Engine Problems of Ford Expedition - part 1

Our 1998 Ford Expedition with the 5. 4 v8 triton engine had another spark plug blow out of the cylinder head. The last time this happened was about 3 years ago, it was the #3 cylinder plug then and last week it was the #6 cylinder plug, I searched the internet concerning this problem and found hundreds if not more of the same issues, and no one is making Ford do anything about this, just thought my voice in this matter might help. Please if there was ever an instance of a recall this is surely one. This is getting very expensive for the auto owner, the first time we had it fixed by Ford and it was $250 and this time it was over $1,000. Thank you for addressing this issue.

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My best friend's 2003 Ford Expedition blew a spark plug out of the cylinder head while pulling a boat across a highway. This caused the vehicle to be stuck in the middle of the road, and several cars had to slam on their brakes and swerve to barely avoid collision. Upon internet research, I learned that thousands of people had the exact same problem with this same engine in Ford vehicles over several years of production. Ford denies this problem exists and endangers lives everywhere with this motor. I saw this problem myself, and mechanics I have talked to said that these Ford cylinder heads are all bad with this problem. This problem exists for every Ford triton 5. 4 liter v8 engine, so it exists across thousands of VIN numbers.

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A week ago I was driving my 2001 Ford Expedition to friends for a social visit. On the way, I drove as I normally do the speed limit as posted. At around 10:00 pm, in the middle of nowhere, I encountered the now well known and dreaded spark plug ejection. Thought I had been shot at there for a second, but soon realized what it was. It couldn't have happened at a worse time nor to a worse spark plug to reach, far left rear. I was only 75 miles from home stranded by my vehicle. I truly am a loyal Ford fan and owner of several, but this is by far the worst vehicle I have ever owned! I am thoroughly disgusted with this piece of you know what! after getting it towed home, I attempted a replacement of the plug only to find the plug hole was screwed up and couldn't get it in there straight. So what the heck do I do now? Ford motor company, this is a crock and you know it! whatya gonna do now? blow it off and do nothing, as I expect. Or are you going to repair it as you well should. These vehicles aren't cheap, but I am beginning to think they area built that way intentionally. What are you going to do Ford?.

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1. Driving, 35mph 2. Spark plug blew out of #2 cylinder, damaging coil 3. Vehicle currently waiting for mechanic to check seals and head to determine extent of damage.

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I have a 1999 Ford Expedition that has continuously blown spark plugs, I have had it repaired several times at a local dealership. I keep my vehicles maintained on a regular basis, and I have no warnings leading up to the spark plug blowing. I am afraid that one of these times it will blow and my engine will catch on fire. I am very diappointed with Ford, that they have not done anything to resolve this issue, except to keep replacing the coil pack and spark plugs and charging me more money. This problem began in Nov 2007, and I have had to have it serviced for the same issure two other times and now as of today I will have to have it repaired again. I have trust in my dealership that they are fully capable of repairing the vehicle as they have serviced my other vehicles with no other problems.

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1999 Ford Expedition 5. 4l v8 triton engine. Number 7 cylinder spark plug was ejected from the head while driving in town. Ignition coil on top of spark plug was sheared off of it's mounting on the head. Needed to use a spark plug thread repair kit to repair the threads in the head and a new ignition coil to replace to broken one. Approx $100 to repair.

2003 Ford f250 and 2004 Ford Expedition. Consumer states right rear spark plug blew out of the cylinder head. This happened on both vehicles the consumer was informed an adapter was made as a temporary fix. About 500 miles later, the same problem happened again. The consumer took the vehicle to a repair shop where the mechanic stated the heads or engine would need to be replaced at a cost of $3000-$4000.

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I own a 2000 Ford Expedition with a 5. 4 liter triton engine which experienced a spark plug blow out. So far, NHTSA has not required Ford to issue a recall for a problem that many others have had with the same type of engine. Ford does not accept responsibility for a defective design of this engine. I am now forced to pay $3,000 to fix the problem before I can even consider trading it in or trying to sell it.

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Spark plug ejected from the engine of my 2001 Ford Expedition. The engine is a triton 5. 4l v8.

Ford Expedition 1999 ejected spark plug problem. After having this problem three time already, I start researching about it and seems that 100th of owner of Ford Expedition from 1997 to 2003 are having a recurring problem. Why is not a recall on this when hundreds of owners are spending from $300 to $700 on repairs that Ford should be responsible. It is noticeable that its a manufacture problem not a customer problem.

The contact owns a 1999 Ford Expedition. After driving all day, the vehicle was parked for a few minutes. When it was restarted, the engine suddenly caught fire. There was smoke emitting from the hood and sparks from the engine. The fire department extinguished the fire. The origin of the fire was unknown. There were no injuries. A fire report was filed. Neither the manufacturer nor the dealer had been notified. The failure mileage was approximately 250,000.

Engine hood insulator material began to smolder and smoke. Needed to remove before vehicle caught fire. Burned two fingers.

1998 Ford Expedition the spark plug blow out.

The spark plug (passenger side, second back from front of engine) ejected from the engine head while parked. We had driven for 20 minutes, stopped at a restaurant, turned off the engine, but restarted it within about 60 seconds. The spark plug ejected immediately after the engine was restarted, within 1 second. There were no injuries, and the vehicle was not in motion at the time. My entire family was in the vehicle at the time. The sound of the ejection was sufficiently loud that it resembled a gunshot, to which an off-duty officer reacted. The coil pack was damaged beyond use, the spark plug insulator shattered. The plugs appeared to be original motorcraft plugs, although at 130k miles, they would be very old. They had sufficient carbon and wear that they could be original plugs or plugs from the first scheduled replacement (if it was done). Repairs have not yet been performed.

I own a 1997 eddie bauer Ford Expedition that I bought in 1998 as a demo model it has run great until it started to blow the spark plug from the heads the first time was last year while my family and I were driving back form texas we were in a remote part of the country when it blew and spent over 500. 00 for towing not to mention the 1200. 00 dollar bill that the dealership tagged on. I was never informed that this was a problem that could re-occur we have taken other trips but did not have issue until just recently it blew another plug and of course the bill in the thousands. Ford needs to take some ownership for the product that they build if they want to keep some of as customers. . .

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Sudden backfire resulting in spark plug ejection. Replaced with helicoil kit.

The contact owns a 2001 Ford Expedition. While driving 15 mph, there was a loud, unusual pop heard from the hood area. The contact moved off the roadway and discovered that the spark plugs had fractured from the vehicle. The vehicle was towed to the contacts place of residence. The dealer was not contacted and the vehicle was not repaired. The failure and current mileage was 114,000.

The contact owns a 2001 Ford Expedition. The vehicle was parked in front of the contact's home when it caught on fire. There were flames shooting from under the hood of the vehicle. The fire department was called to extinguish the fire. A fire report was available. There were no prior warnings indicating the failure. The vehicle was not diagnosed for the cause of the failure. The current and failure mileage was 95,000.

I was driving my family home from yellowstone on i25, when our 2001 Ford Expedition blew a spark plug. We were miles from anywhere with a tow truck, and it took over 2 hours before a tow truck operator got us. At the same time, an escaped murderer was hitchhiking down a different route home. (what if we had chosen that route?) I rented a car to drive home, and it looks like we were way overcharged for the repair. ($3500).

A spark plug was ejected from the cylinder head. Interior of the SUV filled with gas fumes. There was nothing noticeable prior to this occurring. This is the first time this occurred. The mechanic obtained the repair kit to rethread the cylinder head at a cost of $360. 00. The work is not guaranteed. . . If it happens again, the head will need to be replaced at a cost of thousands of dollars.

On my way home from kansas to colorado when we heard a sound like a flat tire but it wasn't. My spark plug had shot out of my cylinder head. This could have caused fuel to spray out and start a fire. This is a common problem with the triton 5. 4l engines, but there has not been a recall or anything to fix it.

Well we were just driving home when the spark plug of our Ford Expedition just shot out of the cylinder head and we cant replace it because its too much money for us.

Driving our 2003 Ford Expedition thru the desert to green river utah. Loud pop and car shuddered and lost power. Pulled over immediately and had it towed back to price ut. Ford dealer said spark plug blew out of cylinder head. $2000 to re-thread head, $3000 for new cylinder head or $5000 for a new motor. Since our motor had 90,000 miles on it we opted for a new motor. But after researching all the other people who blew spark plugs out of their motor's head I do not feel safe driving this vehicle anymore. Come to discover this has happened to many people who own this type of vehicle with the aluminum cylinder head. This is a manufacturers defect that should be recalled. The public is being sold a defective motor and having to pay unnecessarily when it breaks down. Ford needs to recall these defective engines and fix the problem. These motors are not "built Ford tough".

The contact owns a 2002 Ford Expedition. The contact stated the vehicle was parked in his driveway when it caught on fire. The fire department was able to extinguish the fire. There were no injuries. A fire report was available. The contact stated the spark plugs blew out at the cylinder head causing the fuel rail to bend and resulting in a fuel leak that started the fire. The engine was severely damaged. The contacts insurance company advised that the fire originated from a pre-existing failure in the vehicle and would not cover his claim. The vehicle was towed to the dealer where he was advised they were aware of the failure yet would not provide any assistance. The vehicle was not repaired. The failure and current mileages were 190,000.

2002 Ford Expedition, original factory spark plug was violently ejected from the engine during normal operation. Spark plug smashed through fuel injector and dented the hood. Had someone been servicing the engine the injuries could have been severe. Ford motor company refuses to call this a defect and area dealerships want to charge $700 to $3300 to fix this issue. There have been thousands of complaints and this motor design problem should be recalled and fixed by Ford motor company.

I have a 2003 Ford Expedition 5. 4l that has blown the #3 spark plug 3 times. Each time I have purchased oem plugs. It appears that I am not alone in this experience and many speculate that the thread depth is not enough to secure the plug appropriately.

Original factory spark plug backed out from cylinder head. Checked remaining 7 spark plugs. Four of seven loose. Mechanic recommended using heli coil kit on all spark plug threads. Mechanic mentioned that this was a common occurrence on Ford 5. 4 liter engines. If this is true, it appears as though a recall should be required for repair of cylinder heads.

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I have had two spark plugs blow out of my 2002 Ford Expedition 5. 4l v8. The first blew out after pulling out of an intersection from a dead stop. The second was the #2 plug. I was pulling a travel trailer through mountains on a highway. First noticed was a reduction in power for about 60 miles. Then after rounding the top of the mountain, letting off the gas to go down the hill, the plug blew out.

Starting vehicle spark plug broke loose,damaging threads for spark plug and breaking coil pack. This is the second time this has occured. First time the vehicle was at freeway speeds and blew the spark plug out into the engine compartment. The spark plugs had never been changed before the first incident. In order to fix the problem the spark plug hole will have be repaired before a new plug can be put in.

2006 Ford Expedition failsafe mode comes on. It has happened 4 times in 4 months. Have loss of steering and engine has no power. Very dangerous.

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2003 Ford Expedition eddie bauer, spark plug on passenger back side ejected from head while I was driving. They were still original spark plugs. Going to cost over $1000 to temporarily fix problem.

#4 spark plug blew thru head.

1st occurance: 2003 Ford epedition, 5. 4l v8 engine. Factory original spark plug exploded while travelling at 60mph. Mileage: 72,955. Date: 8/17/08. 2nd occurance: same engine, original plugs( less above repair). 2/05/2010, miles 77,525. Spark plug exploded while travelling 40 mph.

Ford spark plug ejection, 2003 Ford Expedition 5. 4l triton engine. "consumeraffairs. Com" has 317 pages of complaints regarding this issue. Ford does not acknowledge a problem. I have had two (2) blow-outs, costing me $1,200. 00 I would like to see a petition for recall started, based on potential fire and safety issues. In my case, I was traveling at 60 mph and lost power while in traffic. I had to carefully pull off highway with very little engine power. This is a serious issue which needs to be addressed. I now own a vehicle that I can not take on a long trip, for fear of having the engine explode again. Hopefully, it will not take a fatality or serious injury to have someone review this problem and take action. The February 21,2007 memo from dot, ref: dp05-005 review is in need of updating. The numbers are now much greater than previously reported. Please review this problem. Ford simply says " not my problem". [xxx].

After pulling out from a stop sign I had a spark plug blow out of my 5. 4l v8 in a 2002 Ford Expedition.