed with ford, that they have not done anything to resolve this issue, except to keep replacing the coil pack and spark plugs and charging me more money. this problem began in nov 2007, and i have had to have it serviced for the same issure two other times and now as of today i will have to have it repaired again. i have trust in my dealership that they are fully capable of repairing the vehicle as they have serviced my other vehicles with no other problems.
02/05/2011125428
 I have a 1999 ford expedition that has continuously blown spark plugs, i have had it repaired several times at a local dealership. i keep my vehicles maintained on a regular basis, and i have no warnings leading up to the spark plug blowing. i am afraid that one of these times it will blow and my engine will catch on fire. i am very diappointed with ford, that they have not done anything to resolve this issue, except to keep replacing the coil pack and spark plugs and charging me more money. this problem began in nov 2007, and i have had to have it serviced for the same issure two other times and now as of today i will have to have it repaired again. i have trust in my dealership that they are fully capable of repairing the vehicle as they have serviced my other vehicles with no other problems.
01/28/2011134182
 1999 ford expedition 5.4l v8 triton engine. number 7 cylinder spark plug was ejected from the head while driving in town. ignition coil on top of spark plug was sheared off of it's mounting on the head. needed to use a spark plug thread repair kit to repair the threads in the head and a new ignition coil to replace to broken one. approx $100 to repair
01/28/2011134182
 1999 ford expedition 5.4l v8 triton engine. number 7 cylinder spark plug was ejected from the head while driving in town. ignition coil on top of spark plug was sheared off of it's mounting on the head. needed to use a spark plug thread repair kit to repair the threads in the head and a new ignition coil to replace to broken one. approx $100 to repair
01/28/2011134182
 1999 ford expedition 5.4l v8 triton engine. number 7 cylinder spark plug was ejected from the head while driving in town. ignition coil on top of spark plug was sheared off of it's mounting on the head. needed to use a spark plug thread repair kit to repair the threads in the head and a new ignition coil to replace to broken one. approx $100 to repair
01/28/2011134182
 1999 ford expedition 5.4l v8 triton engine. number 7 cylinder spark plug was ejected from the head while driving in town. ignition coil on top of spark plug was sheared off of it's mounting on the head. needed to use a spark plug thread repair kit to repair the threads in the head and a new ignition coil to replace to broken one. approx $100 to repair
01/28/2011134182
 1999 ford expedition 5.4l v8 triton engine. number 7 cylinder spark plug was ejected from the head while driving in town. ignition coil on top of spark plug was sheared off of it's mounting on the head. needed to use a spark plug thread repair kit to repair the threads in the head and a new ignition coil to replace to broken one. approx $100 to repair
11/29/2010
 Ford expedition 1999 ejected spark plug problem. aftfer having this problem three time already, i start researching about it and seems that 100th of owner of ford expedition fromm 1997 to 2003 are having a recurring problem. why is not a recall on this when hundreds of owners are spending from $300 to $700 on repairs that ford should be responsible. it is noticible that its a manufacture problem not a customer problem.
11/25/2010250000
 Tl-the contact owns a 1999 ford expedition. after driving the vehicle all day then parked for a couple minutes and then restart the vehicle the engine caught on fire. there was smoke coming from under the hood after opening the vehicle hood there was sparks coming from around the engine. the fire department was call and they came and put the fire out. the origin of the fire was unknown. there were no one injuries and a report from the fire department was available if needed. the vehicle was towed by the insurance. the manufacturer or the dealer was not yet notified. the failure mileage was 250,000....mw
11/29/2010
 Ford expedition 1999 ejected spark plug problem. aftfer having this problem three time already, i start researching about it and seems that 100th of owner of ford expedition fromm 1997 to 2003 are having a recurring problem. why is not a recall on this when hundreds of owners are spending from $300 to $700 on repairs that ford should be responsible. it is noticible that its a manufacture problem not a customer problem.
11/25/2010250000
 Tl-the contact owns a 1999 ford expedition. after driving the vehicle all day then parked for a couple minutes and then restart the vehicle the engine caught on fire. there was smoke coming from under the hood after opening the vehicle hood there was sparks coming from around the engine. the fire department was call and they came and put the fire out. the origin of the fire was unknown. there were no one injuries and a report from the fire department was available if needed. the vehicle was towed by the insurance. the manufacturer or the dealer was not yet notified. the failure mileage was 250,000....mw
11/29/2010
 Ford expedition 1999 ejected spark plug problem. aftfer having this problem three time already, i start researching about it and seems that 100th of owner of ford expedition fromm 1997 to 2003 are having a recurring problem. why is not a recall on this when hundreds of owners are spending from $300 to $700 on repairs that ford should be responsible. it is noticible that its a manufacture problem not a customer problem.
11/25/2010250000
 Tl-the contact owns a 1999 ford expedition. after driving the vehicle all day then parked for a couple minutes and then restart the vehicle the engine caught on fire. there was smoke coming from under the hood after opening the vehicle hood there was sparks coming from around the engine. the fire department was call and they came and put the fire out. the origin of the fire was unknown. there were no one injuries and a report from the fire department was available if needed. the vehicle was towed by the insurance. the manufacturer or the dealer was not yet notified. the failure mileage was 250,000....mw
11/29/2010
 Ford expedition 1999 ejected spark plug problem. aftfer having this problem three time already, i start researching about it and seems that 100th of owner of ford expedition fromm 1997 to 2003 are having a recurring problem. why is not a recall on this when hundreds of owners are spending from $300 to $700 on repairs that ford should be responsible. it is noticible that its a manufacture problem not a customer problem.
11/25/2010250000
 Tl-the contact owns a 1999 ford expedition. after driving the vehicle all day then parked for a couple minutes and then restart the vehicle the engine caught on fire. there was smoke coming from under the hood after opening the vehicle hood there was sparks coming from around the engine. the fire department was call and they came and put the fire out. the origin of the fire was unknown. there were no one injuries and a report from the fire department was available if needed. the vehicle was towed by the insurance. the manufacturer or the dealer was not yet notified. the failure mileage was 250,000....mw
11/25/2010250000
 Tl-the contact owns a 1999 ford expedition. after driving the vehicle all day then parked for a couple minutes and then restart the vehicle the engine caught on fire. there was smoke coming from under the hood after opening the vehicle hood there was sparks coming from around the engine. the fire department was call and they came and put the fire out. the origin of the fire was unknown. there were no one injuries and a report from the fire department was available if needed. the vehicle was towed by the insurance. the manufacturer or the dealer was not yet notified. the failure mileage was 250,000....mw
02/22/20101431221
 1999 ford expedition with the 5.4l triton engine blew out a factory installed original spark plug causing a engine fire. this seems to be common among this particular engine. ford will not acknowledge a defect in the design, but online research concludes this problem is widespread and very dangerous. ford should be compelled to recall these engines and repair or replace the engine at no cost to the customer. *tr
10/11/20091084541
 Heard a knocking noise coming from the engine department, took said vehicle to a dealership to be checked out, was told that it was a leaking exhaust manifold, i then checked what i was told and did not find any problems with the exhaust, then three weeks later without warning the no. 3 cylinder spark plug ejected from its port and breaking the ignition coil assembly, as of now, we are trying to figure out how to fix said problem because i have researched the issue and see that ford does not have to fix said problem. *tr
09/21/20091342341
 While driving my 1999 ford expedition 5.4l and coasting down a hill all of a sudden a loud pop and the a loud exhaust noise. i smelled fuel and immediately pulled over. upon opening my hood i found a small fire (thank god i carry a fire extinguisher) and that my engine had spit out a spark plug stripping all the plug threads. it is now in the shop being repaired for an unknown cost. *tr
04/16/20091570001
 I have a v8 triton 5.4l which has blown a spark plug from the engine block. i was not putting undo stress or wear and tear on my engine when this occurred. i kept maintenance up on my vehicle so therefore this should never have been an issue. there was no accident as i was able to pull over and out of the way of traffic but this could be potentially dangerous since fuels being expelled into the engine and a spark plug blowing out of the head leaving a gaping hole where the fuel is still being expelled and there is still a spark is very dangerous. i have researched this and so many other owners of the same vehicle have had this happen to them stranding people and worse. how is a manufacturer allow a design and integrity flaw like this go unnoticed or fixed. *tr
01/09/20091530001
 Was driving car to work this morning. made a right hand turn and heard a knocking noise suddenly after completing turn. pulled to side of road and immediately shut down vehicle. after shutting down i smelled what appeared to be gasoline. called my insurance company and they had vehicle towed to ford dealership. after waiting a few hours they told me spark plug had popped out and cylinder head needed to be fixed along with plug, and it was indeed gasoline i smelled. they said it would need major repair to fix, and tried to convince me to pay and arm and a leg. i don't care about that, i care that my child could have been in car, as i pick her up every day from school. also mad that a fire could have started and ford does nothing about this problem and that there have been thousands of complaints from ford truck owners with expeditions and f150's from 97-02. something better be done to recall these faulty engine components, or families will suffer from ford's lack of safety with these plugs and cylinder heads/coils. *tr
01/03/20091490001
 1999 expedition 5.4 while driving i heard a loud noise .motor shut off . smoke coming from hood i put out the firer and seen #3 coil blown out . the spark plug was no were to be found the spark plug hole threads came out whit the plug what a have seen ford did not put many theards in the head thy made a new head for that motor so they know the heads are no good plus the injector is putting gas in that cylinder that why it started the fire. *tr
11/07/20081650001
 Driving home from work, i heard what sounded like a gun shot coming from under my hood. come to find out it was the #3 spark plug being blown out causing damage to the coil. i took the car to the ford garage and they gave me 3 options. 1. heli coil it, but they will not guarantee the work and that will be $600. 2. buy a new head, that will cost $3000.00 3. buy a new motor and that will cost $6000.00 i feel that i'm getting the short end of the stick. this is a common problem with the 5.4l trition engines and from what i gather this is a very dangerous defect. someone needs to protect the people. *tr
08/19/20081542391
 1999 ford expidition with 5.4l v8 blew a sparkplug out of the head. *tr
05/26/2008990781
 Two weeks prior to this failure, there was a distinct ticking noise that changed with rpm. sounded like a collapsed lifter. while returning home on memorial day 2008, experienced a loud popping noise, followed by continued whoosing noise and poor engine performance. after inspecting engine, noticed #7 spark plug had come out and broken the coil-on-plug coil unit. failure occurred 2 blocks from my home, so i limped it home. have not had it repaired yet. *tr
03/18/20081160001
 Spark plug # 3 blew out of 4.6 triton ford engine in our 1999 expedition. looking at internet data this seems to be a very common theme with the triton engines. cost us over $1,000 to fix. *tr
09/14/2007118000111/01/2006
 Started my vehicle and heard a loud noise followed by a steady popping noise. i opened the hood and found the rear spark plug on the passenger side had been blown out of the engine. i have since read hundreds of other complaints of this occurring, some causing fires. *jb
05/07/200786800110/11/2006
 Tl*the contact owns a 1999 ford expedition. the contact stated that he heard a loud popping sound when the vehicle was started. the vehicle was towed to the dealer who stated that there is a defect with the cylinder head, which caused the spark plug to disengage. the current and failure mileages were 86,800.
03/20/2007110000107/03/2004
 Tl*- the contact owns a 1999 ford expedition. he was having problems with the aluminum head spark plugs, the number 3 & 4 cylinder failed, and the mechanic told him it was a design flaw. the failure was caused by not having enough thread in the aluminum spark plug head. he needed a new engine or a head job. it will cost him over $3000. he stated that there was a service bulletin for this problem. the current and failure mileage were both 110,000.*ak
01/01/2007135000101/15/2000
 Under normal usage at @ 135,000 miles oil began to leak from the rear of the head gasket on the passenger side of the engine. there are at least five tsb's in effect for this problem. no repair has been made account prohibitive cost. truck being driven. adding 1 quart of oil about every 2 weeks. *jb
12/21/200690000102/09/2005
 Head gasket failure. right hand, rear side of the engine. i can smell strong burning oil when engine is running and after shut-off. oil saturated starter. *jb
09/01/2006108000109/01/1999
 I was driving on a busy road with my three children during rush hour. i heard a loud pop followed by the what sounded like machine gun fire. i immediately pulled over to the side of the road and shut down the vehicle. i was fearful of the safety of my children and had them leave the car. i then had the vehicle towed. a ford repairman looked at the car and stated that the #3 passenger side spark plug blew out. he stated that this a known problem and ford refuses to acknowledge the issue. he said that they see many of these each week and that it is usually the #3 spark plug on the passenger side. he stated that it would be $2500-$5000 to repair the vehicle. we were told by another ford dealer that he could fix it for $300-$500. we had the vehicle towed there and despite informing him which spark plug it was, upon inspecting the vehicle he claimed it would be difficult to repair and increased the repair price to $2100. when we objected he offered to purchase the vehicle for $200-$300. we feel as if the ford dealers are using this issue to run a bate and switch. we have investigated the matter on the internet and have found many others complaining of the same issue and ford's failure to take responsibility. someone is going to get injured if they fail to correct their design defect. *nm
11/25/200681240110/20/1998
 Loud pop then loss of vehicle power, continual popping sounds until i stopped engine. spark plug was ejected from engine. i believe this investigation should be reopened as this should be a defect recall . *jb
08/12/2006880001
 1999 ford expedition, 88k miles, spark plug ejected from passenger side of engine. this occurred in heavy traffic while in left lane of smoketown road in prince william county, virginia. the vehicle stalled after i let off the gas pedal right after a loud bang and popping sound was heard in engine. i was able to restart vehicle, but had to keep the rpm's up to keep from stalling. after cutting off several cars in center and right lane, the vehicle was pulled into a parking lot on right side of road. i detected a strong smell of gasoline present when hood was raised. not once did the check engine light come on; unlike all the other times it came on when nothing was wrong with the truck. the vehicle was towed to a ford dealer and a $3400 head replacement performed because head was ruined by stripped spark plug ejecting. upon checking internet, i found that this is an ongoing increasing problem. it appears that an inquiry done by your agency concluded in january of 2006 that this is a rarely occurring incident of little to no danger. i beg to differ. a simple google query will show thousands if not tens of thousands of complaints regarding ford triton engine spark plug problems posted on various message boards. it is a matter of time before someone gets hurt or killed either directly or indirectly from this obvious problem. i'm just glad i was alone driving and not my wife and children. my wife would have remained in the stalled vehicle while sitting in the passing lane. considering the enormous number of potentially affected vehicle this issue involves, i will also be bringing this matter to the attention of every elected official i can send an email to. *jb
08/02/2006120500105/01/2001
 On august 2, 2006, while traveling in michigan, a spark plug suddenly blew out of my 1999 ford expedition. there was no prior warning or indication of any problem. i had to have it towed to bay city, mi, where a ford dealer told me that it would cost approx. $3500 to repair the problem. he said it was a recurring problem with ford expeditions. my car had approximately 120000 miles on it at the time. i kept the spark plug and coil attachment, and it doesn't look like the grooves on the plug gave way or were stripped. *nm
08/08/2006140000109/01/1999
 Dt*: the contact stated the check engine light illuminated. the vehicle was taken to an independent repair shop where they determined the oxygen sensor needed to be replaced. although repair was made, the check engine light illuminated a second time. the vehicle was taken to the dealership this time where they determined the oxygen sensor needed to be replaced therefore causing a need to replace the engine.
07/26/200659000109/04/1999
 Driving at 25 mph in residential area of cleveland oh spark plug #3 blew out of head, leaving me stranded for 2 days waiting to get repairs finished. 5.4 triton engine, properly maintained with 59,000. miles on it. *nm
04/13/20061
 Spark plug blowing from cylinder head. *nm
06/08/200695000206/15/2003
 In feb of 2005 my 1999 ford expedition with the 5.4 v-8 blew the passenger side 3rd spark plug right out of the head. the car had apox. 95,000 miles on it and ford said warranty would not cover it. it would take 3,500 $ to fix. so i towed it away from grass vallley ford, a decided to have a mecanic fup a heli coil. that lasted little over a year and in june of 2006 the same plug shot out. i think this is fords problem and needs to be dealed with.
06/23/20061210001
 While driving a loud pop was heard followed by an exhaust-type sound emanating from engine compartment. vehicle was driven 4 blocks to our home where inspection revealed the blown plug. *jb
06/06/2006730002
 For the second time in 6 months i had an engine spark plug ejection in my 1999 expedition. the spark plug detached from the cylinder and was ejected from the engine. i heard a loud pop while driving, the vehicle followed by a loud, repetitive clicking or popping sound. i also lost some power while driving, the vehicle did not stall. i did smell gas when the incident occurred. i was able to slowly drive the vehicle to the repair shop. *jb
04/11/2006128068205/15/2001
 Approximately at 8 am, my wife was driving to work when she heard a loud bang under the hood of the car. she was driving a 1999 ford expedition. the engine started making a very loud popping noise. after arriving and starting the car to hear what was going on, i knew what the problem was. 5 years ago i drove a 1999 f250 ford with a v10 and it did the same thing. the local dealership agreed a spark plug had blown out of the engine on the expedition on the #3 cylinder. they repaired it by putting a plug insert (heli-coil) in. they put the insert in while the head was still on the vehicle. now three weeks later the rods on #3 and #7 pistons are bent and the vehicle is inoperable. the dealership only option to us was to replace the engine at a cost of nearly $4,500. *jb
04/04/2006140000101/14/2001
 I am a school teacher that drives a 1999 expedition v8. i was on my way to school two weeks ago and heard a loud bang come from under my hood. it then started to sound like a john deer tractor. i had my spark plugs replaced last year and thought that it would be the same again. i took it to the same mechanic that replaced spark plugs last year and told me that the plug blew my thread out and that it might need some serious engine repairs because of it. he also told me that this is a common problem with these ford vehicles. apparently it is going to cost me 3,000 to fix. i am a teacher and find it ridiculous to have to pay for this when there has been so many complaints over the same engineering problem! ford needs to do something about this. after seeing so many complaints online, it really makes me upset and feel emotional stress. the need to recall these aluminum engines. *jb
04/12/2006251
 I had just left a stop light when i heard a loud pop. it sounded like something blew up! the car was really loud and ran rough after that. i had it towed to the shop. they said we blew a spark plug and stripped the threads that hold it in place. at a cost of $1,600 to repair we are having a friend look at it. he thinks he might be able to order a kit called timesert to possibly fix it. i hope it works because it will save us a great deal of money. after investigating the problem online, it definitely is a big problem for ford. they must issue a recall immediately. *nm
02/28/200680000104/01/2002
 Head gasket is leaking. *nm
02/27/200674000108/07/2002
 Leaking right head gasket due to faulty manufacturing. oil leak is dripping on the muffler potential fire hazard and pollution. *jb
01/05/20051512802
 My 99 ford expedition's spark plug ejected from the head. this has caused emotional distress, not being able to get to and from work and other places. i had it repaired for a price of $300 dollars. this was ridiculous, ford should pay all expenses. then i was driving today and another plug blew. my truck is sitting on the side of the road right now. this is terrible! *nm
01/03/2006100300205/15/2002
 Dt*: the contact stated while driving there was a loud bang in the engine. the vehicle immediately lost power and was uncontrollable. the contact pulled the vehicle to the side of the road. it was towed to an independent repair shop and the spark plugs were replaced. one month later another spark plug blew out of the engine. the vehicle was taken again to an independent repair shop were the spark plugs were replaced. *ak
12/24/200591500112/12/2003
 Pulling out from a stop sign in neighborhood when suddenly smoke smell and loud rhythmic banging from under hood. i immediately pulled over and had the vehicle towed to shop. they discovered a spark plug had blown through the head, requiring a head replacement. subsequently i discovered this is a problem with ford vehicles with the triton engine-design defect in that their are only 5-6 threads holding spark plugs in leaving them susceptible to this type of failure during normal operation. ford would not assist me with repairs stating there was no recall dealing with this issue. *jb
12/24/2005920001
 1999 ford expedition - blow spark plug out of number 3 cylinder. result is loss of power and very poor drivability at low speeds. also, gas smell from leading injector in now open cylinder. fortunately i was not towing when the plug blew, or the loss of power could have resulted in an unsafe situation. ford dealer recommends replacing the cyl. head ($3,000), doesn't acknowledge any defect that ford has authorized. several other mechanics indicate this is a common problem on this engine, deals with insufficient number of threads to hold the plug in the aluminum head. *nm
11/07/2005106927109/15/2005
 Driving down the interstate highway heard a loud pop, then a continious huffing sound from the engine compartment accompanied by a severe vibration. pulled vehicle into the nearest rest stop and checked engine, found the second spark plug on the right bank (passenger side) had forceabily ejected taking the threads with it. the engine is a triton 5.4l. the engine was repaired at a dealer (ford country in henderson nv) by replacement of the head. *nm
11/18/200572000106/12/1999
 1999 ford expedition 5.4l eng. driving between office bldgs at low speed, hear explosion in vehicle front, heard debris impacting under engine hood and wheel wells. had truck towed to dealer. informed of spark plug blowout damaged header. told this is common on 5.4l not covered by warrantee. cost: $3,600. *nm
11/04/20051465001
 Blown spark plug in a 1999 ford expedition with a 5.4l. vehicle was sitting idle when failure occurred. inserts were installed in spark plug hole. *nm
07/26/200439000312/01/2003
 Dt: the contact owns a 1999 ford expedition. had to have repairs done several times. the first time it was the alternator. then, there were problems with the motor. the last time there were transmission problems. *ak
01/31/2001604/01/1999
 1999 ford expedition experiencing problems with the head gaskets. *mr the consumer felt that the engine should be replaced at no cost. the passenger side head gasket leaked oil badly. ford replaced the head gasket once while under the manufacturer 36k mile warranty. the head gasket was replaced again at the consumers expense because the leak resumed. the consumer was informed by three different ford technicians that the oil passage in the block of the engine was so close to the edge of the block that a head gasket would have a problem preventing oil from leaking out and ford developed 2 or 3 revised head gaskets to address the problem since 1999. after th second repair ofthe head gasket, one of the heads leaked anti-freeze. other problems were: an inoperative horn, transmission shifting made a whining noise and the vehicle would not heat up when at zero. *sc *jb
04/29/200555000102/25/2005
 My husband was driving our 1999 ford expedition and had just crossed the state line from connecticut into new york on i-84. there was a loud bang in the engine and a consistent banging thereafter. the car was not drivable and my husband pulled off the highway and called aaa for a tow. we had the car towed over an hour to the ford dealer near our home. they determined that the #3 sparkplug blew out of the engine. it caused major damage. we had to have the entire engine head assembly replaced which cost us over $3500 and we were without our car for two weeks.
01/14/200556000104/23/1999
 Right cylinder head was leaking in 1999 expedition with 56000 miles. dealer or ford would not correct problem and cost $2750 from ford dealer to fix. learned later that is not an isolated problem but wide spread. why isn't ford held responsible??? *ak
04/01/2005120000811/29/2000
 The air bag sensor controls the height of the vehicle. the sensor is malfunctioning and the vehicle's rear is dropping, and will not lift. also, transmission has been replaced four times, and the engine was replaced three times. *bf *nm
03/05/2005117590112/30/2000
 My ford expedition blow a spark plug and know requires a head replacement (over $2500) talked with ford dealership and they indicated that they see at least one ford a month with this problem.
01/25/200590261106/20/1999
 Upon driving our 1999 ford expedition we were noticing a burning smell originating from the engine compartment. in preparation of a road trip we decided to take the vehicle in for service and asked to have the problem diagnosed. it was found that the head gaskets were leaking oil on the engine block as well as the starter and the exhaust, which could result in a fire. we contacted ford motor company to ask for assistance with this problem due to the fact that we were informed by a certified ford engine technician that there has been previous service bulletins out on this problem that we were not notified about, however ford has not responded as of yet, although they have acknowledged our calls and e-mails. at this time nothing has been done to correct the problem, because we do not have $2,500 to $3,000 to have the vehicle repaired and the vehicle has been parked since the diagnostic reports. *jb
12/30/2004900001
 While parked vehicle caught on fire in the engine compartment. the cause has yet to be determined. vehicle was considered a total loss. *ak
09/15/20043
 The number three plug on the engine blew out. the spark plug came completely out of the head. the cylinder head had to be replaced. please provide any further information. also, provide correct vehicle identification number. *jb consumer believe this is a manufacture defect and should be a recall on this recurring problem. have done some research on this problem and found numerous cases. consumer do not think the public should have to pay for ford design flaw. *bf
12/01/2004980001
 The consumer was aware of a ford tsb concerning oil leakage. he experienced an oil leakage from the head gasket into the exhaust system. *jb
11/30/2004103000106/26/2004
 Oil leak from right side cylinder head gasket. oil leaks onto exhaust manifold and under certain conditions it could start a fire.*ak
11/13/200486000107/15/2004
 I had a spark plug blow out of my cylinder head while driving. i have read reports happening all of the time and it is a very common occurrence. no warnings, just a $4000 bill to have the head replaced. *jb
10/10/200484500101/05/2001
 Right head gasket leaking oil. *jb
10/20/20031
 The consumer noticed fluid leaking from underneath the vehicle. the mechanic informed the driver that the head gasket needed to be replaced. please provide further details. *jb
12/20/2003600006
 1 engine blew-100 deductible 2 electrical,lights wont go off - 3 electrical,radio/windshield wipers inop-4 transmission leak-5 transmission going bad-6 alternator bad all within a year and 4 months, been walking more than riding, have not enjoyed truck yet, scared to drive past 200 miles out i got a real lemon that i still have to pay 535 for, i hate ford, will never buy another if it was free, going to iraq, but ill be back 4 justice.... *jb
07/23/200471600104/01/1999
 Oil was leaking from the vehicle. made an appointment with local mechanic, and took vehicle in. it was discovered that right head gasket was defective. then, vehicle was taken to the dealer, a dye was placed into the engine, and after one week it was taken back. the manufacturer stated nothing could be done. *ak
08/25/20041
 While i was driving on the expressway at expressway speeds all of a sudden there was a pop sound and the vehicle lost power and started vibrating badly. when got vehicle to mechanic by tow truck because vehicle had no power, it was revealed to me that the spark plug was blown out the head of the motor. it was the 3rd plug on the passenger side. my vehicle has a complete extended warranty but the warranty company claims that this is due to a loose spark plug. they are the original factory plugs supposedly you don't have to touch them for 100,000 miles. my mechanic states that this happened due to a defect in the head because he not only spoke to ford mechanics but has seen this before. this is a common problem, upon researching this myself i found many other people on the internet with this same problem,at the same exact site on the motor. this is a problem with the head of the motor and my warranty company should fix my truck because this is a covered item it is the engine block that malfunctioned , not the spark plug!!!! please help because this is a very costly repair. *jb
04/15/200485692104/22/2002
 I purchased my 1999 ford expedition used, with 50,140 miles on it. i also purchased an esp warranty plan. my engine always had a knock when cold.i thought that was normal. on the week of april 12th, the engine knock became severe and the vehicle had been using more oil than usual. i brought it to johnson ford for repair. my service advisor told me not to worry, i had the best warranty plan there is, and that this is a very common problem with the 5.4 engines.he even told me that he spends much time calling in similiar claims. the diagnosis was spun rod bearings. after two weeks, my claim was denied, and i removed the vehicle from the dealership after a $6400.00 estimate for a new motor. i brought the vehicle to a reputable independent, and had to purchase a used motor for my ford. after much research, i have found that numerous people have had complaints about defects in the 5.4 ltr engine. i find it very frustrating to have spent $1100.00 on a rental car, $4300.00 on repairs, and $335.00 to johnson ford to tell me that my engine failed. (i knew that when i brought it in!) in addition to that, i spent $2395.00 on an esp warranty that was of no use to me. johnson ford is claiming that my engine failure was due to lack of maintenance. mobile tech (the independent) has stated that my engine was sludge free, and that their opinion is that is was not lack of maintenance. i have written at least 20 letters to the dealership, the bbb, and different departments of ford motor company since april 30th and am getting no answers or satisfaction. the motor remains at mobile tech as i have requested an examination, again, from ford motor company. to date, i have been repeatedly denied my request.*ak
03/31/2004675001
 #3 spark plug blew out at 67,000 miles. original plugs from manufacture with all factory parts. spoke with several ford mechanics and others who have extensive work on this problem. ford acknowledges no design errors. i found online that this has happened to several ford owners with the 5.4 l v8 and the v10 engine and on occasion with 4.6l v8. this appears to me to be a design flaw that ford should have recalled. *jb
03/16/2004109/11/1999
 Engine idling louder than normal. needed a valve asy-idle air control. i know 3 people that had the same problem with their expedition and they had the work done in the last 3 weeks. *jb
03/03/200492000110/19/2002
 Frankly, i need your advice on a matter of great concern i bought a 1999 ford expedition from waldorf ford in oct 2002. recently i had a break down; i had three spark plugs blow-out, yesterday i was told that three cylinders are gone due from the damage of the spark plugs. the assistant team mgr said it would cost $6000.00 to get a new engine or get a new vehicle; i couldn't believe my ears. these trucks are lemons and i believe its time that ford take responsibility for their actions and recalls these engine. i guess they are waiting for someone to get killed. my truck lost power in the middle of rush hour and i was nearly rear ended. other noted problems: the emergency brake cable stays on, the engine light stays on while driving and the brakes pads and shoes are worn out at a higher rate. *jb *bf *nm
02/24/2004107/31/1999
 Approximately 2 weeks ago, i noticed a burning smell/oil leak in my 1999 expedition. i promptly took it in to my mechanic to be diagnosed. it was determined that it had a leaking head gasket (this engine has only 46,000 miles on it, and the vehicle has been extremely well maintained). i spent many hours on the phone with ford, but was told they would not help. feeling stuck, i went ahead and authorized my mechanic to go ahead and fix the head gasket at our expense (of nearly $2000)! unfortunately, this nightmare only got worse! yesterday, my mechanic informed me that while tearing down the engine to get to the head gasket, he determined that the timing chain has worn clear into the guides/tensioners. he (and 2 other qualified mechanics) have stated that there is no explanation for this other than defective manufacturing. there is nothing i could have done to have caused this. the cost to repair this problem would be an additional $1500, now putting my total at nearly $3500! both the mechanic and i spent much of yesterday on the telephone (yet again) with ford, but they are still refusing to take any responsibility for these faulty engines! it sickens me that they can charge $40,000 for a vehicle, then not be made to stand behind them! i have been absolutely amazed at how many other reports i am reading (here and elsewhere) about this very same problem occurring with the head gaskets. why hasn't ford been required to fix this problem? this expedition was my dream car that i saved 2 years to buy. i cannot even begin to tell you how much that dream car has turned into a nightmare!! please make ford take responsibility for these defective engines!!*ak
01/27/200470000112/01/1999
 Right cylinder head warped, required replacement, ford and dealer refused to cover. *jb
01/18/200352000109/03/2003
 While driving my 1999 ford expedition 5.4l on the interstate at 55 mph, a heard a noise which at first felt like something caught in the fan, but was alter determined that a spark plug #2 passenger side had blown out and broken off the coil causing contact with the 2 fuel rail. i have discovered that this is a common problem amongst ford triton engine owners and the aluminum head is inadequate in keeping the spark plugs intact after 50, 00 miles or so due to a design defect. as i understand it, ford has re-designed the head on newer models, but has not issued a recall for this defect. i feel that a recall is necessary because the coil can damage the fuel line and that could cause a fire in the engine compartment. *cb
12/09/200368700110/28/1998
 1999 ford expedition, v8 triton 4.6 liter engine with 68,700 miles has oil leak. inspection at dealership determined head gaskets need replacing with estimated cost of $1200.00 to $1500.00. this vehicle was purchased new and maintaince was maintained according to schedule. a vehicle requiring this type investment should not require repairs of this type at 68,000 miles. a recall for this problem would be appropriate.*ak
11/28/200337000206/15/1999
 Continuing oil leak on a 1999 ford expedition from the head gasket. head gasket replaced at 14,000 miles under warranty and now it is leaking again at 37,000 miles. ford must perform a recall on this problem.*ak
09/30/200255000109/29/2002
 Fire hazard! manufacturers defect causes head gasket failure resulting in severe pressurized oil leak onto hot exhaust manifold, creating a dangerous fire hazard. *jb
11/13/2001270003
 Engine head gasket leaks oil badly. this vehicle had been to dealer twice for replacement of the engine head gasket and it needs replacement again.*ak
08/19/200372330312/21/2002
 Engine problems, i purchased a 1999 ford expedition 4x4 used dec. 21 2002, in feb 2003 i had to take it back to the dealer for a head gasket problem, had to have that repaired, after that was repaired while still in the shop the mechanic couldn't get it to run smooth. i was told that it was missing and was barely running, it would hardly take off and once you got rolling it would spit and sputter and cut off while driving down the road. i finally got it back 2 weeks later, when i asked what the problem was i was given the response, we don't know we just replaced parts until it was running smooth? what kind of answer was that? now here it is aug 2003 and the engine is knocking! i took it straight to the dealer and they said yep sounds like you've got either a bad bearing or some kind of rod was bad???? hello???? then i was told to bring in back in a few days that they couldnt inspect it completely at the moment. then i was told not to be driving it, ok how do i get it home if i cant drive it? how do i get it back in a few days if i cant drive it? i paid a lot of money for this piece of junk, why should i pay $20,000 for a vehicle and have to pay another $5,000 in 6 months just to be able to drive it again? whats up with ford? are they so hard up for money that they have to shaft their customers? way to go ford!! keep up the shafty work we all (customers) like to pay $20,000 + for a hunk of junk that we have to keep putting money into. i cant believe im paying payments on a vehicle that i cant even drive, that really sucks. to bad there isn't anybody that can make ford do something about those bad motors and all the other problems they are having, yes i work everyday to pay for this lemon vehicle and whats even worse is that i have to bum a ride to work, now thats sad with a nice expensive vehicle sitting in my garage.*ak
08/08/200337500105/01/1999
 While driving, the engine made a loud the noise, the vehicle was taken to the dealer, and the consumer was informed the engine needed to be replaced at a cost of $5000. *jb vehicle was taken to the dealer who learned the failure was the result of a scored cylinder. consumer was advised ford would pay for a portion of the repair. consumer felt that since the vehicle was routinely maintained, ford should cover the entire portion. consumer was told the offer was non-negotiable. *ph *nlm
05/16/200375000209/01/1999
 Oil leak from head gasket at about 35,000 miles. oil leak from head gasket at about 75,000 miles. *jb
06/05/20031
 The engine light illuminated on the dashboard, and remained on throughout the entire drive. *jb
05/23/20039000002/05/2002
 Triton v8 5.4l with 90,000 miles spark plug pulled out and destroyed the cylinder head. i was told by 2 mechanics that this was caused by poor design. there are only 3 threads holding in the spark plug. ford has also updated this particular cylinder head but has not recalled it. *tt
06/01/20014000005/15/2001
 I have a 1999 ford expedition that has a faulty right side cylinder head. oil leaks onto the exhaust which is a potential fire hazard. through my own research i have found out that this is a common problem (oil leak from the right side head) with this vehicle. there are thousands of complaints that i have found on the internet. ford refuses to acknowledge the problem with the consumer but has sent out technical support information to their mechanics on how to fix it. to me that's an acknowledgment that a problem exists. if my vehicle was still under warranty they would fix it (which to me is another acknowledgement to this problem) but since it's not they won't back it up. repairs would cost me aprox $ 2,000. through my research i have found that this problem has existed since these vehicle were new, back in 1999. i bought the vehicle with aprox 40k miles on it and today i have aprox 75k miles on it. i noticed a burning smell shortly after i purchased it but only recently did i realize what the problem was. i had an oil change done by an ex ford mechanic and he admitted that the expedition is known for this oil leak but ford won't do anything about it. *tt
01/26/2003755672
 Head warped on engine .008. warp beyond repair tolerance thereby requiring a complete rebuild with new heads or new engine. ford refused to offer any help with this even though this happened at only 75,000 miles. engine shows evidence of head gasket seepage over a long period of time. in service manager's opinion only a head gasket failure could cause this type of failure. this 5.4l v8 is renowned for head gasket failure. according to ford's own admission this is a manufacturing defect and therefore this motor has had this problem from day 1 of the manufacturer's warranty. 6 months prior to this failure this had had a broken valve spring. these heads are also renowned for blowing spark plugs right of the head. *nlm
03/11/199938900103/04/2003
 I just purchased the 1999 expedition 4.6l xlt on march 4, 2003. the vehicle has approximately 38,000 miles on it, and i have only put about 500 on it since the date of purchase. i bought the vehicle in virginia and needed a maryland inspection. upon the inspection, the mechanic noticed a leak around the engine. he did not investigate the issue, since it is not an inspection item. i am afraid that with all the other complaints about the right side head gasket, that this is in fact the problem. will my limited power train warranty that the dealership gave me cover this cost. i think it is a complete shame that ford has knowledge of this recurring problem but does not offer a solution. if there are any programs that ford is offering, i would like to here about them. *jb
09/30/200257378109/26/2002
 Engine oil leak, right side cylinder head leaking oil.*jb
03/07/200340500011/28/2002
 We just bought a 1999 ford expedition with 35000 miles. we have driven it for 5000 miles and now it needs a new right head gasket. i've read many complaints about the same problem. any answers? *nlm
02/27/200335028310/09/2001
 Recurring oil leak, right side cylinder head, ford trucks with 4.6 engine.*jb
01/23/2003300003
 Head gaskets blowing out on 1999 ford expeditions. i have had mine replaced 3 times so far. it is also occurring on other peoples same vehicles. it is on the 4.6 and 5.4 liter engines. the last time i had it to the dealer for this i asked why this keeps happening? they said that ford is aware of the problem but keeps telling the dealer to replace the gaskets. there is a manufacturers defect here.*jb
02/24/2003011/23/1999
 I have a 1999 ford expedition. it has had both head gaskets already replaced once, and now they are blown again. the car is out of warranty and the dealership has informed me that there is an abnormality in my engine which will cause this problem to continue to re-occur unless i pay $5000 to have a new engine put in. ford has recalled similiar vehicles due to the problems with the same engines, however offers no assistance on their much pricier expedition. i guess they figure we can afford the repairs. they refuse to discuss my problems and tell me that blown head gaskets are considered normal wear and tear. the head gasket problem aside, this car has been in the shop over 30 times for non-routine maintenance issues. the leather seats had to be replaced, the exterior molding went bad, the exhaust system was faulty, wiring was faulty, mirrors and windows were faulty, electronic components were faulty, the list goes on and on.
02/19/2003104/14/2002
 On my recent purchase of a used 1999 ford expedition with the 4.6l v8 engine, with low miles only approx 31,500 when purchased, and after only adding 12,000 more miles to the vechicle, in which we haven't had the car for a full year, we experienced a blown right side head gasket that i just recently found out was a known problem with this model. the car wasn't under warrenty and the cost for repairs ran up to 1300.00 which is outragious. i feel that if ford has known about this defect that ford should have recalled this defect long before so many have needed repairs. i regret that this is the last ford i will ever own, which is directly due to the inept customer service that ford is now known for.
01/29/20034801108/23/2002
 I notice oil drops on my driveway, i took my vehicle in to verify where leak was coming from, the dealer stated that my head gasket was blown. the repair cost for labor and parts would be over $1200.00. the extended warrenty would not cover seal or gasket for this vehicle. i request nhtsa have ford dealer or manufactor's do a recall on this vehicle engine. my vehicle has the 4.6l engine with less than 49000 miles.
01/15/20036500001/03/2001
 Oil leak from rh head/block interface. number of complaints and tsb about this issue indicate manufacturing assymbly defects. tsb note chips could be present or dimples in mating surface of gasket area. customers should not have to pay for manufacturing problems that are none to be present.
12/25/200243200103/11/1999
 After an oil change at 42k miles, noticed a burning smell and some smoke coming out of the right side engine compartment near battery. took truck to dealer and was advised that the right side head gasket was leaking towards the rear. vehicle out of manufacturer's warranty but luckily i had an extended warranty. was told by the dealer mechanic that there is indeed a head gasket leak problem with the 97-02 expeditions. head gaskets should not fail at 43k miles and ford should repair problem at no cost to the consumer.
10/10/2002
 While driving approx 70mph w/cruise control engaged, the engine's head gasket blew causing the vehicle to stall. ts
01/17/2002303/01/2000
 Is ford trying to recover money from the explorer/firestone tragedy or what? you would think that they would have learned. it is shameful that a high dollar vehicle like the expedition has become a high maintenance liability. we have repaired this gasket valve cover three times at $1800.00 each. it is embarrassing to drive such a nice vehicle that is polluting the air with oil smells and smoke. the vehicles are sluggish and it will not be long before someone is killed. i pray daily that it is not me, my children and foster children that i transport for my job. my local county government has purchased a fleet of expeditions and each one has been repaired at least once. come on ford step up to the plate. a ounce of prevention is worth a pound of cure. my grandfather hated ford products and stated that ford meant found on road dead. unfortunately now the customers are the ones that are found on road dead because of faulty equipment and the lack of regard for the common citizen. what are you waiting for my car to burst into flames and my kids are scared that i can't get them out of the third row seatbelts before they parish in a burning vehicle. i am a social worker with a demanding schedule and a modest salary and i can't afford the repairs. so many abuses and neglected children lives depend on me and all i am asking is that i have a vehicle that i can depend on to get me there. do the right thing. recall!!!!*ak
05/01/2002103/27/1999
 Engine head gasket needs replacing. headgasket is leaking oil. dealer stated there was no recall. *ak *yh
03/01/2002110/24/2001
 Consumer states while servicing vehicle noticed there was an oil leak in the engine, dealer has been notified and states it is not a manufacturing defect consumer is having it serviced.*jb the cause of oil leak was determined to be head gasket failure. *yh
11/27/2000302/01/2000
 This vehicle has had three blown head gaskets within the first 40000 miles, vehicle hestitates during acceleration which produces a significant safety hazard at intersections.*ak
 Timing chain went out and engine misses. had engine replaced once, still having problems. took vehicle to dealer, and dealer could not duplicate problem. please add vin. *ak
04/04/2002103/01/2002
 Oil leak from right rear corner of engine (head gasket)leaks oil onto hot exhaust causing significant smoke at speed. defect unrepaired as manufacturer will not cover cost.*ak
 Ehicle is leaking oil. took vehicle to dealer, and dealer indicated leak was in head gasket. had repaired it, but problem still exiss. please add vin. *ak
03/02/2002112/01/1998
 4.6l v8 engine was leaking oil, vehicle taken to dealer and informed consumer of a blown head gasket. *ak the vehicle was taken in for routine service when consumer was informed that the vehicle had an oil leak. consumer called the dealership and was informed that there were several vehicles that complained of the same failure but no recall has been issued. *jg
10/01/2001108/01/2000
 The right side head gasket is leaking oil. my dealer told me they have had many of these failures for this model. with only 27000 miles on an expensive vehicle like this, it shouldn't be leaking oil all over my garage floor. the 3 year warranty expired 3 weeks ago and the dealer as well as ford motor company said i will have to pay for it. i am outraged and would like the nhtsa to order a recall. we all know ford motor company will not recall this defect on their own!*ak
12/27/2001105/01/2001
 During christmas while driving around town, we noticed that the truck felt sluggish and non-reponsive to acceleration attempts. at which time it was noticed on the driveway that a oil leak had begun. we took the expedition into the local ford dealership for a service evaluation. we were informed that the head gasket had been blown. we decided to get a second opinion by a respected independent mechanic, who gave us the same prognosis. we again contacted the ford dealership to see if the cost of the repair could be negotiated lower than the $1,850. estimate. a ford mechanic mentioned that a special plan might be available, by extending the warranty due to the nature of the failure. that request was rejected. in trying to talk with a ford factory service manager, he wouldn't talk with me about the problem nor did we receive any additional help. in purchasing a used vehicle, i realize there is a risk of failure, but 7 months & 14,000 miles later, to payout close to $2,000!, that's too extreme. a head gasket should not fail this soon into a vehicle's life. i've noticed that ford's have had a recent history of head gasket problems and we would like this to be recalled and to be reinbursed for this expense. thank you. *ak
08/25/2001104/01/1999
 Passenger side head gasket is leaking oil. this is a common problem on the 5.4l emgine. ford should have a recall to correct the problem. with 60oo miles. i do not expected to have this kind of failure. *ak
06/01/20000
 Light came on the dashboard indicating there wa sno oil inside of vehicle, and it started making clunking noise. dealership was aware of problem.*ak
08/10/2001107/29/1999
 Needle in oil pump was defective. it kept going up and down. oil pump has not been replaced. the dealer was aware of problem.*ak dealer refused to replace the multifunction switch that was included in a recall. *slc
112/01/1999
 These head gasket failures are common on the late 1998 and early 1999 5.4l engines. many have been repaired under the 36,000 mile warranty. how ever, it appears that this defect can occur at any mileage. ford has refused to repair my vehicle since it occurred after the warranty and no recall has been issued. from the number of documented failures of this component, i feel ford should extend the eingine warranty or just recall the engines in question. there are two tsbs on file (8093-122 &13846-124) that detail the dates of manufacture and the engines involved. there are dozens (if not hundreds) of this gasket failure noted on various internet sites, most that i can find have been covered under the 36,000 mile warranty, others under extended warranty. in any event, this gasket/head is a defective component that will fail and should be corrected by ford motor company.*ak
11/20/2000205/01/1999
 This is the second time that this vehicle has been back to the dealer in a 6 month period for engine troubles due to a defective engine block. the dealer has stated that ford motor co. is aware of this defect, however they have not notified consumers that purchased affected vehicles. this dealer has made repairs using a rebuilt, remanufactured engine block. this repair is not satisfactory as i purchased anew vehicle and expect the repairs to be done with brand new not refurbished parts. had i not taken my vehicle to the selling ford dealer for routine maintenance, i would not have known about this problem unitl my engine failed and possibly after my warranty expired. i believe that other consumers may be charged for work that is a result of this same type of engine defect that ford is aware of and has sent technical memo's to the dealers about this problem. the dealer stated that ford motor co. won't allow the dealers to notify consumers about this defect as it could cost significant amounts for ford warranty work. this is a serious defect and a safety issue as engine failure can result if not repaired. the first time my vehicle was leaking oil, and the second time it was leaking engine coolant due to the defective engine block. i feel as though ford motor co. and it's dealers are keeping this information from consumers that have a right to know their vehicles may be defective before they have an accident or incident due to engine failure.*ak
03/23/2000402/01/1999
 The vehicle experienced an oil leak around the head gasket, the consumer is not pleased with the dealer because they replaced the engine with a remanufactured one. nlm
04/03/19990
 Piston knocking and vehicle is losing power, and it stalls. could be dangerous if on a highway. consumer states at 50 mph cars starts to vibrate.*ak
03/23/2000402/01/1999
 Oil leak around the head gasket-had car serviced 4 times replacing plugs,wires ,gaskets and the whole head assembly. finally they agreed to put a new engine in. we keep telling something was wrong with the block. they put in a remanufactured engine. truck was in the shop over 35 days when they could of just drop a new engine the second time..not happy with apple valley ford for jerking me around. now i do not trust this car. i bought new and now i have a used engine in my truck.
02/01/20012
 Right head gasket has cracked, causing oil to leak onto starter motor. dealer has been contacted.*ak consumer states that after repairs were completed, 2 weeks later the head gasket started leaking again, consumer is requesting reimbursement. *slc
08/01/2000
 Engine hesitates. dealer was not able to locate problem or provide remedy. also, vehicle had an oil leak, and knocking noise. dealer replaced head gasket, but problem is reoccurring.*ak
02/15/2001105/31/1999
 Consumer noticed drops of oil on garage floor. dealer stated that head gasket may be leaking. *ak the consumer states that the dealer was aware of head gasket problem and waited until warranty expierd for fixing it. therefore, the dealer should fix the head gasket at no charge. *yh
12/15/2000
 Vehicle is leaking oil at right side of engine, bottom of cylinder head. in at dealer's shop for repairs. also, when vehicle is started there is a loud tapping noise coming from engine for about 5 minuted, then it stops. *ak
03/10/2000111/11/1999
 Vehicle leaking oil due to head gasket failure. yh
03/30/2000302/01/1999
 This vehicle has been back to dealership seven times since purchase for warranty service problems and recalls. in may of 99 there was a recall on the wheel lugs: nuts. in september 99, november 99, and march 2000 it was in for windshield wiper problems; moulding replacement; twice for front end alignments (steers to right); and trailer hitch recall. the constant smelll of burning oil has just been diagnosed on latest visit to dealership 5/15/00 as needing a new cylinder head. vehicle has been in on three other occasions for this same problem, but they could never find it. now parts are on order---will take 3-4 days to obtain parts before they can repair it. regarding the windnoise dealer says its normal yet service bulletins have been issued on this problem (996780 & tsb 99-6-5). in november of 1999, the left tie rod broke off while we were in phoenix. a phoenix dealership did a same day repair for us. *ak
04/17/20000
 Consumer took vehicle to dealer for engine gasket repair, and dealer said it would be 3 to 4 months before parts would be available. this is not a recall part. *ak
06/01/1999212/01/1998
 Second right side head gasket failure in first year of life. *ak
 4.6 liter,v8 engine. engine came with defective design which has a piston slap, causing vehicle to run and idle rough.tsb has been issued. *ak
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
10/25/2007132251103/15/2005
 1999 ford expedition 5.4l while driving heard loud noise from engine compartment. pulled over and lifted hood seen that number 3 coil was moved and sparkplug ws attached. plug had been blown out of sparkplug hole and stripped the threads out as it came out. gas was being blown out of plug hole and the sparkplug was sitting right next to the gas coming outmaking a possible fire hazard. have to have cylinder head replaced to fix stripped threads. *tr
03/28/2006108/24/1999
 My 1999 ford expedition had a spark plug blow out. the vehicle has approximately 60,000 miles. *jb
10/20/2005120000311/15/1998
 Engine spark plug blow out at 80,000 miles on engine. engine had 40,000 on it from new and was consuming oil due to the right head leaking oil. ford replaced the head gasket. the gasket did not solve the problem so a new motor was installed. now at 120,000 (80,000 on the motor) after the spark plugs were changed, a plug blew out of the head. a helicoil was installed after the plug blow out but that also failed. rebuilt head is being installed. feel this is a ford problem on this spark plug blow out. the 5.4l head is not manufactured to withstand the horsepower. *jb
11/20/200564405102/15/2002
 My '99 ford expedition 5.4l engine blew out a spark plug. current mileage is 64,400 miles. *jb
10/14/2005105000112/03/2003
 Upon start up my 1999 ford expedition blew a spark plug out of the engine block. ford refused to admit that there is a problem . repair is approximately$4000.00. numerous complaints at consumer affairs attest to this problem. *nm
08/12/20059300003/31/1999
 While driving on the highway with my family my 6 year old ford expedition blew a spark plug right out of the head. it has come to my attention that this is an on going problem with this vehicle. we had been driving for about 5 hours coming home from a family vacation when this occurred in new jersey. we were lucky in this case because we were able to make it across the highway and off the road. the problem completely destroyed the head on the left side of the engine and the vehicle was unusable for over two weeks while the local ford dealer worked on the problem. that head had to be replaced as well as many other parts associated with this problem. the dealer stated that this could happen again with the head on the right side. between the repairs to the engine and the rental car for the time of repair, this was a very expensive (5000 $) problem. which i stated earlier appears to be an ongoing problem with this motor. *jb
08/25/2005147006110/01/1999
 One spark plug on my 1999 ford expedition exploded and burst through the head of the engine. my wife was picking up my child at school. she parked the vehicle, shut it off and minutes later returned. as she was starting the expedition both her and my daughter heard a very large explosion from the front of the vehicle. the vehicle continued to run and a constant popping sound could be heard. she immediately shut off the engine and noticed a very strong gas/exhaust type smell. she called me and i arrived to check the vehicle out. i inspected all the fluid levels and fuses and they were fine. i briefly started the engine with the hood open to help narrow the location of the sound. the sound was coming from the top of the engine on the passenger side. i started inspecting this area and found that the third spark plug from the front of the engine on the passenger side had been completely blown out of the head of the engine. it is very fortunate that this occurred in a parking lot. my wife and daughter were both very startled by the loud explosion and i can only imagine what would have happened if this had occurred on the road at a high rate of speed. i believe that an accident would have resulted. i have since done some research on this particular issue and have learned that this has happened on numerous occasions on ford vehicles and has been brought to the attention of the nhtsa. i would like to file this complaint and find out what the nhtsa is doing about this specific issue. the design issue with this particular spark plug/engine head combination is well known in automotive circles. what is the nhtsa doing about this issue. thank you for taking the time to hear my concerns, and to reiterate i believe that there would have been an accident if this event had happened on the road at any rate of high speed. *jb
06/26/200560000203/24/2005
 1999 ford expedition 5.4l 4wd driving down road and spark plug shot out of the head. causing a loud popping noise and bad idle. replaced sparkplug and had heli-coil installed. two weeks later, another spark plug shot out of the other side of the head.
05/24/2005131000104/03/2003
 1999 ford expedition with 5.4 triton v8. spark plug is ejected from the aluminum cylindar head. immediately upon the plug being blown from the position on the head i could smell fuel and the engine began to violently make a loud popping sound. i have found numerous complaints on the web regarding this but cannot find any resolution measures. bought the truck used with 85k miles but i have read other complaints where the plugs blow out at much lower mileage. had to have it towed because i was advised by the dealer that, it wouldn't be a good idea to drive it if you smell fuel. i had the service rep tell me that, this is pretty common in our lighting models with the v10, but not with our v8 models. he also tells me that the plugs were too short for the engine but i checked with the mechanic that changed my plugs and he says that he put the replacement spec plugs that ford recommended. links to other sites related to this: http://www.f150online.com/forums/showthread.php?s=&threadid=103042 i know these are not filed complaints with the nhtsa but this is a serious issue. when i took it into the ford dealership at dobb's ford, 7925 hwy 64, memphis, tn 38133-4007, they told me originally it would be $2600. i was almost set to have it done then he tells me that labor was not included in that price and the total price would be $3800.
02/20/200565500104/20/1999
 Spark plug (believe it was #4) blew out of the cylinder head. 66k miles. these were original plugs, so not attributable to faulty mechanic. head re-threaded, new plug inserted.
05/06/200468000105/14/1999
 While driving to myrtle beach i heard a loud bang under the hood.i had the truck towed to a ford dealer where they told me the spark plug blew out of the cylinder head.i have read many complaints about this issue on the internet. i feel this is a safety issue due to the strong smell of gasoline when this happens.ford said they will do nothing and it will cost me 3600.00 to fix this. who says even after replacing the head it wont happen again and again. i am disgusted with the whole thing. i think ford should step up to the plate and fix this problem.
02/15/200364800103/05/1999
 Right side oil leak from head gasket. *ak
12/23/20037500004/06/2001
 I have a 1999 ford expedition 5.4l engine, while drivung the vehicle one of the spark plugs blew out. i contacted ford motor about the problem and they said there is nothing they can do. after doing some research, i found that alot of people have complained about the same problem. ford motor knows they have a problem with this engine but woun't admit it. i think it is a big safety problem and ford sure realize it . if you could do anything for me and unknown amount of other people that purchased this piece of junk please email me thanks
12/26/2003330002
 1999 ford expedition - significant oil leak in the right head gasket. there is a current service bulletin for this problem.*ak
 The owner noticed a burning smell entering the compartment. the right side of the engine has a cylinder failing causing a leakage of oil onto the exhaust system. the owner is aware that the manufacture has (3) technical service bulletins the indicate this type of failure. please describe details. ts
09/10/2002101/01/2099
 Vehicle was purchased in 1999 new, all routine maintenance was performed on time and on schedule, vehicle was purchased with a facotry extended warranty to provide drivetrain coverage to 100,000 miles. engine failure at 103,000. warranty expired, manufature customer service reported so sorry. buy new engine. mr
04/22/2002106/01/2099
 No summary listed for above vehicle. *ak
04/16/2002106/01/2099
 Unexplained fire. car was parked and unattended at the time. no components were on or in operation. nlm
04/16/2002106/01/2099
 Unexplained fire. car was parked and unattended at the time. no components were on or in operation. nlm
01/15/2002103/01/2001
 There is a low recurring beep when driving. *ak
 While driving engine completely shutdown. cause unknown. took vehicle to dealer. please provide further information.*ak
 Vehicle is leaking oil. also, every two weeks conusmer has to add a quart of oil. also, fumes of oil burning go inside of vehicle. contacted dealer, and dealer is not willing to do anything. *ak
05/20/2000312/01/1998
 Please note that brandon ford has not helped me resolve some of these issues. no safety defect mentioned in summary. *ak (tiresize: 26516)( dot number: tire size: 26516 )
10/17/19994
 Over the past two years, there have been two incidences where vehicle has lost engine power while driving on highway, cruise control engaged both times, vehicle regains power after the engine is shut off for about 15 minutes, the vehicle has been serviced for this problem 4 times, dealership is not able to duplicate malfunction and therefore could not solve problem. cj
08/01/2000
 Engine hesitates. dealer was not able to locate problem or provide remedy. also, vehicle had an oil leak, and knocking noise. dealer replaced head gasket, but problem is reoccurring.*ak
02/01/2001110/01/1998
 This is the second ford vehichle purchased. initial vehicle traded because of saftey issue involving seat belt malfunction. this particular vehicle needed an engine replaced and extensive transmission repairs. ford motor company is basically untouchable for comments. service technician at dealership admitted to knowing the engines in the 1997- 1999 expeditions were having problems. i was never notified. *ak
01/06/20010
 After changing oil could still smell oil. then ,took vehicle back to dealer where they found blown out head gasket. this was second time. first was repaired by dealer under warranty, but this time it was not under warranty. *ak
11/05/20001010/01/1998
 Engine loses power without warning, creating hazardous condition. multiple repair attempts failed. ford has displayed no concern for the safety of their customers. *ak
12/27/20001
 Engine noise upon cold start. sounds like marbles churning about inside a coffee can. *ak
12/15/1999209/01/1999
 Engine experienced vibration and in cold weather the engine rattled, dealer replaced the engine, vehicle experienced a bad oil leak. *slc
07/01/1999102/01/1999
 At 3000 miles the engine was replaced due to a knock in the engine. at 11,000 miles there was a severe vibration in the drive train at 65 mph with the vechile under load - ford couldn't identify the problem and had no fix. at 12,500 miles the torque converter failed resulting in the vechile stalling at stops. the torque converter and transmission were replaced. this reduced the vibration but did not eliminate it. again ford tried several times but could not identify and correct the problem. at 21,000 miles the vechile lost all power and would only move by reving the engine (like severe clutch slippage on a manual transmission). ford is presently investigating. both failures could have resulted in severe accidents if the driving conditions had been slightly different at the time of the failures. the problem appears to me to be in the computer constrol system for the transmission resulting in possibly the second failre of the transmission.
10/09/2000111/01/1999
 After noticing an oil leak, i took the vehicle to the dealer for repair. i was told that the cylinder head was warped and had to be replaced. my expedition has only 12,000 miles on it. i believe ford has issued technical bulletins regarding cylinder head leaks and replacing the head gasket on the ford expedition. there may be more expeditions having the same problem as mine.
3
 The vehicle oil consumption is getting progressively worse, at first a quart in 6,000, then 3,000 miles and now 1,800 miles. nlm
3
 The vehicle oil consumption is getting progressively worse, at first a quart in 6,000, then 3,000 miles and now 1,800 miles. nlm
 While traveling at 75 mph vehicle stalled without any indication. dealer has been notified. please provide further information.*ak
02/28/2000312/01/1999
 Driven for 20 minutes and let sit 20 minutes, and it hesitated and ran roughly until cooldown 3 to 4 hours, runs better. why is this happening? everytime i drive and let it sit for 20 minutes it runs like this. also, engine check light goes on and off.
08/01/1999
 While driving or coming to a stop or a yield sign, vehicle hesitates which could cause a crash. dealer cannot determine the cause of the problem. please provide further information. *ak
06/15/19992
 Automobile hesitates from a complete stop while attempting to accelerate. consumer has escaped accidents twice. both times had to get to the shoulder to avoid the other automobile. *ak
03/01/19993
 Three engine replacements within 35,000 miles. *mjs
12/26/199905/01/1999
 When i turned the car off, it started smoking. later i notice a leak coming from under the car.
01/26/1999211/01/1998
 Engine rough idle. vehicle rumbles at idle. dealership contacted; no satisfaction. *ak
10/18/199908/01/1999
 After parking vehicle exploded in flames, totaled. only 2000 miles. ford said recall 98v312 does not apply. problem may be more pervasive than ford thinks. still under investigation.
 While vehicle was parked in the driveway it caught on fire in the engine compartment, cause unknown. please give any further details. *ak
10/04/19990
 While pulling out from a stop sign vehicle will just cut off. *ak
08/06/1999
 While turning vehicle on there was stalling. consumer cut the vehicle off to restart, and engine revved. vehicle was driven straight to the shop after the first episode, and it stalled all the way there. *ak
08/12/1999108/01/1999
 This is a replacement vehicle from ford for my 1999 ford expedition. the replacement vehicle has many of the same problems. the stalling when accelerating in an intersection is a serious safety problem. we we're nearly t- boned. ford sometimes admits that they are aware of the problems and then at times will deny them. please investigate
05/21/19994011/01/1998
 Vehicle does not accelerate, it hesitates/backfires and stalls. vehicle has been seen by the dealership twice for this problem. however, dealer is not able to correct the problem. *ak *sb
04/01/19993
 When drving at any speed and without prior warning vehicle shuts down. vehicle has been back to the dealer three times, and dealer can't determine the problem. *ak
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS
6
 In nine months of ownership the consumer had problems with the high tensioner, the outer steering tie rod ends, which had fell apart while driving, the brake system, and the inner tie rod ends. scc *jb
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
10/07/200660123109/25/2006
 Dt*: the contact stated a loud exhaust noise was heard while driving 55 mph on normal road conditions. there were no prior warning signals. the vehicle was taken to the dealer, who determined the bolts were snapping off the exhaust manifold due to a manufacturer defect. the vehicle has yet to be repaired.
02/23/200457000203/17/2002
 Follw up on letter dated oct. 7, 2002 1999 ford expedition. nvs-216, mek, ref. # 567329. no components mentioned. the consumer called into the hotline to indicate that the engine was replaced because of a snapped intake valve that was laying against the piston. *ak
01/15/200356820110/18/2002
 An oil leak on right & left banks of the 4.6l & 5.4l v8 winsor and/or romeo produced engines could produce possible oil leak.causing oil to leak onto the exhaust manifold and possibly causing a fire. ford corp. is aware of this situation and has issued a bulletin article 02-22-7 published 10-31-2002
06/01/2099
 Engine check light has been on for several months. when i contacted bird-kulgen ford, wes told me it was an emmission problem and a computer check would need to be done. it was and the computer could not find the problem... now they are in trial and error and labor intensive time...just began today but others may be having the same problem, so i wrote to you.*ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
04/24/2007145000201/10/1999
 Spark plug ejected, very inconvenient, vehicle is not drivable can not afford to repair need the car for work. *tr
02/28/200475500007/01/2002
 I purchased a 1999 expediton. and shortly after buying it notice a tapping noise that goes away after about 2-3 minutes of warm up. i believe ther is other problems causing this. my major complaint is with the constant oil leak on the righthand side head gasket. the is a constant leak of oil down ont the exhaust manifold and catalyst converter,causing a possible fire hazard. i have read of over 53 other compalints for the same problem and question why ford has not recalled this problem. it all comes down to economics, i feel the are quick to fix small problems i.e... trailer hitches and wiring problems, but when it comes to a known manf. defect in these particular engines ford is not willing to stand behind there work. iwould like to see n.h.t.s.a force ford to correct this problem. if people are spending over 25,000 for a vehicle they should have the piece and mind that their families will live long enough to pay off the vehicle. my point is that i am a u.s. marine and my life is at danger whenever we go off to war and its a possiabilty that my life can be ended by a single bullet, and i am willing to make that sacarfice. but i never thought i would be ask to die in my vehicle on the open roads in the land of the free. the way i see it ford is willing to save a few dollars by not accepting responsiabity of this known defect. but my wife, 5 year old daugter, 3 year old son, and 2 year old son should mean alot more than $1800- $5000 saved by them not fixing the problem. i would really like to see what can be done to remedy this situation. and if they still refuse to fix the problem lets just send all the iraqi's and terrorist a free 99 ford expediton that should solve our war on terrorism... not so respectfully submitted, gunnery sergeant united states marines. *ak
08/22/2001112/01/1998
 The oxygen senor shorted out causing the wiring harness to burn completly through. this then caused the wiring harness below the oxygen senor wiring to also burn through which then caused the computer to the engine to be damaged and in need of replacement. if would seem this is a safety hazard if a wiring harness can completely burn through itself. this could have caused a severe fire in the vehicle. dealer and manufactuer state this is not a problem and an isolated incident.*ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CRANKCASE (PCV)
11/25/200566795204/01/1999
 Dt: the contact stated while driving vehicle experienced sudden acceleration. when depressing the brakes the rmps revved very high. when lifting foot off the brakes the vehicle accelerated. he eventually depressed the brakes hard enough so that the vehicle stopped. the cruise control was not in use. he took his vehicle to the dealer. they told him that the pcv had a leak in the vacuum system. the vehicle is now being repaired.*ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
02/21/2008136000101/01/2003
 I was getting a loud noise from the passenger side when i would accelerate. i took it to the shop and found that all of the nuts and studs holding the exhaust manifold to the engine had rusted away. the tech said it is a common problem he finds with fords. i also talked with a guy and he had the same year truck and had the same problem. i have a friend who is also a auto mechanic and he sees it often as well. *tr
01/05/200486830101/01/1999
 On my 1999 ford expedition i noticed the smell of hot oil. when i would stop and park the vehicle the smell became stronger and smoke would come up around the hood of the vehicle. i also noticed some oil drops on the ground. upon taking the vehicle to the local ford dealer i was informed the the head gasket was leaking oil on the rear of the right head. cost to repair was $1,295.04. i then found on the internet that this was a know problem and was widespread. apparently there was a manufacturing defect in the head which would cause an oil leak in the right rear or left front of the head. again this was a know problem by ford but no recall has been issued and if your vehicle was not under warranty the owner had to absorb the repair cost. to me this was a safety issue and should have been addressed by ford. the oil was leaking onto the exhaust pipe and could have caused a fire. *tr
02/27/2006860001
 Dt*: the contact stated when taking the vehicle in for normal routine service, a leak in the head gasket was discovered. the vehicle is currently at the dealership awaiting repairs.
04/13/200131000208/25/2000
 I have a 1999 ford expedition with 95,000 miles. at 31,000 it had warranty work performed to repair an oil leak between the cylinder head and the block. the warranty work was performed prior to the first technical service bulletin (011202) dated 6/12/01. the vehicle now has the leak again in the same area. the technical bulletin has this as the issue: some vehicles equipped with the romeo built 4.6l 2v engine or 5.4l supercharged engine may exhibit an oil leak or oil weepage from the cylinder head gasket at the right hand rear or the left hand front of the engine. oil weepage is not considered detrimental to engine performance or durability. an oil leak may be caused by metal chip debris lodged between the head gasket and the block, chip debris between the cylinder head and the head gasket, or by damage to the cylinder head sealing surface that occurred during the manufacturing process. i believe that this is a manufacturer issue not a consumer issue.*ak
06/01/20008900201/29/1999
 While driving at 8,900 miles gasket blew. took vehicle to dealer for repairs. again at 22, 000 miles the gasket blew again. also, vehicle was leaking oil. *ak all gaskets had been replaced. little white dot on headlight switch doesn't light up. switch assembly replaced. *tt
05/29/20031
 99 ford expedition spark plug blow out right cylinder # 2. this occurred 10,000 miles after having ford dealership tune my vehicle up. my local mechanic claim it was a defective spark plug and that ford should remedy problem. that hasn't happened as of yet. my vehicle had 97,000 at time of blow out. i personally have put 60,000 highway miles on vehicle last year alone. this vehicle has a service bulletin on coolant hose clamp as well as insufficient threads on heads. *ph