Manifold/header/muffler/tail Pipe problems of the 1999 Ford Expedition

12 problems related to manifold/header/muffler/tail pipe have been reported for the 1999 Ford Expedition. The most recently reported issues are listed below.

car   Manifold/header/muffler/tail Pipe problem 1
Failure Date: 02/24/2015

The contact owns a 1999 Ford Expedition. While driving approximately 45 mph, the bolts from the exhaust manifold released. The vehicle was taken to an independent mechanic. The technician diagnosed that the exhaust manifold and bolts needed to be replaced. The manufacturer was notified of the failure. The approximate failure mileage was 143,000.

car   Manifold/header/muffler/tail Pipe problem 2
Failure Date: 10/13/2013

Vehicle ran perfect during the day. Stopped for about 1 hour around 9 pm, went to restart the engine around 10 pm, heard a loud "pop" followed by very loud flapping noise from under the hood as the engine continued to run but very rough (sounded like "blap, blap, blap. . . . . . "). On investigation, found #6 spark plug had been blown completely out laying on the top of the manifold and the coil broken off its mount. The spark plug was not broken, but the threads looked a little rounded, but otherwise ok. Tried to reinstall the plug, but it never would seat and when pulled out vertically it felt like the threads were stripped in the head. Had the vehicle towed to a local Ford dealership in wichita.

car   Manifold/header/muffler/tail Pipe problem 3
Failure Date: 10/11/2009

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.

car   Manifold/header/muffler/tail Pipe problem 4
Failure Date: 02/21/2008

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.

car   Manifold/header/muffler/tail Pipe problem 5
Failure Date: 02/27/2006

Leaking right head gasket due to faulty manufacturing. Oil leak is dripping on the muffler potential fire hazard and pollution.

car   Manifold/header/muffler/tail Pipe problem 6
Failure Date: 02/27/2006

: 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.

car   Manifold/header/muffler/tail Pipe problem 7
Failure Date: 11/30/2004

Oil leak from right side cylinder head gasket. Oil leaks onto exhaust manifold and under certain conditions it could start a fire.

car   Manifold/header/muffler/tail Pipe problem 8
Failure Date: 01/05/2004

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.

car   Manifold/header/muffler/tail Pipe problem 9
Failure Date: 05/29/2003

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.

car   Manifold/header/muffler/tail Pipe problem 10
Failure Date: 09/30/2002

Fire hazard! manufacturers defect causes head gasket failure resulting in severe pressurized oil leak onto hot exhaust manifold, creating a dangerous fire hazard.

car   Manifold/header/muffler/tail Pipe problem 11
Failure Date: 04/13/2001

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.

car   Manifold/header/muffler/tail Pipe problem 12
Failure Date: 06/01/2000

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. All gaskets had been replaced. Little white dot on headlight switch doesn't light up. Switch assembly replaced.

Switch Make:
Switch Model:
Safety Ratings of Expedition Cars
Fuel Economy of Expedition Vehicles
Expedition Service Bulletins
Expedition Safety Recalls
Expedition Defect Investigations