Engine Clicking And Tapping Noises Problems of Ford Expedition - part 2

There were no symptoms leading up to the failure. My 2003 Ford Expedition made a load pop noise and then continued to make a loud but muffled popping sound under the hood. I immediately pulled over and shut off the engine. I had the truck towed to my local Ford dealership where they diagnosed the problem. The problem was the # 3 spark plug had "backed out" or was "spit out" of the engine head. The estimated repair cost to replace the head was $3,500. 00. A less expensive fix of $700 - $800 to rethread the head for the #3 spark plug, but with no guarantee how long it would last. The reason for the complaint is that after having my vehicle repaired I found out through a friend that this was not an isolated incident. After researching online I found that hundreds of people had the same problem with the #3 spark plug. Even the service manager at the Ford dealership told me it was an issue and a poor design on Fords part. However, Ford is not taking responsibility for the problem - leaving it's customers with a hefty repair to say the least. I also filed a compliant directly to Ford headquarters.

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The contact owns a 2000 Ford Expedition. While attempting to accelerate from a stop, the contact heard a loud popping sound followed by a noise coming from under the hood. The vehicle hesitated and would not accelerate. The contact had to glide the vehicle downhill and into her driveway. A mechanic discovered that a spark plug blew out of the hole. The dealer has not been notified and the vehicle has not been repaired. The current and failure mileages were 140,000.

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The contact owns a 2004 Ford Expedition. The contact stated that there was inadequate sealant on the front windshield. In rainy conditions, water would leak into the vehicle. In addition, when the windshield wiper unit was activated, the windshield cleaner would also leak into the vehicle. The contact could hear a crackling sound coming from the dashboard. All the digital components on the instrument panel became inoperable due to the leak in the front windshield. The dealer stated that the windshield could be resealed at the cost of less than $100. If the windshield needed to be replaced, it would cost over $200. There were no recalls for the failure. On a separate occasion, the engine started on its own. The VIN was unable to be accepted by the system. The current and failure mileages were less than 97,000. Updated 04-20-09 updated 04/24/09.

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The contact owns a 2002 Ford Expedition. The contact heard a clinking noise coming from under the hood when the vehicle was started. She inspected the vehicle and noticed that the spark plug blew off. The mechanic confirmed the failure, but was unable to determine the cause. The consumer stated dealer informed her this is a common problem with Expeditions, the mechanic had not repaired the vehicle. The powertrain was unknown. The current is 82,362 and the failure mileages was 76,400. Eq-10203932-4200, date received 12/12/07. Updated 12/12/07.

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The contact owns a 1999 Ford Expedition. The contact stated that he heard a loud popping sound when the vehicle was started. The vehicle was towed to the dealer who stated that there is a defect with the cylinder head, which caused the spark plug to disengage. The current and failure mileages were 86,800.

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Failure of cam shaft and valve, lifter parts associated with the right side of this 5. 4l engine. Most likely due to variable cam timing units. 5. 4 l engine in 2005 Expedition, first placed in service in December 2004. Right side of engine began making a ticking noise within 30,000 miles. Dealer service stated ticking noise is normal, no issues. Noise continued. Noise recently became worse. Right side of engine. Mileage for vehicle is at 142,000 miles. Independent mechanic states hydraulic lifter issue, cam shaft is bad. $1,200+ repair. Doing research on various car sites reveals many issues similar to this with the 5. 4l Ford engine. Issues stated dealt with: defective cylinder heads, failing cam phasers, camshaft bearings failing, failed cam solenoids, thrust bearing failure, variable cam timing (vct) failure and cam shaft failure due to other parts. This defect seems to be covered in a tb put out by Ford (TSB 05-15-8), but did not involve a recall. This issue has affected 100's if not 10,000's of Expedition owners. Initiate an investigation and I believe that you will agree Ford should issue a recall to repair or replace.

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Wife was driving the 2003 Ford Expedition with 73000 miles on it when loud popping noise was heard, upon examination sparkplug was found to have been ejected from the engine block repair at closest Ford dealer was $3000.

The contact owns a 2007 Ford Expedition. The contact stated that the vehicle shifts roughly and makes a loud sound when shifting from first to second gear or accelerating from a stop at 15 mph. The vehicle has been to the dealer numerous times. Initially, the failure was diagnosed as the throttle cable. The second time, the dealer stated that nothing was wrong with the vehicle. The third time, the vehicle made a popping noise and the rear axles were replaced. The fourth time, the dealer stated that the cause of failure was the transmission. They dealer would temporarily repair the vehicle, but the failure would recur days later. The failure has still not been corrected. The failure mileage was 2,800 and current mileage was 14,300.

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Loud pop then loss of vehicle power, continual popping sounds until I stopped engine. Spark plug was ejected from engine. I believe this investigation should be reopened as this should be a defect recall .

Vehicle was brought into Ford dealer for a "tapping noise" in engine area. . Dealer ran a test and found nothing wrong. Several days later engine starting making popping noises and was unable to drive vehicle due to engine not operating properly. . Same dealer towed to their facility and said spark plug in #3 cylinder came loose and was ejected and damaged the head. They want $3k to repair this. . . Vehicle has 75k miles with no more warranty.

We were traveling at about 30-40 mph on a sharp curve on a freeway on-ramp. We experienced a loss of power and a very loud popping noise. We pulled over since driving at freeway speeds seemed impossible. We were stranded in a very dangerous spot about 100 feet in front of the freeway on-ramp. After aaa informed us it would be about an hour for a tow truck and an accelerating vehicle came within inches of our car, my family and I decided to abandon the vehicle and climb a very steep and dangerous embankment. I feared for my three kids and wife's the whole time waiting for the tow truck. We were towed to a Ford dealer where they told us( a week later) the number three spark plug had blown. The usual problem with these engines. The plug blows because there are only five threads for the spark plug in these aluminum heads. The new design from Ford now has 12 threads. We decided to have the whole engine replaced since this cost less than having two heads replaced. Its 5500 for the engine and 3500 per head. We wanted both heads since the other head would be prone to the same problem. I think Ford should own up to this problem because eventually there are going to be serious consequences to someone as a result of this. We were only inches away from this happening.

1999 Ford Expedition, 88k miles, spark plug ejected from passenger side of engine. This occurred in heavy traffic while in left lane of smoketown road in prince william county, virginia. The vehicle stalled after I let off the gas pedal right after a loud bang and popping sound was heard in engine. I was able to restart vehicle, but had to keep the rpm's up to keep from stalling. After cutting off several cars in center and right lane, the vehicle was pulled into a parking lot on right side of road. I detected a strong smell of gasoline present when hood was raised. Not once did the "check engine" light come on; unlike all the other times it came on when nothing was wrong with the truck. The vehicle was towed to a Ford dealer and a $3400 head replacement performed because head was ruined by stripped spark plug ejecting. Upon checking internet, I found that this is an ongoing increasing problem. It appears that an inquiry done by your agency concluded in January of 2006 that this is a rarely occurring incident of little to no danger. I beg to differ. A simple google query will show thousands if not tens of thousands of complaints regarding Ford triton engine spark plug problems posted on various message boards. It is a matter of time before someone gets hurt or killed either directly or indirectly from this obvious problem. I'm just glad I was alone driving and not my wife and children. My wife would have remained in the stalled vehicle while sitting in the passing lane. Considering the enormous number of potentially affected vehicle this issue involves, I will also be bringing this matter to the attention of every elected official I can send an email to.

For the second time in 6 months I had an engine spark plug ejection in my 1999 Expedition. The spark plug detached from the cylinder and was ejected from the engine. I heard a loud pop while driving, the vehicle followed by a loud, repetitive clicking or popping sound. I also lost some power while driving, the vehicle did not stall. I did smell gas when the incident occurred. I was able to slowly drive the vehicle to the repair shop.

1. Frequent horrible grinding noise on cold start-up. 2. Loud clunking noise and feel vehicle shudder in reverse under light acceleration.

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Approximately at 8 am, my wife was driving to work when she heard a loud bang under the hood of the car. She was driving a 1999 Ford Expedition. The engine started making a very loud popping noise. After arriving and starting the car to hear what was going on, I knew what the problem was. 5 years ago I drove a 1999 f250 Ford with a v10 and it did the same thing. The local dealership agreed a spark plug had blown out of the engine on the Expedition on the #3 cylinder. They repaired it by putting a plug insert (heli-coil) in. They put the insert in while the head was still on the vehicle. Now three weeks later the rods on #3 and #7 pistons are bent and the vehicle is inoperable. The dealership only option to us was to replace the engine at a cost of nearly $4,500.

Two weeks ago I replaced the spark plugs on my 2000 Ford Expedition and yesterday while driving to work I noticed a loud clanking noise. After investigating, I found that the #2 spark plug had been blown from the cylinder head. The Expedition has 10300 miles on it and has been very reliable.

The contact owns a 1999 Ford Expedition. In 2005, while driving 55 mph, the contact heard a popping sound and stopped the vehicle. He noticed that the spark plug had come through the engine. A month later, the failure recurred. The purchase and incident dates were unknown. The current mileage is 130,000 and failure mileage was 90,000.

1999 Ford Expedition 5. 4l 4wd driving down road and spark plug shot out of the head. Causing a loud popping noise and bad idle. Replaced sparkplug and had heli-coil installed. Two weeks later, another spark plug shot out of the other side of the head.

While driving vehicle suddenly heard a loud popping sound followed by a strong odor of gasoline. Stopped immediately, and had vehicle towed to firestone dealer ,who informed consumer the spark plugs blew off the cylinder. The threading around the spark plug was too thin, this had a defect. Then, had towed to Ford dealer where has a premium warranty, but this was not covered under warranty. No repairs as of yet, it is still at the dealer with over $3,000 worth damage to the engine.

When accelerating from a traffic light, I heard a pop and then my 5. 4l engine on my 1998 Ford Expedition started making a loud continous popping/ticking sound. We had it towed to the local Ford dealer and they diagnosed it as a blown spark plug caused by the cylinder head threads giving way and causing the spark plug to be blown out of the spark plug hole. They are charging us almost $3300 to fix the defect in their cylinder heads. They deny there is any type of recall, but I did see a TSB# 98b33 which relates to cylinder head replacement. . Read more...

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I purchased a 2003 Expedition in September of 2002. I reported a vibration in steering wheel and brake pedal, a clanking noise in the front end, along with a slippage when taking off as vehicle seems to not want to respond when pushing on the gas. They stated the engineers were aware of problem and where working on it. The vehicle has been taken in several times, but these problems still exist. On the 2 appointment for my vehicle I stated to the service area that my brake pedal would go to the floor, and I would have no brakes. They told me my brakes were fine although this has happened twice while driving ever since. As of oct. 9, 2003 they have had my vehicle a week, and are stating they do not know these problem existing with any other Expedition so they are unsure how to fix the vehicle. At your website that is not true, as I have seen several reports of these same problems on the same vehicle as mine. I am very concerned for mine and my children's safety.

Begining in the fall of 2003 my 2001 Ford Expedition with the 4. 6l engine begain to make a ticking sound at start up (when engine is cold). I've had the vehicle in the dealer several times and they have heard the sound, but they have offered no reasonable explanation of the cause or nature of the problem and the potential damage it may cause. There are several service bulletins, including 03256, that noted this problem.

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Light came on the dashboard indicating there wa sno oil inside of vehicle, and it started making clunking noise. Dealership was aware of problem.

I heard a tapping noise in the hood. I took it to a dealership they stated I needed a new engine.