Ten problems related to dash wiring have been reported for the 1997 Ford Expedition. The most recently reported issues are listed below.
This issue was at night while driving the headlight to see at night had turned off at a 35 mph speed no bumps no turn just driving straight. This is a serious issue, you use your lights for night and your are left with no lights, as a result for this huge problem I received a ticket that is how I found out my lights were not working. The headlights fuses, module components, wiring were checked no issues there, as for all other lights example emergency lights, rear lights interior lights are functioning. But as the electrician found the directional switch combo was burned left with a white shadow in one area it was replaced, and now functioning. As for the suspension not functioning properly is this an issue that has not been able to be resolved. I have taken it to different shops and there is no air leakage in the suspension pump and other areas that are linked with the suspension. The suspension pump still repeatedly pump air every 45-60 minutes which it's fine, but not when the vehicle bounces very vigorously for 15 minutes or more till it activates the suspension to pump air. When the suspension is down the steering wheel functions different as the bouncing makes it hard to drive at a certain speed, not safe but manageable in the mean while. During this time I'm not appreciating the quality of my Expedition components.
Electrical devices in the car have turned on without keys even in the ignition. Concerned with fire hazard if such things as lights and blower motors turn on on their own, perhaps for extended periods. Also concerned as to what other electrical malfunctions will present themselves in unattended vehicle. Failure is apparently due to leaking windshield seals draining water onto gem (electronic module) and the fuse panel for the vehicle, shorting electrical connection and corroding the units over the long term. The fuse box and gem will need to be replaced to eliminate the dangerous condition (after having re-sealed the faulty seal).
The interior dash lights of my 1997 Expedition go out every time it rains or the vehicle gets wet. The cause of this appears to be in the electrical system connect with the dimmrer switch that cause a short that then blows the 5 amp fuse. I have replaced this multiple times and is fine as long as it is dry (ohio isn't a very dry climate). I have gone through many 5 amp fuses. I have delayed getting anything done since the first occurance back in 2000 due the costly expense of just trying to diagnose the problem. This seems similar to other complaints that I have read posted on this web site due to water leaking from windshield. I have even had my windshield replaced and still have this problem to date. I have now stopped replacing the fuse and live with no dash lights at night. Very dangerous when you don't know what speed your going. In my professional engineering opinion there appears to be a water leak issue in the windshield/firewall area. This water leak issue should be looked into as the root cause to other failures that have been seen on Expeditions and f-150s in regards to electrical issues and fires.
On 4-12-2000 I was driving to children's hospital with my wife and daughter. We were n/b on I-5, at 60 mph in the seattle. I attempted turn on the radio and pushed the button. Nothing happened for a couple of minutes and then smoke came out of the radio. The smoke started to fill the passenger compartment . I was afraid the dashboard area was about to catch fire. I managed to find a exit to get off the freeway, stopped the car and get my family out. I turned off the ignition however the smoke was still coming out of the radio. The smoke stopped about 1 or 2 minutes later. I called bowen scarff Ford in kent and was referred to sound on wheels for radio repair. The manager at sound on wheels pulled the radio from the dash and showed me the water damage on the radio and coxial antenna wire leading from the antenna to the back of the radio. When the water got into the back of the radio a short was caused and the smoke started. I was told this was a problem with the 97 Ford Expedition. I took my vehicle to bowen scarff Ford and was informed a tech memo had been put out to Ford mechanic but nothing had been sent to Ford owners of Expedition. What I experience was a safety issue. I could have panic and cause a major accident on a freeway at high speeds. I believe this type of short could cause a major malfunction of the electrical system. Could the doors lock, trapping people inside? most deaths related to fire occure from inhaling smoke. These were some to the things going through my mind while attempting to get my family to safety. Why has there not been a recall to fix this problem. How many must be injured or killed before a recall. None I pray.
Intermittent problem of something burning from the dash area; dealer notified and inspected and some repairs was made by replacing heating coil; but condition still reoccurring. Can NHTSA help in this matter.
While driving 65mph dashboard caught on fire due to a defective electronic control module.
Consumer parked vehicle and went inside the house, and vehicle exploded, catching on fire. Fire department explained to consumer that fire started in the glove compartment.
Generic electronic module system failure caused relay to fail, 4-wheel drive control/transfer case failure. Yh.
Shorts in the electrical system resulted in misfunctioning door locks (repaired), electronic 4wd (still malfunctioning) and failure of internal dome light to turn off. All occurred within the first 12000 miles. 4wd and dome light are still a problem. . Dome light makes vehivcle difficult to drive at night.
Sometimes the system flutters between on and off.