general problems of the 2003 Ford Expedition - part 2

My husband was driving his 2003 Ford Expedition on the way home from work on Feb. 4,2010. He heard a bang and smelled a small vapor of gas along with the truck not running very well. He made it home safely to find that spark plug blew through the head!! we went online to see about this problem,and what could be done. He has only 69,000 miles on it and he is the original owner and takes care to keep up on everyday mainentance. I have made phone calls to no avail--Ford cistomer relationship center told me to take it to the dealer or reputable service center. This is not covered under any warranty at all!! so I am going further with this because if you go to get it fixed--(a) it could happen again and (b) a fire could start, and (c) very expensive to get fixed. We have read many other consumers have had this same problem but Fords does'nt want to help out. This is a safety issue that needs to be addressed before worse scenarios happen with possible deaths. To make matters worse, I own a 2004 f-150 and have read stories of it happening in those engines too!.

My Ford Expedition has less than 90,000 miles and the spark plug for #3 cylinder fell into the cylinder chamber thus the piston was hitting the spark plug ,this repair can cost as much $1800. 00. . . For a spark plug that cost around $5. 00 on a SUV that cost $50,000. 00. . . This could have caused a fire since the piston was pushing into the engine compartment, a fuel air mixture, plus, the presence of electrical spark are a perfect mixture for a fire. . . !!! I was charged $ 689. 00 for a tow back to my home. I want this problem to be addressed by Ford ASAP before someone loses their life!!!! a recall is in order! I want Ford to pay for my repair and towing bill because this is an engineering flaw and it is extremely hazardous!!! contact me please! I hope this can helps other Expedition owners.

2003 Ford Expedition spark plug blew out of cylinder head. Apparently a common problem that needs to be readdressed.

2003 Ford Expedition spark plug # 2 blown out.

My 2003 Expedition, with the v8 5. 4 trition engine, is being declined to be fixed by local Ford dealerships, due to the fact of the "known" issue, with the spark plug, they want me to pay for the fix of the heli coil which isn't a guarantee and then hope it works, if not it will be a rebuilt engine, the first time the spark plug blew it was at night, upon starting, sounded like gun fire, had vehicle towed and then researched it on the internet for solutions, found out what it was and then replaced the spark plug and ignition coil and then hoped it would stay, upon starting it , it did it again, bought more spark plugs and ignition coils, and got it to seat better, and then 4 weeks to the day while driving is when it made the same sound like gun fire and we knew then what it was, pulled over on a highway and proceeded to look and see what damage had been done, once again a spark plug and a new ignition coil, however this time the spark plug was vastly discolored and burnt in appearance, 1 week and 1 day later upon starting it does it again, and this time no spark plug can be put in, there are no more threads is what I was told by my mechanic, they told be they will have to remove the engine to put the heli coil in, and that isn't a guaranteed fix, also that I should just replace the engine, since it can and probably will continue to happen again, I had the auto towed to my residence and I began to research my options, I called all the Ford dealerships in which they said they could do the heli and there is not a guarantee for this to work, so at what cost is a human life to Ford? per the info and research it does say that it can catch fire, and explode. . . . . Or pay a fortune for a car that can't be fixed. We do have some of 6 the spark plugs that have "shot" out, I am told because it is the 3rd plug near the firewall that the angle is not approachable. . . . Help now!.

The contact owns a 2003 Ford Expedition. The contact stated upon inspection of her vehicle, she noticed that the spark plug ejected from the engine head on the passenger side near the firewall. If this occurred while driving, there is a high risk for a vehicle crash. The vehicle is in the process of being taken to the dealer for diagnostic testing. The manufacturer was notified, but she was not provided with any recourse. The failure and current mileages were 105,000.

My 2003 Ford Expedition just blew a spark plug out of the cylinder head. It was the second to last cylinder passenger side. There was raw fuel and vapors coming into the engine compartment and a fire could have started had a spark ignited those fumes. These are the factory plugs and factory head and the Ford dealer commented that this was a fairly common issue but that Ford has not issued a recall yet. Now I am out $2800 for what seems to be a defect in the design of the head.

Spark plug blow out on 2003 Ford Expedition 5. 4 l engine.

While driving my 2003 Ford Expedition eddie bauer one of the eight spark plugs blew out of the engine.

I own a 2003 Ford Expedition with a 5. 4,and while driving around town we noticed the vehicle started running rough,so we took it to a local shop to have it looked at and upon inspection we found that the number 7 plug had blown out and caused damage to the coil which caused the rough running,the mechanic at the shop said this is very common with these trucks and motors,so at the cost $700 I got it fixed with the understanding that this could happen again because of the way these motors are made.

While driving on a local road in clear weather my 03 Expedition suddenly threw plug #7. In so doing it destroyed the coil assembly, but the impact of the coil assembly on the fuel rail saved the car's hood from further damage (the top of the coil assembly clearly evidenced the impact mark from contact with the fuel rail). Given the fact that the damaged coil insulation was now arcing its spark across the engine head and that the fuel mixture was spewing out of the spark plug hole it's surprising that we avoided an engine fire under the plastic shroud. I had the car towed to the local independent service center (pep boys, laurel MD - the same location that had changed the plugs a year prior). They examined all the spark plug threads and advised that they appeared ok, with the exception of this one cylinder. To effect repairs they advised to have the vehicle towed to another outlet 36 miles ($104 charge) up the road. They further advised that this is not an uncommon problem with the 5. 4 engine and that this may occur in other cylinders in the future. Ford customer assistance (800#) disclaims any knowledge of this being a common problem and referred me to the local dealer for technical advice. At the local dealer, the mechanic was very familiar with the issue, pronounced it rather common and advised that Ford would be happy to repair the problem, however his estimate would cost me more than twice the estimated fee from the independent (inclusive of the additional tow costs). Subsequent google searches for "Ford Expedition thrown spark plug reveal 11,200 web page hits. . Read more...

The spark plug coil on my 2003 Ford Expedition was ejected from the cylinder causing my vehicle to become disabled. My wife was stranded alone in an unfamiliar neighborhood. After researching the problem I have found that I am only one of thousands of people who have had similar problems regarding the stability of the spark plug and the problems that can occur as a result of the unexpected and totally sudden ejection of the coil. How many people will be forced to submit to the predatory practices of most repair shops until something is done? there is obviously a major problem here and action must be taken. So far this has cost me one hundred dollars and who knows how much it will cost to fox it right. The way is should have been when it was manufactured. I have read this is believed to be a result of a flaw in the design of the cylinder heads and the number of incidents should warrant an investigation into the design and Ford's response to the number of vehicles disabled by this error.

Purchased a used 2003 Ford Expedition with a triton 5. 4 v8. The car had about 80,000 miles when I purchased it and at about 84,000 miles a sparkplug ejected out of the engine. The repair was around $650 for a "not for sure" fix. Apparently the threads that hold the sparkplugs in had stripped, causing the blowout of the sparkplug. I was told by the mechanic at our local Ford dealership that the permanent fix would require the replacement of the heads at around $4000. I opted for the cheap fix because of the lack of financing for the more expensive repair. I did a search on the internet and found that many other consumers who had purchased for SUV's and trucks with same model engines were reporting the same problem in overwhelming numbers, many with multiple blowouts at various incidences. I was hoping my problem was confined to only one cylinder but at around 90,000, 5 1/2 months later, another sparkplug blew out. Now the repair was even more due to a new part that is to provide a more permanent fix. This time the repair was $830. Knowing that this was an issue with these model engine I asked my local Ford dealer's service man "if Ford knows about the problem, why don't they fix it"? his reply was that the problem is not a danger so no recall has ever been called. The guy went as far as telling me that the problem is caused by improper threading into the head. The threads were machined to shallow and eventually they become loose and finally blowout when the thread completely fail. I think if you investigate this further you will see that in more than one instance the ejecting sparkplug has severed gas lines and caused fires. Not exactly what I consider to "not be a danger". Ford admits non fault on their part even know they know they have sold a faulty product in mass numbers to an enormous amount of people and businesses.

In less than seven days, two spark plugs blew out of my 2003 Ford Expedition engine. It is a 5. 4l triton engine. Both occurrences were while driving normally down the interstate. The consequences were sudden loss of power while driving on the highway both times. I went from driving 70 mph to 45 mph in a matter of seconds with my wife and 9 month old baby in the vehicle! Ford knows about the problem and has issued a repair report, but not a factory recall. The issue is a flaw in the engine design or manufacture; thousands of others have reported the same issue (a quick google search of "Ford 5. 4l spark plug blowout" demonstrates this). Had there been traffic behind or beside me, we would have caused an accident or worse. Since Ford knows of the issue, they ought to pay for the repairs or replace the engine at their expense. I no longer trust my vehicle. The repairs for this one issue have cost me approximately $1,000 to date, and there is no guarantee it will not happen again.

The contact owned a 2003 Ford Expedition. While driving less than 60 mph, the contact noticed smoke underneath the hood in addition to a strong burning odor. She was able to maneuver the vehicle to safety. She lifted the hood with another person's assistance and heard crackling and sparkling sounds. She also noticed a hole in the insulator directly into the hood of the vehicle. There was a recall on other years, makes, and models, but none for the contact's particular vehicle. The origin of the fire has yet to be determined. The failure and current mileages were less than 165,000.

At 92,000 about miles the passenger side plug blew out. I put jb. Weld around the plug and put it back in the truck. It worked for 3 months and now its done it again. I am now out of work and my wife can't make it to here job because of the truck. So I am looking for a heli coil repair kit. But no way to go and get it I have one truck. So I don't know what to do next.

Today is the second time we have had a spark plug blow out of the cylinder of our Ford Expedition. The first time it stranded my family in the mountains of southern California in the winter. We are supposed to go away for a weekend trip tomorrow. It cost us 3k the first time and today's quote is about the same. This is very dangerous and unbelievable given the amount of occurrences that nothing is being done. This is bs! Ford is digging their own grave and if someone dies due to this happening it will cost them more than money. . . . Blood on their hands.

The # 1 spark plug on my 2003 Ford Expedition blew out and stripped the threads and broke the coil.

No warning. Engine stop. At least a dozen times. No body at Ford will admit there is a problem.

While driving 2003 Ford Expedition spark plug blew out and truck reduced speed. The incident caused damage to the engine - which required replacement approx. $6,000. 00. I asked the downey Ford dealer if this was a manufacturing defect? they replied: they did not know although the truck was not on recall. This defect - blown spark plug may cause excessive injury and or death if this were to occur on the freeway.

December 15, 2007, my 2003 Ford Expedition's spark plug was blown out. Leaving my three kids and myself stranded on the highway. After paying $1,200 to get it fix, on March 9, 2008 the same thing happen.

64000 on 2003 Ford Expedition blew the #2 plug while traveling at highway speed and cruise control on. Had a hela coil put in. Contacted the dealer, no response, 2 weeks later 68000 blew the #3 plug sitting at a traffic light again had a hela coil repair. Again no help from the dealer, and told there was no open recall on that motor . I am filing a complaint with the attorney generals office in minnesota. Both repairs were done at a different Ford dealership, they stated replacing the head wa s the correct fix, but Ford allowed them to do hela coils, but imagine that, they won't warranty it !!.

On April 13, 2007 my 2003 Ford Expedition with the 5. 4 liter triton engine blew out the #3 spark plug destroying the threads and requiring a total head replacement. The cost of this repair, in spite of the fact I purchased the extended warranty, was $3655. 22. Upon further research I have found that apparently this is a very common occurrence affecting thousands of Ford owners.

Original and 2nd Ford engine blew. 1st threw a rod, 2nd block cracked and ruined engine due to rapid coolant loss. Dealers offered no warranty as both engines blew at 112,000 and 120,000 respectively. This car was very well maintained and received routine recommended service for oil and fluid changes.

2003 Ford Expedition caught on fire while parked. The consumer expressed a concern about any risk or danger of sudden short circuiting, sparking, explosion or fire with parking this vehicle, when one day while sitting in their kitchen, they heard a loud rumble emanating from the rear of the house when they saw the front of the vehicle engulfed in flames with the hood blown off. The fire also spread to the consumers home consuming most of it.