Five problems related to manifold/header/muffler/tail pipe have been reported for the 1997 Ford Expedition. The most recently reported issues are listed below.
1997 Ford Expedition--aluminum heads are engineered incorrectly. The problem is the spark plug recess bore is to thin, the spark plug does not have enough material to properly seat in the head and after awhile the plug will back out. The pressure from the combustion will eventually blow the plug out. This will lead to costly damage to fuel injection damage, piston, intake manifold, etc. The problem is ranging from 96' to 2005 triton engines. Ford will not help you nor will the engine manufacturer until someone dies! repairing this problem. . . . . . Low cost-heili coil insert $100 to $1000 depending on your service tech. Or a complete head replacement (steel heads) $3000 to $5000.
Spark plug on my 97 Ford Expedition blow out. The engine is a triton 5. 4l. It happened while I was driving on residential street at 30 miles per hour.
The contact owns a 1997 Ford Expedition. The dealer informed the contact that the manifold bolts have rusted out and need to be rebuilt and re-drilled. The vehicle was not included in any recalls. The contact heard a ticking sound coming from the passenger side of the motor due to the manifold rusting. The noise ceases when the vehicle heats up. The current mileage is 190,000 and failure mileage was 188,000.
Towing trailer and exhaust manifold studs broke. This caused a loss of power climbing a steep grade. Car behind almost hit us.
The tail pipe separated from the muffler & fell off. Dealer referred owner to muffler shop. They welded pipe on & it fell off sometimes later again.