Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||||
| 041601 | 11/14/2005 | 05228 | 10018745 | Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running. *tt | 01/12/2006 |
| ENGINE AND ENGINE COOLING - ENGINE | |||||
| 07212 | 10/01/2007 | 10023943 | Some 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. *pe | 02/20/2008 | |
| 031404 | 08/23/2004 | 04161 | 10011162 | Engine 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 |
| 041511 | 08/09/2004 | 10011156 | Misfire at idle with diagnostic trouble codes p0300-p0308, p0316. *tt | 01/04/2005 | |
| 02177 | 09/02/2002 | 10008581 | Cooling system-motorcraft premium gold engine coolant-serivce tips. *mj | 08/05/2004 | |
| 16403 | 11/01/2002 | 10008334 | Engine-light tick or rattle type noise from engine after cold start. *mj | 07/28/2004 | |
| 02227 | 11/11/2002 | 10008310 | Engine-cylinder head deck leak-4.6 and 5.4l engines-new service-only gasket and cylinder head kits availability. *mj | 07/27/2004 | |
| 03256 | 12/22/2003 | 10008278 | Engine-romeo built 4.6l 2v-tick noise from engine-engines built before 9/17/2003. *mj | 07/26/2004 | |
| 03144 | 07/21/2003 | 10003744 | Engine 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. *tt | 10/29/2003 | |
| 03164 | 08/18/2003 | 10003118 | Some vehicles, equipped with the 4.6l 2v engine, with an engine build date prior to 8/29/03 may exhibit an engine tick noise that is present at all temperatures during idle. 2004 models included. *tt | 10/08/2003 | |
| 16683 | 03/01/2003 | 10001937 | False failure of the vapor management valve (vmv). *tt *jb | 07/28/2003 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||||
| 16079 | 07/01/2002 | 636279 | Some vehicles may exhibit a no-start condition with no fuel pressure present and / or fuel pump circuit diagnostic trouble codes p0231 or p0232. *tt | 11/07/2002 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||||
| 17135 | 09/01/2003 | 10004051 | Moaning noise from the exhaust system, or vibration in the rear passenger floor pan, when driving 45-55 mph and 1200-1400 rpm all without flex coupling in the exhaust. *tt | 11/17/2003 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE) | |||||
| 05417 | 03/07/2005 | 10014666 | Intermittent rough idle - non-commanded egr (exhaust gas recirculation valve) flow. *tt | 05/05/2005 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE | |||||
| 0554 | 03/21/2005 | 10014685 | Use of stainless steel exhaust studs in service for 5.4l 2v engine. *tt | 05/05/2005 | |
| 17320 | 11/01/2003 | 10008169 | Broken exhaust manifold studs. *tt | 07/22/2004 | |
| 16885 | 06/01/2003 | 10002602 | Rapid rattle, buzz, flutter, or gurgle noise from the muffler. this condition is intermittent and occurs most predominantly when vehicle is warm, or under a light load, between 1500-2000 rpm. *tt | 09/08/2003 | |
Investigations
| NHTSA ID | Manufacturer | Date open | Date close | Subject | Recall campaign | |
|---|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK 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 | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK 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 | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK 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 date | miles | occurences | Purchase date |
|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||
| 04/23/2012 | 104045 | ||
| Recently purchased this 2003 expedition with the 5.4l engine. purchased on 12/20/2011. since owning said vehicle i have had two spark plug failures. on cyl 8 and cyl 3. the first incident happened at a speed of about 25 mph. the second and recent happened driving highway speed, cruise set to 65 mph. the plug ejects from the cyl causing damage to the coil, and possibly creating a fire hazzard. there was no recent tune up to my knowledge. | |||
| 04/18/2012 | 103000 | ||
| Tl-the contact owns a 2003 ford expedition. the contact stated that the vehicle was parked and shut off when he noticed flames erupting from under the hood on the driver | |||
| 04/18/2012 | 103000 | ||
| Tl- the contact owns a 2003 ford expedition. while in his home the contact noticed flames coming from under the hood on the driver side of the vehicle. the fire department was called to exstinguish the fire and the vehicle has not been diagnosed. the current and failure mileages were 103,000. bml | |||
| 04/05/2004 | 25000 | ||
| The transmission has failed twice in my ford explorer, first at about 2500 and now, after a rebuilt engine was installed, at 205,000. as well, i have had differential problems, moon roof issues, paint issues, cracked head, etc. | |||
| 11/19/2011 | 175000 | ||
| While driving on the freeway our enging just turned off with no warning. this has happened 3 tmes. this could cause serious accidents. we do not know the cause of this but i think ford should figure it ot and fix it. | |||
| 04/04/2012 | 95000 | ||
| Tl-the contact owns a 2003 ford expedition. the vehicle was taken to an independent mechanic for an inspection however, the vehicle failed as a result of excessive rust corrosion in the core radiator support bracket. the vehicle had not been repaired. the manufacturer was notified and they informed the contact that there was not a recall related to the defect. the approximate failure mileage was 95,000. kmj | |||
| 04/03/2012 | 104000 | ||
| A month or so ago the truck started running rough and engine light came on. it turns out it was spark plug #4 misfiring. replaced it and all was golden until yesterday (4/3/12) when i heard a loud pop upon starting the truck and then it was idling rough. check engine light came back on and spark plug #4 is misfiring again. we bought this truck used and it's been one thing after another. so disappointed in ford. hope they address this issue and due the proper thing. | |||
| 04/04/2012 | 95000 | ||
| Tl-the contact owns a 2003 ford expedition. the vehicle was taken to an independent mechanic for an inspection; however the vehicle failed as a result of the excessive rust corrosion in the core radiator support bracket. the vehicle had not been repaired. the manufacturer was notified and they informed there was not a recall related to the defect. the approximate failure mileage was 95,000. js | |||
| 04/03/2012 | 104000 | ||
| A month or so ago the truck started running rough and engine light came on. it turns out it was spark plug #4 misfiring. replaced it and all was golden until yesterday (4/3/12) when i heard a loud pop upon starting the truck and then it was idling rough. check engine light came back on and spark plug #4 is misfiring again. we bought this truck used and it's been one thing after another. so disappointed in ford. hope they address this issue and due the proper thing. | |||
| 04/04/2012 | 95000 | ||
| Tl-the contact owns a 2003 ford expedition. the vehicle was taken to an independent mechanic for an inspection; however the vehicle failed as a result of the excessive rust corrosion in the core radiator support bracket. the vehicle had not been repaired. the manufacturer was notified and they informed there was not a recall related to the defect. the approximate failure mileage was 95,000. js | |||
| 04/03/2012 | 104000 | ||
| A month or so ago the truck started running rough and engine light came on. it turns out it was spark plug #4 misfiring. replaced it and all was golden until yesterday (4/3/12) when i heard a loud pop upon starting the truck and then it was idling rough. check engine light came back on and spark plug #4 is misfiring again. we bought this truck used and it's been one thing after another. so disappointed in ford. hope they address this issue and due the proper thing. | |||
| 04/04/2012 | 95000 | ||
| Tl-the contact owns a 2003 ford expedition. the vehicle was taken to an independent mechanic for an inspection; however the vehicle failed as a result of the excessive rust corrosion in the core radiator support bracket. the vehicle had not been repaired. the manufacturer was notified and they informed there was not a recall related to the defect. the approximate failure mileage was 95,000. js | |||
| 04/03/2012 | 104000 | ||
| A month or so ago the truck started running rough and engine light came on. it turns out it was spark plug #4 misfiring. replaced it and all was golden until yesterday (4/3/12) when i heard a loud pop upon starting the truck and then it was idling rough. check engine light came back on and spark plug #4 is misfiring again. we bought this truck used and it's been one thing after another. so disappointed in ford. hope they address this issue and due the proper thing. | |||
| 03/15/2012 | 100000 | ||
| While driving at a low rate of speed, my expedition made a loud pop and then strange knocking noise. upon further inspection i noticed i had blown out a spark plug and my coil pack was blown apart as well. when i called a local ford dealership (thomas ford, stillwater ok) the man laughed and said no it is not a recall, but absolutely should be as this is a very common occurence in the triton motor. i ask that you re-look back into this common problem as this is a terrible thing to overlook. | |||
| 11/11/2011 | 106000 | ||
| Driving home from a near by store i stopped at the stop sign and then got ready to go and heared a loud pop and the car sounded like a dirt bike my husband came to get me and he said that the spark plug blew out since then its been blowing out alot and we have 4kids so a small car wont do i also still pay payments on the car so i don't think its fair!! i saw online that many people have the same problem so please do a recall already i love fords so much but now that this keeps happening i don't think i will ever get a ford again so please recall it please !!! | |||
| 12/28/2011 | 117201 | ||
| My wife was driving with our infant son and our teenage daughter in our 2003 expedition xlt 4.6l 2x4. she heard a loud pop and the vehicle lost power and started smoking and shaking violently. she thought the expedition was going to blow up. we had the expedition checked out and the cylinder number 7 spark plug blew out. the aluminum threads in the head gave and the spark plug blew out, the injector kept spraying raw fuel and the coil ignited it. when all this happened it burned the ignition coil, coil boot, spark plug and the coil harness. now we were told we would have to have the cylinder head replaced. we love our expedition and i considered buying a new one, but i don't know now. | |||
| 09/19/2011 | 75500 | ||
| While driving at highway speeds the engine cuts out/dies. | |||
| 11/19/2011 | 97000 | ||
| After making a complete stop at a traffic light i made a left turn and began to accelerate when i heard a loud pop which at first i thought was a tire blow out. the engine was running so erratically that i could feel it in my steering. we inspected the vehicle for a flat when we noticed every tire was fine. i opened the hood and removed the top cover to the engine to discover a spark plug laying on top of the engine and the coil that was once attached blown off of the plug and damaged off to the side still connected to its electrical source. this cold have caused a fire. for the record these plugs were the original factory spark-plugs. via the internet i have discovered this website to file a complaint. | |||
| 11/01/2011 | 80000 | ||
| Tl* the contact owns a 2003 ford expedition. the contact stated that the vehicle would stall at anytime while in motion. the dealer attempted to repair the defect, but the failure recurred. the manufacturer was not contacted. the failure and the current mileage was 80,000. | |||
| 11/01/2011 | 80000 | ||
| Tl- the contact owns a 2003 ford expedition. the contact stated that the vehicle would stall at anytime while in motion. the dealer attempted to repair the defect, but the failure recurred. the manufacturer was not contacted. the failure and the current mileage was 80,000. kmj | |||
| 08/16/2011 | 104000 | ||
| Tl* the contact owns a 2003 ford expedition. the contact stated that the engine bolts were rotted and causing fumes to enter the vehicle. the contact stated that the smell of the fumes caused difficult in driving the vehicle. the contact took the vehicle to the dealer where the dealer advised that the nickel bolts weakened after time and began to rot. the dealer stated that the failure was common in the particular year, make, and model. the failure mileage was 104,000. | |||
| 09/18/2011 | 83000 | ||
| Blew #3 spark plug after starting up from a traffic light. pulled over to side of road. with vehicle idling, opened the hood, but the vehicle then stalled. called aaa and had vehicle towed to ford dealership. | |||
| 08/16/2011 | 104000 | ||
| Tl* the contact owns a 2003 ford expedition. the contact stated that the engine bolts were rotted and causing fumes to enter the vehicle. the contact stated that the smell of the fumes caused difficult in driving the vehicle. the contact took the vehicle to the dealer where the dealer advised that the nickel bolts weakened after time and began to rot. the dealer stated that the failure was common in the particular year, make, and model. the failure mileage was 104,000. | |||
| 08/16/2011 | 104000 | ||
| Tl-the contact owns a 2003 ford expedition. the contact stated that the engine bolts were rotted and causing fumes to enter the vehicle. the contact stated that the smell of the fumes caused difficult in driving the vehicle. the contact took the vehicle to the dealer where the dealer advised that the nickel bolts weakened after time and began to rot. the dealer stated that the failure was common in the particular year, make, and model. the failure mileage was 104,000. kmj | |||
| 09/18/2011 | 83000 | ||
| Blew #3 spark plug after starting up from a traffic light. pulled over to side of road. with vehicle idling, opened the hood, but the vehicle then stalled. called aaa and had vehicle towed to ford dealership. | |||
| 08/16/2011 | 104000 | ||
| Tl-the contact owns a 2003 ford expedition. the contact stated the engine bolts a rotted out causing fumes to enter the vehicle. the contact stated the smell of the fumes makes it very difficult to drive. the contact took the vehicle to the dealer. the contact stated the bolts are made of nickel and not iron. the dealer stated the nickel bolts weaken after time and start to rot. the dealer stated this is a common problem for this year, make, and model. the failure mileage was 104,000. jo | |||
| 09/18/2011 | 83000 | ||
| Blew #3 spark plug after starting up from a traffic light. pulled over to side of road. with vehicle idling, opened the hood, but the vehicle then stalled. called aaa and had vehicle towed to ford dealership. | |||
| 03/07/2011 | 143000 | ||
| Spark plug striped and blew out of cylinder head on my 5.4l engine. | |||
| 02/06/2003 | 70000 | ||
| Tl- the contact owns a 2003 ford expedition. the contact stated the vehicle has a tendency surge forward while sitting idle in forward or reverse. the contact stated when this happens the vehicle as to be put in neutral or turn the vehicle off because the brakes do not stop the vehicle. the contact thinks the problem is connected to a failure of the throttle body. the vehicle had not been inspected at the time of the complaint. the failure mileage was 70000 and the current mileage was 89187.rl | |||
| 03/20/2010 | 120000 | ||
| Tl-the contact owns a 2003 ford expedition. while driving at approximately 65 mph the vehicle stalled. upon restart it operated as normal. approximately 5 months later the failure recurred while turning at approximately 20 mph. after approximately 20 minutes the vehicle restarted and was taken to an independent mechanic where she was informed they were unable to diagnose the failure. the vehicle was not repaired. the failure mileage was 120,000 and the current mileage was 127,000. sm. | |||
| 08/11/2010 | 88546 | ||
| Tl-the contact owns a 2003 ford expedition. the contact stated that while driving approximately 55mph the vehicle begin to smoke from the engine compartment and inside the vehicle. the vehicle also made a loud noise and the engine eventually stopped. the vehicle was towed to a ford dealer where they advised a spark plug had melted into the engine and the vehicle would need a new engine at the owners expense. ford motor company was contacted and they stated there was nothing they could do. the vehicle has not been repaired. the failure and current mileages were 88,546. rd | |||
| 06/13/2010 | 85000 | ||
| Spark plug ejecting from my 2003 ford expedition 5.4 triton engine. 3rd plug that has shot out. | |||
| 08/13/2009 | 49688 | ||
| I have an 2003 ford expedition suv, the spark plug in the #3 cylinder head pops out every 5-8k miles. resulting in a loss of power, per the 3 dealerships i have spoken to as well as the b.a.r ford is aware of this problem and refuses to fix it. per the b.a.r. it is an casting/manufacturing defect. im worried that i will be on the freeway and loose power, and get in an accident due to not being able to exit the free way under my own power. the problem goes back to the 2000 model year. i have had the car worked on at the ford dealership 2 times to correct this issue,and it is currenly broken again. the dealer ship refuses to fix it as an warranty on their repair done on 8/13/09 or as an factory defect from ford direct. dont know where else to turn, any help or direction would be greatley appreciated. troy troutman sr. 3011 rossmore way san jose ca. 95148 | |||
| 04/19/2010 | 79850 | ||
| We own a 2003 ford expedition eddie bauer. in january 2009, we had a misfire in the #6 spark plug and was advised to change all of the spark plugs - which we did. since that time, we've had 3 other misfires in the #6, #8 and #7 spark plugs. each time a repair is made, there is a misfire in another spark plug within 3 months of the repair. on 4/19/2010, the number 4 sparkplug blew completely out of the engine upon starting the car. we have had the vehicle serviced regularly at the ford dealer and all repairs have been made by the ford dealer. we've been told that ford knows of the design defect in their engines and it is a regular problem with the v8 engines in the ford trucks and they are choosing to do nothing about it. we have spent well over $3000 total to fix all of these issues. why isn't ford standing behind their product - are they waiting for a injury or worse, a fatality in order to issue a recall? | |||
| 03/11/2010 | 112000 | 1 | |
| My 2003 ford expedition threw a spark plug. *tr | |||
| 02/18/2010 | 108780 | 1 | |
| I was stopped at a light. i went to go and i heard a pop,so i went under the hood and i could see the last spark plug in the rear on the passenger side firing. *tr | |||
| 02/04/2010 | 69000 | ||
| My husband was driving his 2003 ford expedition on the way home from work on feb.4,2010. he heard a bang and smelled a small vapor of gas along with the truck not running very well. he made it home safely to find that spark plug blew through the head!! we went online to see about this problem,and what could be done. he has only 69,000 miles on it and he is the original owner and takes care to keep up on everyday mainentance. i have made phone calls to no avail--ford cistomer relationship center told me to take it to the dealer or reputable service center. this is not covered under any warranty at all!! so i am going further with this because if you go to get it fixed--(a) it could happen again and (b) a fire could start, and (c) very expensive to get fixed. we have read many other consumers have had this same problem but fords does'nt want to help out. this is a safety issue that needs to be addressed before worse scenarios happen with possible deaths. to make matters worse, i own a 2004 f-150 and have read stories of it happening in those engines too! | |||
| 01/02/2010 | 108000 | 1 | |
| 2003 ford expedition spark plug blew out of cylinder head. apparently a common problem that needs to be readdressed. *tr | |||
| 02/01/2010 | 82421 | 1 | |
| My ford expedition has less than 90,000 miles and the spark plug for #3 cylinder fell into the cylinder chamber thus the piston was hitting the spark plug ,this repair can cost as much $1800.00...for a spark plug that cost around $5.00 on a suv that cost $50,000.00... this could have caused a fire since the piston was pushing into the engine compartment, a fuel air mixture, plus, the presence of electrical spark are a perfect mixture for a fire... !!! i was charged $ 689.00 for a tow back to my home. i want this problem to be addressed by ford asap before someone loses their life!!!! a recall is in order! i want ford to pay for my repair and towing bill because this is an engineering flaw and it is extremely hazardous!!! contact me please! i hope this can helps other expedition owners. *tr | |||
| 09/30/2009 | 95786 | 1 | |
| My 2003 expedition, with the v8 5.4 trition engine, is being declined to be fixed by local ford dealerships, due to the fact of the known issue, with the spark plug, they want me to pay for the fix of the heli coil which isn't a guarantee and then hope it works, if not it will be a rebuilt engine, the first time the spark plug blew it was at night, upon starting, sounded like gun fire, had vehicle towed and then researched it on the internet for solutions, found out what it was and then replaced the spark plug and ignition coil and then hoped it would stay, upon starting it , it did it again, bought more spark plugs and ignition coils, and got it to seat better, and then 4 weeks to the day while driving is when it made the same sound like gun fire and we knew then what it was, pulled over on a highway and proceeded to look and see what damage had been done, once again a spark plug and a new ignition coil, however this time the spark plug was vastly discolored and burnt in appearance, 1 week and 1 day later upon starting it does it again, and this time no spark plug can be put in, there are no more threads is what i was told by my mechanic, they told be they will have to remove the engine to put the heli coil in, and that isn't a guaranteed fix, also that i should just replace the engine, since it can and probably will continue to happen again, i had the auto towed to my residence and i began to research my options, i called all the ford dealerships in which they said they could do the heli and there is not a guarantee for this to work, so at what cost is a human life to ford? per the info and research it does say that it can catch fire, and explode.....or pay a fortune for a car that can't be fixed. we do have some of 6 the spark plugs that have shot out, i am told because it is the 3rd plug near the firewall that the angle is not approachable....help now! *tr | |||
| 10/06/2009 | 100070 | 1 | |
| 2003 ford expedition spark plug # 2 blown out. *tr | |||
| 09/12/2009 | 105000 | ||
| Tl*the contact owns a 2003 ford expedition. the contact stated upon inspection of her vehicle, she noticed that the spark plug ejected from the engine head on the passenger side near the firewall. if this occurred while driving, there is a high risk for a vehicle crash. the vehicle is in the process of being taken to the dealer for diagnostic testing. the manufacturer was notified, but she was not provided with any recourse. the failure and current mileages were 105,000. | |||
| 09/10/2009 | 96000 | 1 | |
| My 2003 ford expedition just blew a spark plug out of the cylinder head. it was the second to last cylinder passenger side. there was raw fuel and vapors coming into the engine compartment and a fire could have started had a spark ignited those fumes. these are the factory plugs and factory head and the ford dealer commented that this was a fairly common issue but that ford has not issued a recall yet. now i am out $2800 for what seems to be a defect in the design of the head. *tr | |||
| 07/15/2009 | 71000 | 1 | |
| Spark plug blow out on 2003 ford expedition 5.4 l engine. *tr | |||
| 06/15/2009 | 1 | ||
| While driving my 2003 ford expedition eddie bauer one of the eight spark plugs blew out of the engine. *tr | |||
| 06/01/2009 | 86882 | 1 | |
| I own a 2003 ford expedition with a 5.4,and while driving around town we noticed the vehicle started running rough,so we took it to a local shop to have it looked at and upon inspection we found that the number 7 plug had blown out and caused damage to the coil which caused the rough running,the mechanic at the shop said this is very common with these trucks and motors,so at the cost $700 i got it fixed with the understanding that this could happen again because of the way these motors are made. *tr | |||
| 05/13/2009 | 135000 | 1 | |
| While driving on a local road in clear weather my 03 expedition suddenly threw plug #7. in so doing it destroyed the coil assembly, but the impact of the coil assembly on the fuel rail saved the car's hood from further damage (the top of the coil assembly clearly evidenced the impact mark from contact with the fuel rail). given the fact that the damaged coil insulation was now arcing its spark across the engine head and that the fuel mixture was spewing out of the spark plug hole it's surprising that we avoided an engine fire under the plastic shroud. i had the car towed to the local independent service center (pep boys, laurel md - the same location that had changed the plugs a year prior). they examined all the spark plug threads and advised that they appeared ok, with the exception of this one cylinder. to effect repairs they advised to have the vehicle towed to another outlet 36 miles ($104 charge) up the road. they further advised that this is not an uncommon problem with the 5.4 engine and that this may occur in other cylinders in the future. ford customer assistance (800#) disclaims any knowledge of this being a common problem and referred me to the local dealer for technical advice. at the local dealer, the mechanic was very familiar with the issue, pronounced it rather common and advised that ford would be happy to repair the problem, however his estimate would cost me more than twice the estimated fee from the independent (inclusive of the additional tow costs). subsequent google searches for ford expedition thrown spark plug reveal 11,200 web page hits. the webpages at the 1st hit alone, www.consumeraffairs.com/automotive/ford_spark.html reveals a litany of very similar complaints over a number of years, some of which have resulted in more tragic consequences. given the danger represented by potential engine fires and the apparent frequency of the problem why has there not been a recall to effect the correction of this apparent defect. *tr | |||
| 02/11/2009 | 107025 | 1 | |
| The spark plug coil on my 2003 ford expedition was ejected from the cylinder causing my vehicle to become disabled. my wife was stranded alone in an unfamiliar neighborhood. after researching the problem i have found that i am only one of thousands of people who have had similar problems regarding the stability of the spark plug and the problems that can occur as a result of the unexpected and totally sudden ejection of the coil. how many people will be forced to submit to the predatory practices of most repair shops until something is done? there is obviously a major problem here and action must be taken. so far this has cost me one hundred dollars and who knows how much it will cost to fox it right. the way is should have been when it was manufactured. i have read this is believed to be a result of a flaw in the design of the cylinder heads and the number of incidents should warrant an investigation into the design and ford's response to the number of vehicles disabled by this error. *tr | |||
| 01/14/2009 | 90000 | 1 | |
| Purchased a used 2003 ford expedition with a triton 5.4 v8. the car had about 80,000 miles when i purchased it and at about 84,000 miles a sparkplug ejected out of the engine. the repair was around $650 for a not for sure fix. apparently the threads that hold the sparkplugs in had stripped, causing the blowout of the sparkplug. i was told by the mechanic at our local ford dealership that the permanent fix would require the replacement of the heads at around $4000. i opted for the cheap fix because of the lack of financing for the more expensive repair. i did a search on the internet and found that many other consumers who had purchased for suv's and trucks with same model engines were reporting the same problem in overwhelming numbers, many with multiple blowouts at various incidences. i was hoping my problem was confined to only one cylinder but at around 90,000, 5 1/2 months later, another sparkplug blew out. now the repair was even more due to a new part that is to provide a more permanent fix. this time the repair was $830. knowing that this was an issue with these model engine i asked my local ford dealer's service man if ford knows about the problem, why don't they fix it? his reply was that the problem is not a danger so no recall has ever been called. the guy went as far as telling me that the problem is caused by improper threading into the head. the threads were machined to shallow and eventually they become loose and finally blowout when the thread completely fail. i think if you investigate this further you will see that in more than one instance the ejecting sparkplug has severed gas lines and caused fires. not exactly what i consider to not be a danger. ford admits non fault on their part even know they know they have sold a faulty product in mass numbers to an enormous amount of people and businesses. *tr | |||
| 12/27/2008 | 89000 | 1 | |
| In less than seven days, two spark plugs blew out of my 2003 ford expedition engine. it is a 5.4l triton engine. both occurrences were while driving normally down the interstate. the consequences were sudden loss of power while driving on the highway both times. i went from driving 70 mph to 45 mph in a matter of seconds with my wife and 9 month old baby in the vehicle! ford knows about the problem and has issued a repair report, but not a factory recall. the issue is a flaw in the engine design or manufacture; thousands of others have reported the same issue (a quick google search of ford 5.4l spark plug blowout demonstrates this). had there been traffic behind or beside me, we would have caused an accident or worse. since ford knows of the issue, they ought to pay for the repairs or replace the engine at their expense. i no longer trust my vehicle. the repairs for this one issue have cost me approximately $1,000 to date, and there is no guarantee it will not happen again. *tr | |||
| 12/06/2008 | 165000 | ||
| Tl*the contact owned a 2003 ford expedition. while driving less than 60 mph, the contact noticed smoke underneath the hood in addition to a strong burning odor. she was able to maneuver the vehicle to safety. she lifted the hood with another person's assistance and heard crackling and sparkling sounds. she also noticed a hole in the insulator directly into the hood of the vehicle. there was a recall on other years, makes, and models, but none for the contact's particular vehicle. the origin of the fire has yet to be determined. the failure and current mileages were less than 165,000. | |||
| 10/22/2008 | 100008 | 1 | |
| At 92,000 about miles the passenger side plug blew out. i put jb. weld around the plug and put it back in the truck. it worked for 3 months and now its done it again. i am now out of work and my wife can't make it to here job because of the truck. so i am looking for a heli coil repair kit. but no way to go and get it i have one truck. so i don't know what to do next. *tr | |||
| 09/22/2008 | 1 | ||
| My wife was almost to the end of the off ramp to the 210 freeway and heard a loud pop and then an awful noise. it sound like she blew a hole in the exhaust manifold. it turned out to be the #3 spark plug being ejected from the engine. we purchased the vehicle from the dealer and have never changed plugs. we were fortunate that it happened local and not on the road for vacation. the truck was towed and repaired and a tune up down. an expensive day and needless time off work for a problem that seems to due to bad engineering. a tapered spark plug and 1/4 thread lock in the head is not a safe and smart design. a 3/4 thread lock would be much better. *tr | |||
| 09/20/2008 | 71221 | 1 | |
| Spark plug blew out of engine head on a 2003 ford expedition with a 5.4l engine the spark plug blew out of the engine head and gasoline were expelled on the engine and exhaust fumes into the passenger compartment. the engine head had to be repaired at a cost of $1,832.48. *tr | |||
| 09/18/2008 | 100000 | 1 | |
| Today is the second time we have had a spark plug blow out of the cylinder of our ford expedition. the first time it stranded my family in the mountains of southern california in the winter. we are supposed to go away for a weekend trip tomorrow. it cost us 3k the first time and today's quote is about the same. this is very dangerous and unbelievable given the amount of occurrences that nothing is being done. this is bs! ford is digging their own grave and if someone dies due to this happening it will cost them more than money....blood on their hands. *tr | |||
| 09/06/2008 | 66687 | 1 | |
| The # 1 spark plug on my 2003 ford expedition blew out and stripped the threads and broke the coil. *tr | |||
| 08/12/2006 | 112000 | 1 | |
| Original and 2nd ford engine blew. 1st threw a rod, 2nd block cracked and ruined engine due to rapid coolant loss. dealers offered no warranty as both engines blew at 112,000 and 120,000 respectively. this car was very well maintained and received routine recommended service for oil and fluid changes. *tr | |||
| 05/05/2008 | 50000 | 1 | |
| No warning. engine stop. at least a dozen times.no body at ford will admit there is a problem. *tr | |||
| 03/26/2008 | 81461 | 1 | |
| While driving 2003 ford expedition spark plug blew out and truck reduced speed. the incident caused damage to the engine - which required replacement approx. $6,000.00. i asked the downey ford dealer if this was a manufacturing defect? they replied: they did not know although the truck was not on recall. this defect - blown spark plug may cause excessive injury and or death if this were to occur on the freeway. *tr | |||
| 03/09/2008 | 2 | ||
| December 15, 2007, my 2003 ford expedition's spark plug was blown out. leaving my three kids and myself stranded on the highway. after paying $1,200 to get it fix, on march 9, 2008 the same thing happen. *tr | |||
| 02/28/2008 | 119282 | 1 | 12/11/2002 |
| 2003 expedition 5.4l engine. production date 10-08-02 . having oil leak from right head gasket diagnosed by ford. i believe problem is related to tsb 02-22-7. this should be a recall and repair expenses covered by ford / manufacturer. *tr | |||
| 11/24/2007 | 60000 | 15 | |
| My 2003 ford expedition is shutting off while i am driving, nearly causing me to lose control and be rear ended. it happens when i least expect it and the dealership is baffled. all their expensive diagnostic equipment can't even track down the issue. so far they have replaced some fuel parts and my fuse box but it still shuts down unexpectedly. i am $900. in the hole already, let alone i am going to have my first grandchild within a week, and i have this tank that shuts down on the middle of the highway. it sounds electrical and i am in fear of catching fire. *tr | |||
| 06/10/2007 | 81175 | 2 | 04/01/2003 |
| Vehicle underwent normal driving. 2. suddenly upon starting the vehicle a loud popping noise from the engine compartment was heard. there was loss of power, and would continue whenever the engine started. the odor of gasoline and oil was emitted into the vehicle. the vehicle had to be immediately brought into a ford dealership. instead of replacing the entire head as required by ford , helicoil, spark plug, and ignition coil had to be installed by the dealership. *ak | |||
| 05/12/2007 | 64000 | 2 | 02/12/2007 |
| 64000 on 2003 ford expedition blew the #2 plug while traveling at highway speed and cruise control on. had a hela coil put in. contacted the dealer, no response, 2 weeks later 68000 blew the #3 plug sitting at a traffic light again had a hela coil repair. again no help from the dealer, and told there was no open recall on that motor . i am filing a complaint with the attorney generals office in minnesota. both repairs were done at a different ford dealership, they stated replacing the head wa s the correct fix, but ford allowed them to do hela coils, but imagine that, they won't warranty it !! *ak | |||
| 04/13/2007 | 59022 | 1 | 11/22/2006 |
| On april 13, 2007 my 2003 ford expedition with the 5.4 liter triton engine blew out the #3 spark plug destroying the threads and requiring a total head replacement. the cost of this repair, in spite of the fact i purchased the extended warranty, was $3655.22. upon further research i have found that apparently this is a very common occurrence affecting thousands of ford owners. *tr | |||
| 02/10/2007 | 73000 | 1 | 09/01/2004 |
| Wife was driving the 2003 ford expedition with 73000 miles on it when loud popping noise was heard, upon examination sparkplug was found to have been ejected from the engine block repair at closest ford dealer was $3000. *ak | |||
| 08/07/2004 | 1 | 07/09/2003 | |
| Dt: the contact says that his engine is stalling at anywhere from 45-70mph. the engine stalls while he is trying to accelerate. there is no prior warning to the failure. the engine just completly shuts off. it takes it a couple of minutes after the failure for his engine to start up again. the engine is an automatic transmission and it has done this to him at least ten times. has came very close to having accidents because of this problem because he has know warning to get out of the road.*ak | |||
| 04/01/2005 | 1 | ||
| 2003 ford expedition caught on fire while parked. *mr the consumer expressed a concern about any risk or danger of sudden short circuiting, sparking, explosion or fire with parking this vehicle, when one day while sitting in their kitchen, they heard a loud rumble emanating from the rear of the house when they saw the front of the vehicle engulfed in flames with the hood blown off. the fire also spread to the consumers home consuming most of it. *sc *jb | |||
| 01/01/2005 | 33000 | 4 | 02/16/2004 |
| Vehicle stalled intermittently and without warning while driving 40 mph up to 70 mph. vehicle had been to the dealer on three separate occasions, and they were unable to duplicate the problem. *ak | |||
| 06/30/2004 | 4000 | 4 | 09/21/2003 |
| Car stops running while driving a speed. this has happened 4 times in the last 9 months. the dealer cannot correct problem until it is reproduced. *ak | |||
| 10/02/2003 | 8000 | 5 | 09/11/2002 |
| I purchased a 2003 expedition in september of 2002. i reported a vibration in steering wheel and brake pedal, a clanking noise in the front end, along with a slippage when taking off as vehicle seems to not want to respond when pushing on the gas. they stated the engineers were aware of problem and where working on it. the vehicle has been taken in several times, but these problems still exist. on the 2 appointment for my vehicle i stated to the service area that my brake pedal would go to the floor, and i would have no brakes. they told me my brakes were fine although this has happened twice while driving ever since. as of oct. 9, 2003 they have had my vehicle a week, and are stating they do not know these problem existing with any other expedition so they are unsure how to fix the vehicle. at your website that is not true, as i have seen several reports of these same problems on the same vehicle as mine. i am very concerned for mine and my children's safety. *la | |||
| ENGINE AND ENGINE COOLING - COOLING SYSTEM | |||
| 07/01/2007 | 20000 | 1 | |
| First, the door ajar light came on and stayed on. i continued to go around the vehicle opening and shutting the doors and the light remained on. consumer could not start the vehicle since the light came on, and had to get a jump to start it. after a few days of this the battery was finally ruined, and i was forced to buy a new one. i used lubricants to try and clear debris from the door sensors and this worked for 3 months. now it will not work at all. talked to dealer and they want to charge 600 dollars per sensors. nothing wrong with sensor its just dirty. second, the rear ac is making a clicking noise and will not control temperature. i sent it under warranty to the dealership and replaced the ac mechanism, stated this was a common defect with the vehicle. 5 months later this part went out again and it was no longer under warranty and the dealership would not replace the problem and wanted to charge me over 300 dollars. they apparently replaced the defective part with the same defective part and would repair it again 5 months later!!!. third, the side panels on the expedition exterior started fading at about 20,000 miles. the dealership replaced them under warranty. about 20,000 miles later we noticed they had faded again. we took it to the dealership and they would not replace the defective panels this time because it was know longer under warranty. even though it was another defect replaced with a defective part. forth, the rear passenger exterior door/window trim is bubbling and peeling off. this looks horrible! fifth, the front passenger and font driver window switches that roll down the windows are having issues. i had the motor replaced for the passenger window and it fixed the issue for a little bit. now the passenger can not roll down the window. however the driver can??? please help! i need help with any or all of these issues. i don't know where else to go! *tr | |||
| 11/26/2007 | 1 | 08/30/2003 | |
| Going in the highway the oil pump just stopped working and the engine was damaged, stopped in the middle which was one of the most dangerous situation i have lived. *tr | |||
| 12/20/2003 | 6 | 06/01/2003 | |
| While making a stop, the check engine light appeared on the dashboard and remained on. the vehicle was taken to the dealer for inspection numerous times, but the mechanic could not duplicate the problem. while applying the brake pedal, the vehicle failed to stop completely. the vehicle was taken to the dealer for inspection, and the mechanic determined that the brake rotors needed to be replaced. *ak when stopping, the motor starts shaking and the vehicle would shut off. when turning the vehicle, it would not respond until attempting 2 or 3 times, then finally a lot of smoke appears. the suspension appeared to be loose and one sensor on the wheels did not respond. *sc | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 07/08/2011 | 110000 | ||
| My best friend's 2003 ford expedition blew a spark plug out of the cylinder head while pulling a boat across a highway. this caused the vehicle to be stuck in the middle of the road, and several cars had to slam on their brakes and swerve to barely avoid collision. upon internet research, i learned that thousands of people had the exact same problem with this same engine in ford vehicles over several years of production. ford denies this problem exists and endangers lives everywhere with this motor. i saw this problem myself, and mechanics i have talked to said that these ford cylinder heads are all bad with this problem. this problem exists for every ford triton 5.4 liter v8 engine, so it exists across thousands of vin numbers. | |||
| 11/03/2010 | 101000 | ||
| Oil leaking from head gasket on passenger rear of head..... leaks onto manifold where a fire can start. ford mechanics know that there is a problem. the mechanics say that there is a flaw in the casting in the head. there are numerous complaints of this happening | |||
| 07/13/2010 | 113000 | ||
| Tl- the contact owns a 2003 ford expedition. while traveling 55 mph the contact noticed that the vehicle had suddenly shut off without warning. the vehicle was taken to the dealership where the contact was informed that the vehicle was performing normally. there were no prior warnings. the failure mileage was 113000 and the current mileage was 117000. bml | |||
| 08/21/2010 | 103000 | ||
| Sudden backfire resulting in spark plug ejection. replaced with helicoil kit. | |||
| 04/02/2010 | 78000 | ||
| Spark plug ejected fron the engine causuing the coil to brake as well, and the whole car to smell of gas. this happened once in april, and again the other day (may 17th), on a different plug. it has caused me to lose work, and my mechanic installed a repair kit with a new spark plug. it was $200-$300 for each repair. ford says its not a problem, but my mechanic has had other cases like this, and stated ford issued a service bulletin on how to fix the problem. i have contacted ford, asking them to at least check my other plugs to make sure they are tight, but they were unhelpful. there was no warning in either case. the truck drives fine, and then suddenly starts making a loud noise as its driven, and the whole truck smells of gas. these are the original plugs, and the truck has 78k miles on it. i believe the head needs to be replaced so it doesn't keep happening. i went on different car problem websites, and this seems to be a problem with this model truck. | |||
| 05/15/2010 | 123789 | ||
| I have a 2003 ford expedition 5.4l that has blown the #3 spark plug 3 times. each time i have purchased oem plugs. it appears that i am not alone in this experience and many speculate that the thread depth is not enough to secure the plug appropriately. | |||
| 04/05/2010 | 108023 | ||
| Spark plug had blown out of its place in the engine. at first, i had the check engine light on and i had promptly taken to the shop (ase cert.) but the light didn't come on any more. after the service man ran the test some time later, nothing appeared to be wrong. a day or so later, i was hearing a clicking sound under the hood, later, i had lost a spark plug. which by the way is a horrible noise! i was told by the service techician that it was a problem with ford vehicles. | |||
| 02/04/2010 | 77000 | 1 | |
| Ford spark plug ejection, 2003 ford expedition 5.4l triton engine. consumeraffairs.com has 317 pages of complaints regarding this issue. ford does not acknowledge a problem. i have had two (2) blow-outs, costing me $1,200.00 i would like to see a petition for recall started, based on potential fire and safety issues. in my case, i was traveling at 60 mph and lost power while in traffic. i had to carefully pull off highway with very little engine power. this is a serious issue which needs to be addressed. i now own a vehicle that i can not take on a long trip, for fear of having the engine explode again. hopefully, it will not take a fatality or serious injury to have someone review this problem and take action. the february 21,2007 memo from dot, ref: dp05-005 review is in need of updating. the numbers are now much greater than previously reported. please review this problem. ford simply says not my problem. [xxx] *tr | |||
| 02/18/2010 | 81023 | 1 | |
| 2003 ford expedition eddie bauer, spark plug on passenger back side ejected from head while i was driving. they were still original spark plugs. going to cost over $1000 to temporarily fix problem. *tr | |||
| 02/05/2010 | 72955 | ||
| 1st occurance: 2003 ford epedition, 5.4l v8 engine. factory original spark plug exploded while travelling at 60mph.mileage: 72,955. date: 8/17/08. 2nd occurance: same engine, original plugs( less above repair). 2/05/2010, miles 77,525. spark plug exploded while travelling 40 mph. | |||
| 01/06/2010 | 82000 | 1 | |
| My 2003 ford expediton was making a slight tapping noise all day as i drove around town. when i hit my home town i was a .10 of a mile from my house and a huge banging noise occured. the vehicle lost power and i could smell gasoline vapors. from inspection under the hood i noticed the coil assembly above in the right rear cylinder was broken and the spark plug was laying on the motor. it had blown a spark plug. i had purchased an extended warranty when i purchased the vehicle. i had the car towed and was told they would inspect for repairs. the car was sub-letted out to a ford dealer. the ford dealer said that a helicoil repair was what was once accepted but their dealership no longer performed that procedure because it was only a temporary fix. ford put out a service bulletin that said the best repair is to replace the head but a helicoil type repair would suffice. because of this temporary fix announcement and ford's inablilty to admit there is something wrong with the triton motor built between 1997 and 2008 my extendede warranty company will not make the best recommended fix. ford needs to be held accoutable. i do not want to put my family of five at risk of breaking down and possible engine fire because of this defect. *tr | |||
| 04/06/2009 | 104000 | ||
| Tl*the contact owns a 2003 ford expedition which was purchased new in 2003. the spark plugs were blowing out of the head gasket and causing the coils to break. this failure has occurred three times within 8 months. the dealer stated that the vehicle would cost over $1200 to repair at the owner's expense. there were no recalls on her vehicle nor for her particular model pertaining to the failure. the failure and current mileages were under 104,000. updated 2/22/10 *cn | |||
| 01/04/2010 | 113000 | 1 | |
| 2003 ford expedition 5.4l v-8 engine blew a sparkplug out of the cylinder head. *tr | |||
| 11/24/2009 | 123232 | 1 | |
| One of the spark plugs blew out of the head while i was driving on the highway. there was no external damage, however internal damage to the engine is unknown. this could have started a fire under the right circumstances as raw fuel was being blown through the spark plug hole. this vehicle has the original spark plugs, so this is not a case of someone putting too much torque on replacement plugs. this is a serious issue and after reading the posts on the internet from other ford owners that have had the same problem, i am convinced that ford needs to do a recall. *tr | |||
| 10/30/2009 | 76864 | 1 | |
| While driving my 2003 ford expedition down the freeway @55 mph noticed a loud pop and a weird noise. stopped vehicle, popped hood and inspected. found #5 coil hanging by harness and #5 plug sitting on manifold. plugs are original as the truck has on 76,000 miles. no other damage noted. will helicoil the hole using a kit for this specific problem. | |||
| 09/04/2009 | 102000 | 1 | |
| I have park my truck and went to have dinner with my family and upon my return when i start my truck. the engine make a loud sound and spark plug blow out from the engine. *tr | |||
| 09/05/2009 | 117000 | 1 | |
| My 2003 ford expedition blew a spark plug out of the engine today. after reading about events leading up to this failure, my auto was acting exactly like all the others. a slight ticking sound while the engine idles. while driving 20mph, a slight loud bam occurred and the engine began to idle hard. the car was towed 70 miles to a repair center near my home and i now am to decide on a new manifold or a coil repair that is risky. how a company can operate with critical engine part that are so poorly designed is beyond my imagination. the internet is filled with complaints of spark plugs popping out of engines in f150s and explorer/expeditions. it is a shame that such a simple thing as engineering a thread deep enough to hold a spark plug in place for the life of a car is too challenging for a car company. this repair should be the responsibility of the manufacturer. they were able to handle replacing millions of firestones and should be held to a standard close to their reputation as a tough vehicle. without recourse, ford will find it acceptable to cut corners and engineer sub par part. *tr | |||
| 08/01/2009 | 94000 | 1 | |
| 2003 ford expedition 5.4l ejection of factory spark plug form cylinder head. *tr | |||
| 03/17/2009 | 99876 | 1 | |
| Driving from las vegas to phx we were at wickenberg, az a loud pop occurred and knocking sound from the engine. the smell of gas was present and wouldn't run properly. the ford dealership in wickenberg was luckily open and instructed us that the spark plugs had blown out in the 1st and 2nd cylinders. they did also tell us that this occurs often in and there is a temp fix for it. they tapped out the head and inserted a steel sleeve for those 2 cylinders. taking 2 hours it was fixed and we were on our way very happy to have it fixed but not happy at all at ford for having such a blatant design flaw. this needs to be fixed. *tr | |||
| 03/12/2009 | 65000 | 1 | |
| I have a 2003 ford expedition with a 5.4l engine. was driving the truck when i heard a pop and the engine started to misfire. spark plug no. 7 had been ejected breaking the coil. i have owned the truck since it was new and it has been well maintained, only 65000 miles. i have read many of the other complaints online and i'm amazed at the numbers of issues with this engine. this was obviously a bad design that spans a number of years. *tr | |||
| 08/01/2007 | 58400 | 1 | |
| My 2003 ford expedition blew a spark plug completely out of the cylinder head without warning. this happened while driving at almost 65 mph, and the engine stalled, causing a very dangerous condition. the vehicle had less than 59k miles at the time of the incident. it cost me over $4k to repair, and i now find out that this has happened to thousands of owners with ford triton motors from 1999 to 2004. *tr | |||
| 06/01/2008 | 99000 | 1 | |
| I have a 2003 ford expedition and have had 3 spark plugs blow causing the cylinders to misfire. in each case, i have the car repaired and each time it was a different spark plug to blow, not a previously fixed one. *tr | |||
| 03/12/2008 | |||
| Tl*the contact owns a 2003 ford expedition. after inserting oil into the engine, the oil level abnormally depleted shortly afterward. the vehicle was taken to the dealer on several occasions, but they could not determine the cause of the failure. the failure mileage was unknown and the current mileage was 93,000. | |||
| 12/15/2008 | 97222 | 1 | |
| Coil #1 misfire & had to be replaced. mileage 97,000. *tr | |||
| 11/15/2008 | 53000 | 1 | |
| I have experienced the | |||
| 08/22/2006 | 86000 | 1 | |
| My 2003 ford expedition blew the #3 spark plug on august 22, 2006. the triton 5.4 liter engine has 86k+ miles. the dealership informed me that this is a known problem that ford refuses to acknowledge. i have been a loyal ford customer purchasing 12 ford vehicles over the past 32 years. it is time for the ford motor company to take ownership of this problem and at least take care of their customers that have experienced this defect. my replacement cost of the engine was $5,400.00. *tr | |||
| 11/10/2007 | 66000 | 1 | |
| As i was driving, my vehicle made a loud pop, and then a rattling sound. i immediately pulled to the side of the road, and popped the hood to see what was going on, and noticed that my spark plug had ejected out of the cylinder head. i then had to walk approx 1/2 mile (while i was 8 months pregnant) to call a tow truck to have my vehicle taken to a mechanic. the mechanic reported that the plugs that were in were factory, and informed me that this was a very common problem among fords. the mechanic replaced the plugs with a healing coil, and then informed me that this was not a guaranteed fix, it was more like putting a band aid on the problem, if i wanted to guarantee the issue was fixed, that i would need to replace the head. i opted to replace the plugs because they were considerably cheaper, and about 5 months later, i experienced the same problem again. since i was quite a ways away from the mechanic that had previously worked on it, i took it to a different shop. they fixed the problem by putting an insert in, and charging me an additional $300. *tr | |||
| 06/08/2008 | 87628 | 1 | |
| I was driving to a ballgame when i heard a loud pop. i pulled over to determine the problem. i opened the hood to notice the #3 spark plug in my 2003 ford expedition 5.4l v8 was flopping around on top of the hood. i had the vehicle towed home. i took my vehicle to the local ford dealership and was told that the entire right side head needed to be replaced from this one spark plug blowout. after doing research on several online websites, forums, and blogs, i have determined this is a major problem with the design of the ford engine. numerous complaints have been made from ford owners about this same problem. *tr | |||
| 06/17/2007 | 95000 | 1 | |
| Tl*the contact owns a 2003 ford expedition. while driving 80 mph, the vehicle caught fire under the hood. the contact stated that the air conditioning shut off and the blower produced warm air before the fire occurred. he smelled something burning and he shut down the engine completely. the contact then noticed smoke coming from the defroster vent under the windshield. the state police and fire department arrived and extinguished the fire. the vehicle was towed from the scene. the vin, purchase date, and engine size were unknown. the current and failure mileages were 95,000. | |||
| 01/10/2007 | 71880 | 1 | 04/10/2006 |
| While driving along i suddenly heard a loud 'bang'. thinking it must be a flat tire i pulled over to inspect my tires. after i found no issues with my tires, i noticed that the noise was in fact coming from my engine which also smelled as if something was burning. after having the vehicle towed to be inspected, i was advised that the aluminum around the spark plug had melted and i needed a new head replaced which will cost over 3000 dollars. they initially thought the spark plug had ejected. what will it take to have ford stand behind their vehicles? *jb | |||
| 12/28/2006 | 55300 | 1 | |
| Driving normally. #3 spark plug blew out damaging ignition coil and ruining threads. this seems to be a frequent problem with these ford truck engines. | |||
| 11/02/2006 | 1 | 06/01/2002 | |
| Dt*: the contact stated while traveling 65 mph on normal road conditions, a loud popping sound was heard. the contact pulled the vehicle to the side of the road and had it towed to a local dealer. upon examination, it was determined that the spark plugs blew due to inadequate engine design of the threading. the vehicle was not included in a recall due to the vin. the dealer replaced the spark plugs and threading. the contact encountered similar complaints about the engine and engine cooling:engine that related to the contact's issue. | |||
| 05/12/2006 | 18 | 1 | 10/01/2004 |
| 1.) i was just driving the vehicle and the spark plug blew out of the engine. 2.) i have a 2003 ford expedition 5.4 l triton v8 with 78,000 miles and the spark plug blow out of the engine. 3.) a ford dealer is replacing the head on my expedition, cost $3000. *jb | |||
| 01/18/2006 | 105000 | 1 | 01/15/2005 |
| On january 18, 2006 i was driving my 2003 ford expedition with a 5.4l triton v8. just south of chicago the engine blew a spark plug from the #5 cylinder. ford wants $4500 to repair and seems to believe that there is no known problem. this could have resulted in fire since the plug was out of the engine and the injector was still firing putting raw gas in the cylinder. i could smell the gas. if it had spilled out onto the engine, a fire could result. ford has no interest in repairing this problem. *nm | |||
| 04/08/2005 | 59646 | 1 | 02/11/2003 |
| A spark plug blew out of my 2003 ford expedition and mess up the whole engine, requiring replacement of both heads. ford denies it was a engine problem, but there are thousands of incidents like mine around the country. *nm | |||
| 11/18/2003 | 10000 | 17 | |
| Consumer was at a stop in traffic while gradually the vehicle moved up. upon depressing the brakes the pedal went to the floor and would not stop the vehicle. this problem occurred more than ten times in the last six months. also, while driving at any speed the engine check light and battery light came on. sometimes, the lights blinked rapidly, and sometimes they would just stay on. dealer examined the vehicle seven times, and was unable to resolve the problem. *ak | |||
| 1 | |||
| When starting the vehicle the consumer noticed that the engine would not turn over. *ak | |||
| 10/02/2003 | 1 | ||
| While driving at 70 mph and with no warning vehilce stalled, causing the consumer to pull off the road. the dealership has been contacted. *ak | |||
| 04/12/2003 | 1 | 10/28/2002 | |
| The vehicle in question has been in the shop twice for misfire in the engine. the motor started running rough right after a startup one morning with a substantial amount of smoke coming out of the exhaust and about a week later another enormous amount of smoke on startup in the morning. the chain of events also caused other intermitten problems with the performance of the vehicle such as a sense of slack between the engine and rear differential when up shifting and down shifting. the vehicle also has intermitten problems starting , for example, you have to crank the engine three to four seconds longer than normal and at times i have had to stop the ignition and try again. there have been other problems with the vehicle that have been resolved and a continued problem with the mirrors moving when they are not supposed to, although i have not seen them move while driving as of thus far. please note the incident date shown below is approximate and is when the problems started. i have filed complaints with ford motor company,department of consumer affairs and mailed an application to the dispute settlement board offered through ford motor company.*ak | |||
| 05/11/2003 | |||
| 2002 ford expedition. engine suddenly speeds up when applying brakes during slow speed stop. considerable brake peddle pressure required to stop vehicle. *nlm | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||
| 11/13/2007 | 86895 | 1 | 09/11/2002 |
| There were no symptoms leading up to the failure. my 2003 ford expedition made a load pop noise and then continued to make a loud but muffled popping sound under the hood. i immediately pulled over and shut off the engine. i had the truck towed to my local ford dealership where they diagnosed the problem. the problem was the # 3 spark plug had backed out or was spit out of the engine head. the estimated repair cost to replace the head was $3,500.00. a less expensive fix of $700 - $800 to rethread the head for the #3 spark plug, but with no guarantee how long it would last. the reason for the complaint is that after having my vehicle repaired i found out through a friend that this was not an isolated incident. after researching online i found that hundreds of people had the same problem with the #3 spark plug. even the service manager at the ford dealership told me it was an issue and a poor design on fords part. however, ford is not taking responsibility for the problem - leaving it's customers with a hefty repair to say the least. i also filed a compliant directly to ford headquarters. *tr | |||
| 06/08/2007 | 83000 | 1 | |
| 2003 ford expedition with 5.4 liter v8 with approximately 80,000 miles. #3 spark plug blew out of cylinder head. *tr | |||
| 02/28/2007 | 60055 | 1 | 04/05/2005 |
| Engine failure on my 2003 ford expedition having a 5.4 liter triton v8 engine. number 2 spark plug was blown out and the cost to repair is $3000. ford has known of this issue for some time but will not accept blame. the number of threads to hold the spark plugs is too few. *nm | |||
| 08/27/2006 | 75000 | 1 | |
| Vehicle was brought into ford dealer for a tapping noise in engine area.. dealer ran a test and found nothing wrong. several days later engine starting making popping noises and was unable to drive vehicle due to engine not operating properly..same dealer towed to their facility and said spark plug in #3 cylinder came loose and was ejected and damaged the head. they want $3k to repair this...vehicle has 75k miles with no more warranty. *jb | |||
| 04/10/2006 | 107000 | 2 | 08/20/2003 |
| After my 100,000 mile service which included a spark plug change, two spark plugs blew out, causing damage to the cylinder head and major repair cost. *jb | |||
| 10/31/2005 | 65000 | 1 | 07/15/2002 |
| This complaint is in reference to a mechanical problem i had with my 2003 ford expedition. while driving on interstate i-90 near boston, ma, the engine ejected a spark plug from the head casing of my motor (third plug on the passenger side). when the plug ejected, it took with it all of the threads in the casing, resulting in significant damage to the head. this happened very suddenly, and resulted in a dramatic reduction in vehicle performance - which nearly caused a vehicle crash on the highway. i was stranded on the massachusetts turnpike for some time and had to have the vehicle towed. much to my surprise, my mechanic indicated that this was the 4th expedition he had seen this year with this damage to the exact same plug casing - in his mind clearly a defect given that these were all relatively new vehicles without significant mileage on them. i called ford on this - but they claimed this was not a common problem (i did not believe them). my repair costs for this were over $2,000. subsequent review of your website indicates that a class action lawsuit has been filed by several persons in california claiming to have incurred the same type of damage. it appears as though this is on your radar screen, but i would like to formally submit this request that this be looked into on my behalf as well as for others who i'm sure this has happened to already - but are not aware that this may be a widespread defect/safety issue. *jb | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||
| 03/13/2010 | |||
| I have a 2003 expedition 5.4l and since 2006 to present every two or three months i have to replace a coil pack and spark plug. now since the coil packs have blown out so many times my catalytic concerter on the passager side has melted on the inside. | |||
| 09/05/2009 | 117000 | 1 | |
| My 2003 ford expedition blew a spark plug out of the engine today. after reading about events leading up to this failure, my auto was acting exactly like all the others. a slight ticking sound while the engine idles. while driving 20mph, a slight loud bam occurred and the engine began to idle hard. the car was towed 70 miles to a repair center near my home and i now am to decide on a new manifold or a coil repair that is risky. how a company can operate with critical engine part that are so poorly designed is beyond my imagination. the internet is filled with complaints of spark plugs popping out of engines in f150s and explorer/expeditions. it is a shame that such a simple thing as engineering a thread deep enough to hold a spark plug in place for the life of a car is too challenging for a car company. this repair should be the responsibility of the manufacturer. they were able to handle replacing millions of firestones and should be held to a standard close to their reputation as a tough vehicle. without recourse, ford will find it acceptable to cut corners and engineer sub par part. *tr | |||
| 07/10/2008 | 69529 | 1 | |
| I was driving at about 15 miles an hour and all of a sudden i heard a loud pop. i had to have it towed to a ford dealership. they said that from what i was describing it was a spark plug that blew out of the engine. but since it was almost 5:00 p.m. and they were about to close they wouldn't know anything until they could look at it the next day. i didn't damage the heads but it still cost me over $400.00 to fix it. *tr | |||
| 06/11/2008 | 92000 | 1 | |
| I was driving my 2003 ford expedition to work this morning and heard a loud pop noise, the vehicle began to vibrate and i smelled gas fumes. when i lifted the hood, i immediately noticed that the engine had blown a spark plug. *tr | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CRANKCASE (PCV) | |||
| 04/20/2005 | 8 | ||
| Since we have owned this 2003 expedition we have had the windshield replaced due to noise and loose stripping, then, the contracting person put in the wrong years windshield. the emissions canister was cracked and was replaced. the muffler would pop after turning off the engine, but couldn't be fixed until verified by ford. i waited for 3-4 hours one day with 3 children while they let my car run and shut off. we finally called ahead, and had them wait outside on us until we killed the engine to hear it pop. it was a poor muffler weld and was repaired. the side molding rattled badly, and was terribly faded, and that was replaced. the door gets a lot of wind noise , and a whistle in the window. they said window passed the dollar bill test and was fine but it still whistles. they, put a clear strip along inside of door to help noise. it doesn't. then ,the rear continental tire had such horrible, uneven wear, it was extremely dangerous. bought new tires for $600. then rear differential malfunctioned, and would make a grinding on turning left or right. they fixed that in march 2005, and it just started doing it again. now, there is a strange noise when revving the engine to drive coming from under the hood. it is going in tomorrow for the noise and the rear differential. on top of all the repairs, we have had a squeaky brake issue. also, they have said they were good. they just get a lot of brake dust, just sand them. our side windows shimmies all the time. ! i did invest in an extended warranty!. *ak | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE | |||
| 04/20/2005 | 8 | ||
| Since we have owned this 2003 expedition we have had the windshield replaced due to noise and loose stripping, then, the contracting person put in the wrong years windshield. the emissions canister was cracked and was replaced. the muffler would pop after turning off the engine, but couldn't be fixed until verified by ford. i waited for 3-4 hours one day with 3 children while they let my car run and shut off. we finally called ahead, and had them wait outside on us until we killed the engine to hear it pop. it was a poor muffler weld and was repaired. the side molding rattled badly, and was terribly faded, and that was replaced. the door gets a lot of wind noise , and a whistle in the window. they said window passed the dollar bill test and was fine but it still whistles. they, put a clear strip along inside of door to help noise. it doesn't. then ,the rear continental tire had such horrible, uneven wear, it was extremely dangerous. bought new tires for $600. then rear differential malfunctioned, and would make a grinding on turning left or right. they fixed that in march 2005, and it just started doing it again. now, there is a strange noise when revving the engine to drive coming from under the hood. it is going in tomorrow for the noise and the rear differential. on top of all the repairs, we have had a squeaky brake issue. also, they have said they were good. they just get a lot of brake dust, just sand them. our side windows shimmies all the time. ! i did invest in an extended warranty!. *ak | |||
| 09/18/2003 | 4 | ||
| Upon starting the vehicle, large amount of oil smoke came out from the tail pipe. vehicle was serviced 4 times by the dealership, in which a diagnostic test was performed. no failure code was found. dealership indicated that this was a normal characteristic of the vehicle.*ak | |||