One problem related to horn assembly has been reported for the 2005 Ford Expedition. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2005 Ford Expedition based on all problems reported for the 2005 Expedition.
My wife was driving our 2005 Ford Expedition with 50,000 miles. She stated that the radio quit working and then the vehicle quit running. At that point the horn began to blow continuously until smoke started to come out of the right side of the dash. At this time she exited the vehicle with our boys and called the fire dept. By the time they arrived the vehicle was fully involved with fire. Needless to say the Expedition is totaled from the fire. The entire interior is burnt up and melted. I have found similar complaints on several forums.