Engine Exhaust System Problems of Ford Expedition - part 1

I think too much exhaust gas comes inside.

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The contact owns a 2017 Ford Expedition. The contact stated while starting the vehicle, he heard an abnormal noise. The contact stated no warning light was illuminated. The contact took the vehicle to the local dealer however, the mechanic was unable to diagnose the failure and the contact was advised to replace the exhaust system. The vehicle was not repaired and continued to experience the failure. The contact took the vehicle to an independent mechanic and was also informed that exhaust system needed to be replaced. The vehicle was repaired but continued to experience the failure. The manufacturer had been informed of the failure. The failure mileage was approximately 80,000.

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Upon hard acceleration over 3000 rpm a burnt exhaust odor enters the cabin. At all times.

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Truck has smelled like exhaust during hard acceleration numerous times. I have had to lower my windows to allow it to escape.

Smell of exhaust inside vehicle whenever rear wing windows are open; generally occurs during acceleration or idling. This has been an ongoing issue since vehicle purchase in August 2016.

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Spark plug ejection! I just experienced a problem with my Ford triton motor where the spark plug will eject from the aluminum cylinder head. I have a 2003 Ford Expedition that experienced this on Saturday. I was driving home from wal-mart with my family in the truck, we turned a corner and my heart stopped! it sounded like I was involved in machine gun fire. I pulled over immediately and my looked. Couldn't initially see anything. My husband checked under the truck thinking it was exhaust related. We were luckily 2 blocks from home, so we were able to get it home and into the driveway. My husband began trying to diagnose the problem and I took to the internet. He took the engine cover off and discovered the spark plug missing and the coil wire broken off and sparking. Long story short it seems that we have experienced the situation where the cylinder head has stripped on the one spark plug. We have begun looking into ways to fix the situation, but it seems Ford has not deemed this to be an issue. Truly don't understand how so many people can report the exact same happenings and no one will do anything about it. . . . . Merry stinkin christmas!!! we are reaching out to our local Ford dealer but am pretty sure they are going to tell us we are crap out of luck and will fall on us to repair if we choose.

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(takata recall) I have purchased my truck from a legal car dealership in reno nv had 135000 miles wen bought ive had to replace fuel pump had to buy different rims/tires due to wear of stock rims . . Exhaust problems replaced fuel injector. . Wear of thing causing water damage when raining outside. Spark plug ejected from engine was in motion 45 mph stationary moving problems also n wen turning.

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We own a 2004 Ford Expedition. On June 29th my wife and two children were driving the truck home when a spark plug blew out of the head. She drove the truck to me at work not knowing what really happened. There was a plug attached to the coil bouncing against the block near a hole spitting gas an gas vapor. I'm not sure what situation is needed to order a recall but it looked to me like one unlucky bounce and an engine fire would breakout. I have since looked this matter up and found multiple people with the same problem. At the very least Ford should be responsible to inform their buyers that this is a possibility. I had no previous knowledge of this being a problem or I would have put anti-seize on the plugs which could have stopped the problem. In a time when Toyota had to cause accidents and death to get something done maybe we could be a little more proactive on this one.

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I have a 2003 Expedition 5. 4l and since 2006 to present every two or three months I have to replace a coil pack and spark plug. Now since the coil packs have blown out so many times my catalytic converter on the passenger side has melted on the inside.

Blown out spark plug from 2001 Ford Expedition triton 4. 6l engine during operation on a public road. The second spark plug on the passenger side blew out of the engine while it was being driven on the road. This made a loud "bang" sound as if a tire blew out. The loud sound continued like a loud exhaust leak and gasoline vapors were immediately present in the passenger compartment. The driver shut off the engine to prevent an engine fire after attempting to safely park on the side of the road while avoiding moving traffic. This required aggressive maneuvering to avoid moving traffic. The car is now awaiting repairs, which is est. At >$3,000. The mechanic reported that this is a very common problem on Ford vehicles with the triton engine. I have never before seen a spark plug "blown" out of the socket like this. The plugs were replaced once at about 50k miles. The engine has about 110k miles today.

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While driving my youngest daughter to school there was a loud bang from under the hood and a noticeable loss of power. It sounded like the car had a severe exhaust leak. When taken to my local dealer I was informed that a spark plug had blown out of the engine and that this was a very common occurrence with the 2002 5. 4 liter engine. I was told that repairs would run anywhere from $700 to $3500.

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I own a 2002 Ford Expedition. The spark plug popped out of the engine head on two occasions. The first time it happened was on thanksgiving, 11/26/2009. The engine was smoking and it smelled like gasoline. My mechanic said this is happening to Fords all over the country and that it is documented all over the internet if you do a "google " search on Ford spark plugs popping. The repair cost me $500. On January 8, 2010, another spark plug popped out from a different cylinder. The truck is in the shop now. My mechanic advised me not to put new Ford heads on the truck because the new heads will have the same defect. I expect this new repair to cost $500 as well. Ford needs to be ordered to issue a recall. This is a dangerous defect that can cause a fire or an explosion under the hood due to the gas vapors being pumped into the engine compartment while the popped out plug is still sparking. I was fortunate to shut down the engine when I started to smell the strong gas fumes.

While driving my 1999 Ford Expedition 5. 4l and coasting down a hill all of a sudden a loud pop and the a loud exhaust noise. I smelled fuel and immediately pulled over. Upon opening my hood I found a small fire (thank god I carry a fire extinguisher) and that my engine had spit out a spark plug stripping all the plug threads. It is now in the shop being repaired for an unknown cost.

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1998 Ford Expedition 4x4 4. 6l, the poor quality steel used for the exhaust manifolds and bolts rust very fast. Mine resulted in the driverside bolts rusting away causing exhaust coming directly out of the engine, also the egr tube rusted off the drivers manifold causing hot exhaust to blow toward the top of the engine. On the passenger side the manifold bolts/studs also rusted away causing exhaust to disperse in the engine bay. Also on the passenger side the manifold cracked about 3 inches long on the top of the manifold causing hot exhaust to blow upward to the upper engine bay. I corrected this problem by replacing the bad manifolds/studs with pacesetter shorty headers and bolts, it was the cheapest fix. . Read more...

Driving home from doctor visit, heard a loud pop, and lost power, very loud engine noise as if I had no exhaust. Mechanic looked at it apparently the engine blew out a spark plug making it necessary to replace the cylinder head since it stepped the treads. And also broke the coil. Am on disability and fixed income, the repair cost is so high I have to wait and be without a car. Do not know what to do. The mechanic told me it is a common problem with this vehicle and Ford. And I researched the web and found out that many others experienced the same thing. Furthermore when going to Ford for repair, they say that the new head is a improved version. So if it is an "improved" version that mean that they know that there is a problem with the product to begin with. Ford should replace the faulty heads at no cost to vehicle owner.

Spark plug blew out of engine head on a 2003 Ford Expedition with a 5. 4l engine the spark plug blew out of the engine head and gasoline were expelled on the engine and exhaust fumes into the passenger compartment. The engine head had to be repaired at a cost of $1,832. 48.

I was driving at about 15 miles an hour and all of a sudden I heard a loud pop. I had to have it towed to a Ford dealership. They said that from what I was describing it was a spark plug that blew out of the engine. But since it was almost 5:00 p. M. And they were about to close they wouldn't know anything until they could look at it the next day. I didn't damage the heads but it still cost me over $400. 00 to fix it.

I have a 1997 Ford Expedition, engine coils were replaced , check engine light went off and there was no jump in acceleration. 2 weeks later check engine light back on.

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I was driving my 2003 Ford Expedition to work this morning and heard a loud "pop" noise, the vehicle began to vibrate and I smelled gas fumes. When I lifted the hood, I immediately noticed that the engine had blown a spark plug.

2001 Ford Expedition 5. 4 v8 triton engine keeps blowing out spark plugs. This happened 2 months ago for the 1st time. I replaced the spark plug. 1 month after that, the same spark plug blew again with my wife and two kids. Once again I fixed it. Then 2 weeks later, the same thing happened again while I was out of town, and this time it took the threads with it. Now I am looking at spending $1,000. 00 + to fix it.

On December 22, 2007 while traveling we heard a 'pop' in the engine compartment and then the sound an smell of exhaust escaping the engine. When taken to bob tomas Ford in mckinney texas I was told the the #3 sparl plug had been ejected from the engine head which had stripped the threads. I was then told that this has been an ongoing problem but that Ford has not issued a recall and was not providing any financial assistance for those customers who were no longer covered by a warranty. My vehicle had 97,433 miles when this problem occurred. The total repair bill was $3375. 20 to replace the right head. I requested assistance from Ford after pointing out that the maintance schedule that came with the vehicle did not require a check of the spark plugs until the vehicle had reached 100,000 miles. Ford stated they would not assist in any way.

On the underside of the vehicle there is an audible, high frequency rattle or vibration that is increased when the vehicle is in gear, stopped and in idle. The noise reduces and often goes away when the engine rpms are increased above 600 per minute. The vehicle has been examined by the dealer three times, has had all of the exhaust brackets tightened or replaced to no avail. Owner was informed that it was a "backed out bolt in the exhaust heat shield", this bolt was changed by dealer on the 3rd trip, with no change, in fat, that made it worse. Two different muffler shops have looked at and notice nothing else loose or missing. On the last visit to the dealer, owner was told that the reason for the noise is that the "exhaust pipe is torqued and twisted a little bit from heat contraction and expansion. ".

: the contact stated a loud exhaust noise was heard while driving 55 mph on normal road conditions. There were no prior warning signals. The vehicle was taken to the dealer, who determined the bolts were snapping off the exhaust manifold due to a manufacturer defect. The vehicle has yet to be repaired.

Blown spark plug on a 2002 Ford Expedition. Mileage:36046 cylinder number 3 I took the truck to Ford 4 days before the incident as I had been hearing a slight ticking nose coming from engine. Ford dealer told me to keep driving it until something bigger happened as my extended warranty might not cover all labor costs if they couldn't find the problem. Turns out it was small exhaust leak around the threads of the plug. Once the plug blew on the highway approximately 65 mph loud noise and loss of power. Now the vehicle needs a new head and will be with dealer for over a week.

2001 Ford Expedition 5. 4l for about 2 weeks it sounded like there was an exhaust leak. Had an appointment to have exhaust looked at on 9/6/05. Coming home from work on 9/2/05, was stuck in slow traffic. When traffic broke up, I started to accelerate and heard a pop and lost power. I had to get over 3 lanes of traffic to pull over. The truck was making a loud noise and smelled gas. Had to call a tow truck to pick it up. It cost me $200 to have it towed home. On 9/6 I called the dealership that had worked on it last and they pretty much told me that did not want to look at it. So I called the local Ford dealer and they told me the same thing. So I had it towed to a local engine shop for repairs. They are pulling both heads and installing 8 new head certs, which cost me $2000.

One spark plug on my 1999 Ford Expedition exploded and burst through the head of the engine. My wife was picking up my child at school. She parked the vehicle, shut it off and minutes later returned. As she was starting the Expedition both her and my daughter heard a very large explosion from the front of the vehicle. The vehicle continued to run and a constant popping sound could be heard. She immediately shut off the engine and noticed a very strong gas/exhaust type smell. She called me and I arrived to check the vehicle out. I inspected all the fluid levels and fuses and they were fine. I briefly started the engine with the hood open to help narrow the location of the sound. The sound was coming from the top of the engine on the passenger side. I started inspecting this area and found that the third spark plug from the front of the engine on the passenger side had been completely blown out of the head of the engine. It is very fortunate that this occurred in a parking lot. My wife and daughter were both very startled by the loud explosion and I can only imagine what would have happened if this had occurred on the road at a high rate of speed. I believe that an accident would have resulted. I have since done some research on this particular issue and have learned that this has happened on numerous occasions on Ford vehicles and has been brought to the attention of the NHTSA. I would like to file this complaint and find out what the NHTSA is doing about this specific issue. The design issue with this particular spark plug/engine head combination is well known in automotive circles. What is the NHTSA doing about this issue. Thank you for taking the time to hear my concerns, and to reiterate I believe that there would have been an accident if this event had happened on the road at any rate of high speed.

The contact stated the inside of the vehicle occasionally had a strong smell of gasoline when driving at 75 mph. The vehicle was taken to a mechanic, but the mechanic could not duplicate the problem. The contact only used the vehicle for driving her children to school, which was about 5 or 6 blocks away. Due to her fears about the smell she tried to exchange the vehicle for another but the dealer denied her request.

The Expedition that I have makes an annoying noise at varying speeds. This has been going on for the last 8 months. It was taken to the shop in Feb for a noise which ended up being a problem with the rear end.

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While driving at any speed steering vibrates violently. Dealer states the steering rod malfunctioned. All 4 wheels were balanced, however steering wheel is still vibrating and noisy. Blue smoke from exhaust. No problem found. All windows slow to go down and squeaks. No problem found. Abnormal starting. Engine fan noisy. Dealer found normal operation. Clanking noise in steering column. Lower steering shaft was replaced.

Upon driving our 1999 Ford Expedition we were noticing a burning smell originating from the engine compartment. In preparation of a road trip we decided to take the vehicle in for service and asked to have the problem diagnosed. It was found that the head gaskets were leaking oil on the engine block as well as the starter and the exhaust, which could result in a fire. We contacted Ford motor company to ask for assistance with this problem due to the fact that we were informed by a certified Ford engine technician that there has been previous service bulletins out on this problem that we were not notified about, however Ford has not responded as of yet, although they have acknowledged our calls and e-mails. At this time nothing has been done to correct the problem, because we do not have $2,500 to $3,000 to have the vehicle repaired and the vehicle has been parked since the diagnostic reports.

The consumer was aware of a Ford TSB concerning oil leakage. He experienced an oil leakage from the head gasket into the exhaust system.

Follw up on letter dated oct. 7, 2002 1999 Ford Expedition. Nvs-216, mek, ref. # 567329. No components mentioned. The consumer called into the hotline to indicate that the engine was replaced because of a snapped intake valve that was laying against the piston.

The vehicle in question has been in the shop twice for misfire in the engine. The motor started running rough right after a startup one morning with a substantial amount of smoke coming out of the exhaust and about a week later another enormous amount of smoke on startup in the morning. The chain of events also caused other intermitten problems with the performance of the vehicle such as a sense of slack between the engine and rear differential when up shifting and down shifting. The vehicle also has intermitten problems starting , for example, you have to crank the engine three to four seconds longer than normal and at times I have had to stop the ignition and try again. There have been other problems with the vehicle that have been resolved and a continued problem with the mirrors moving when they are not supposed to, although I have not seen them move while driving as of thus far. Please note the incident date shown below is approximate and is when the problems started. I have filed complaints with Ford motor company,department of consumer affairs and mailed an application to the dispute settlement board offered through Ford motor company.

I have a 1999 Ford Expedition. It has had both head gaskets already replaced once, and now they are blown again. The car is out of warranty and the dealership has informed me that there is an abnormality in my engine which will cause this problem to continue to re-occur unless I pay $5000 to have a new engine put in. Ford has recalled similiar vehicles due to the problems with the same engines, however offers no assistance on their much pricier Expedition. I guess they figure we can afford the repairs. They refuse to discuss my problems and tell me that blown head gaskets are considered "normal wear and tear". The head gasket problem aside, this car has been in the shop over 30 times for non-routine maintenance issues. The leather seats had to be replaced, the exterior molding went bad, the exhaust system was faulty, wiring was faulty, mirrors and windows were faulty, electronic components were faulty, the list goes on and on.

An oil leak on right & left banks of the 4. 6l & 5. 4l v8 winsor and/or romeo produced engines could produce possible oil leak. Causing oil to leak onto the exhaust manifold and possibly causing a fire. Ford corp. Is aware of this situation and has issued a bulletin article 02-22-7 published 10-31-2002.