Engine Exhaust System problems of the 1999 Ford Expedition

13 problems related to engine exhaust system have been reported for the 1999 Ford Expedition. The most recently reported issues are listed below.

car   Engine Exhaust System problem 1
Failure Date: 09/21/2009

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.

car   Engine Exhaust System problem 2
Failure Date: 10/29/2008

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.

car   Engine Exhaust System problem 3
Failure Date: 10/07/2006

: 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.

car   Engine Exhaust System problem 4
Failure Date: 08/25/2005

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.

car   Engine Exhaust System problem 5
Failure Date: 01/25/2005

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.

car   Engine Exhaust System problem 6
Failure Date: 12/01/2004

The consumer was aware of a Ford TSB concerning oil leakage. He experienced an oil leakage from the head gasket into the exhaust system.

car   Engine Exhaust System problem 7
Failure Date: 02/23/2004

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.

car   Engine Exhaust System problem 8
Failure Date: 02/24/2003

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.

car   Engine Exhaust System problem 9
Failure Date: 01/15/2003

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.

car   Engine Exhaust System problem 10
Failure Date: 04/04/2002

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.

car   Engine Exhaust System problem 11
Failure Date: 06/01/2001

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.

car   Engine Exhaust System problem 12

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.

car   Engine Exhaust System problem 13

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.

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