Ford Expedition owners have reported 3 problems related to automatic transmission cooler (under the power train category). The most recently reported issues are listed below. Also please check out the statistics and reliability analysis of Ford Expedition based on all problems reported for the Expedition.
The steel lines connection the transmission to a transmission cooler rusted out and failed resulting in a loss of fluid. This causes it to start slipping and almost get stuck in traffic. I had to cut out several bad sections of steel line and replace them. Note that the filler tube to replace the fluid also rusted out.
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I was braking and brake pedal sank to the floor. It turned out steel hydraulic brake lines had failed. I had all of them replaced in about 3/06 for a cost of $1000. I did not replace at the time the master cylinder to abs lines. They failed on 11/23/2006 and I have retained them. If these components had failed at highway speeds it could have been potentially deadly. Note that my 1994 taurus sho had a similar failure. This vehicle has also had the transmission cooler steel lines fail and other severe undercarriage rust problems.
Two transmission oil line fittings that are located on the radiator worked loose, causing the lower radiator hose to swell and potentially rupture. Transmission is burning on the engine from getting thrown back by radiator fan.