Engine problems of the 2002 Ford Expedition

24 problems related to engine have been reported for the 2002 Ford Expedition. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2002 Ford Expedition based on all problems reported for the 2002 Expedition.

car   Engine problem 1
Failure Date: 05/06/2011

1. Driving, 35mph 2. Spark plug blew out of #2 cylinder, damaging coil 3. Vehicle currently waiting for mechanic to check seals and head to determine extent of damage.

car   Engine problem 2
Failure Date: 06/30/2010

Well we were just driving home when the spark plug of our Ford Expedition just shot out of the cylinder head and we cant replace it because its too much money for us.

car   Engine problem 3
Failure Date: 06/16/2010

The contact owns a 2002 Ford Expedition. The contact stated the vehicle was parked in his driveway when it caught on fire. The fire department was able to extinguish the fire. There were no injuries. A fire report was available. The contact stated the spark plugs blew out at the cylinder head causing the fuel rail to bend and resulting in a fuel leak that started the fire. The engine was severely damaged. The contacts insurance company advised that the fire originated from a pre-existing failure in the vehicle and would not cover his claim. The vehicle was towed to the dealer where he was advised they were aware of the failure yet would not provide any assistance. The vehicle was not repaired. The failure and current mileages were 190,000.

car   Engine problem 4
Failure Date: 05/17/2010

2002 Ford Expedition, original factory spark plug was violently ejected from the engine during normal operation. Spark plug smashed through fuel injector and dented the hood. Had someone been servicing the engine the injuries could have been severe. Ford motor company refuses to call this a defect and area dealerships want to charge $700 to $3300 to fix this issue. There have been thousands of complaints and this motor design problem should be recalled and fixed by Ford motor company.

car   Engine problem 5
Failure Date: 04/21/2010

I have had two spark plugs blow out of my 2002 Ford Expedition 5. 4l v8. The first blew out after pulling out of an intersection from a dead stop. The second was the #2 plug. I was pulling a travel trailer through mountains on a highway. First noticed was a reduction in power for about 60 miles. Then after rounding the top of the mountain, letting off the gas to go down the hill, the plug blew out.

car   Engine problem 6
Failure Date: 01/28/2010

After pulling out from a stop sign I had a spark plug blow out of my 5. 4l v8 in a 2002 Ford Expedition.

car   Engine problem 7
Failure Date: 12/26/2009

The #3 spark plug blew out of the engine of my 2002 Ford Expedition while traveling at 65 mph on a crowded four lane highway. We could have easily been in a severe accident but were able to safely navigate our way to the side of the road.

car   Engine problem 8
Failure Date: 12/10/2009

6 days after having sparkplug #5 blow out of the cylinder #4 blew out.

car   Engine problem 9
Failure Date: 12/04/2009

2002 Ford Expedition blew two (2) sparkplugs out in one week. Had #5 fixed at a Ford dealer, 6 days later #4 blew out.

car   Engine problem 10
Failure Date: 12/02/2009

Spark plug pooped out of my truck twice now. . . Lost power. . . . Fuel spurting out of the plug opening into the engine compartment. . . . Very costly repairs. It is happening all over the united states. . . . Probably worse issues then the current Toyota recall in progress now. . Read more...

car   Engine problem 11
Failure Date: 08/27/2009

2002 Ford Expedition spark plug ejection. #3 spark plug shot out of engine stripping threads and requiring an expensive repair.

car   Engine problem 12
Failure Date: 08/12/2009

2002 Ford Expedition spark plug blow out. What the !@#$%. . . If this is such a huge problem, why isn't anyone taking responsibility. Oh ya they want our money for a problem they are aware of. . .

car   Engine problem 13
Failure Date: 07/18/2009

The contact owns a 2002 Ford Expedition. While driving 40 mph, one of the spark plugs ejected from the engine. The vehicle has not been diagnosed by the dealer. The current and failure mileages were 182,000.

car   Engine problem 14
Failure Date: 06/09/2009

Ford spark plug blow out defect. It is a known defect thousands have experienced. It is where the spark shoots out of engine head stripping threads and damaging the head and sometimes causing fire. My car had this happen and now I am stranded. There are some temporary fixes but no permanent fix. The helicoil can come out. You can replace the engine but it will have the same defect. My car is a 2002 Ford Expedition 4. 6 triton v8. It is affecting 1997 through 2004. Ford is aware but says they wont fix it. I am going to try class action. This can cause fire. This is a 9 passenger vehicle used to carry my kids if it catches fire from it I may not get everyone out in time.

car   Engine problem 15
Failure Date: 11/25/2008

The spark plug in my 2002 Ford Expedition blew out while I was driving the speed limit on the highway. After this happened, I tried unsuccessfully to get my car repaired at a non-dealer mechanic. Every mechanic I called said that they would not touch my car because of the engine and the threads being insufficient. And that most of the repairs are not lasting so the situation escalates to the point where they are losing money to fix this problem that they did not create. The dealer fixed my car and said that the fix has no warranty even though it cost me $1116. 98 to repair. I was also told that the problem is common. And that 1 in 100 of the repairs do not hold. The spark plug repair is recommended at the 100k tune-up mark. My car has had all maintenance recommended by the manufacturing including the every 3k mile oil changes. This should not have happened to my car. It was near but not over the 100k mark. And even if the spark plugs had been changed as recommended, the coil would have still blown because the problem is with the thread on the engine, not the plug itself. This item should be recalled and Ford knows that they are responsible for putting safe cars on the roads. Thank you, vicki bezio.

car   Engine problem 16
Failure Date: 10/17/2007

My 2002 Ford Expedition 4x4, 5. 3l engine with 71k miles had the #3 spark plug became dislodged as I was driving on the highway at ~65 mph. Turns out the threads on the cylinder head are stripped. My car had to be towed to the dealer and is awaiting being fixed. If I choose to have the cylinder head replaced, it will cost ~$3000. I've read other articles and complaints on the internet that lead me to believe there are thousands of people who've experienced the same thing with their Ford trucks. I believe there is sufficient data to suggest Ford should do a recall on these trucks for this problem.

car   Engine problem 17
Failure Date: 09/01/2007

My 2002 Ford Expedition (83,000 miles) on the way home from lake powell blew a spark plug out of the cylinder head. We were 350 miles from home on vacation and had to obtain assistance and added expense to return home in time for our jobs. The vehicle is still in st george, utah at a Ford dealership being repaired. It was explained that the spark plug issue is well known. There is no assistance from Ford for repairing the well known design flaw.

car   Engine problem 18
Failure Date: 08/27/2007

Vehicle threw a spark plug without warning while at highway speeds. This stripped out the plug socket requiring rebuilding of the engine heads to really fix it correctly to be sure it wouldn't happen again. Mechanic expressed that this was common on these vehicles. Destroyed the spark coil and wiring as it blew out. Could easily have caused a severe accident at highway speeds, towing a trailer. We were lucky it was late and traffic was light.

car   Engine problem 19
Failure Date: 06/12/2007

The contact owns a 2002 Ford Expedition. While driving 30 mph, the spark plugs blew out from the side of the engine. The contact pulled over and the vehicle was towed to the dealer. The vehicle is currently waiting to be repaired. The current and failure mileages were 68,000.

car   Engine problem 20
Failure Date: 06/01/2007

The contact owns a 2002 Ford Expedition. When the contact started the vehicle, he noticed smoke coming from the engine. The vehicle was towed to the dealer. The dealer stated that the cause of failure was due to a blown spark plug cylinder. The dealer replaced the spark plug cylinder. Approximately two weeks later, while driving 65 mph uphill, the vehicle lost power. The mechanic replaced the spark plugs and performed a tune up. The following day, while driving 65 mph uphill, the vehicle lost power again. The dealer stated that the engine was blown and needed to be replaced. As of July 11, 2007, the engine has not been replaced. The purchase date was unknown. The current mileage is 106,710 and failure mileage was 106,000.

car   Engine problem 21
Failure Date: 06/23/2006

Today I had the spark plug blow out of my Ford Expedition when I was on the freeway with my 3 kids. Come to find out this is a common problem and Ford won't do anything to fix this problem.

car   Engine problem 22
Failure Date: 12/19/2005

The contact stated while driving at approximately 25 mph heard a loud boom. The vehicle sputtered and jerked. He pulled the vehicle to the side of the road. The vehicle was towed to a dealership, where they found the problem to be a blown out spark plug. No repairs were made.

car   Engine problem 23
Failure Date: 11/22/2005

Blew spark plug.

car   Engine problem 24
Failure Date: 02/22/2002

While sitting inside car at convenience store with the Expedition idling the number 3 spark plug shot out the cylinder head. The car started popping and had to have the auto towed. There are numerous drivers having these problems with Ford tritron 5. 4l engines. Had to place a heli coil to hold a new spark plug.

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