Manifold/header/muffler/tail Pipe Problems of Ford Expedition - part 1

This is the 2nd time it happened to my 2003 Ford Expedition. While driving heard a loud popping noise, followed by continuous popping loud popping noise like a broken exhaust muffler, sounded like a motorcycle. After investigating, found out that the #3 spark plug popped out (ejected) of the head cylinder, broke the spark ignition coil. When this happened, I smelled fuel, and saw smoke coming from under the hood, so I did not drive the car and towed the car home. I had to replace the ignition coil and spark plug and reinstalled the spark plug but it seemed to be still loose, so I took it out and put thread lock and reinstalled it but did not tighten it to the max and did not start the car till after 24 hours so the thread lock will hold it in place. Yesterday the same thing happened to #8 spark plug, it also broke the coil, and when I tried to install the new spark plug, found out that the threads on the head cylinder will not grab the spark plug, and now I am stuck without a car. When I asked around, people said this is a common problem on the Ford expedtion. This is dangerous and could kill someone if the engine caught on fire, because I smelled gas and smoke. If this is a common dangerous problem on the Ford expedtion, how come there is no recall for it???? are we waiting for someone to die due to engine / vehicle fire to do something about it? please look into this issue ASAP and let Ford fix this dangerous problem. Spark plugs ejecting out like this? I noticed that there are only 4 threads on the head cylinder holding the park plug, but the spark plug has 10 or 11 threads and ofcourse only 4 of those threads are being held by the head cylinder. This is a dangerous problem waiting to hurt or kill someone, please ask Ford to fix this big problem, thank you. . . .

See all problems of the 2003 Ford Expedition 🔎.

I understand the welds for high pressure fuel pump may fracture. I have already had repaired, running rough on start up plus white smoke from tail pipe. I believe there is another problem occurring, as before in April 2019. It is February 2021, and and running as before. They torn my engine down, keeping for 4-5 days.

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Tl- the contact owns a 2004 Ford Expedition. The contact stated while vehicle was in a stand still the vehicle was leaking oil on muffler system and starter, oil coming out of tail pipe. The contact stated while driving 25 mph, encounter a burning odor from muffler area . The contact stated check engine warning light was illuminated. The contact stated a local dealer was not contacted. The vehicle had not been diagnosed or repaired as of yet. The contact stated that head gasket would need to replaced. The manufacturer had been informed of failure, and who referred contact to NHTSA. The failure mileage was approximately  210,000.

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Tl the contact called on behalf of the owner of a 2006 Ford Expedition. When the vehicle was started, there was an odor of antifreeze in the vehicle. Additionally, the temperature gauge and cylinder head temperature switch became inoperable. The vehicle was taken to an independent mechanic who diagnosed that the intake manifold and cylinder head temperature switch needed to be replaced. The vehicle was not repaired. The dealer was not contacted. The manufacturer was made aware of the failure. The approximate failure mileage was 245,000.

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Exhaust manifold leak caused by broken manifold stud. Vehicle had approximately 118,000 miles at time of failure.

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Cam phaser issue resulting in heated/cracked manifold, melting into piston 4, disabling engine. Requires full engine replacement at $6k parts & labor.

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The intake manifold needs to be replaced my mechanic told me and it leaks anti.

See all problems of the 2000 Ford Expedition 🔎.

The contact owns a 1999 Ford Expedition. While driving approximately 45 mph, the bolts from the exhaust manifold released. The vehicle was taken to an independent mechanic. The technician diagnosed that the exhaust manifold and bolts needed to be replaced. The manufacturer was notified of the failure. The approximate failure mileage was 143,000.

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The contact owns a 2015 Ford Expedition. While driving unknown speeds, there were abnormal fumes inside the vehicle. The vehicle was taken to loveland Ford (999 e. Eisenhower blvd, loveland, CO 80537) where it was diagnosed that the undercoating and muffler needed to be replaced. The vehicle was repaired, but the failure persisted. The manufacturer was notified of the failure and did not assist. The VIN was unknown. The failure mileage was 18,000.

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After accelerating from a stop, a loud bang was heard. What had happened? a spark plug blew out of the aluminum head, taking the threads with it. I was not aware that fuel would continue to blow out of the spark plug hole which could have been ignited by the ignition coil or exhasut manifold. Ford is aware of this issue, but has not recalled the defective aluminum heads, but rather offered a repair kit to fix the stripped threads when this issue occurs. This could have been a very different ending if the fuel would have ignited.

Just stopped at stop light, pulled away and heard a small popping noise, slowed down to turn corner to try to pull over and look and vehicle started popping like a popcorn popper. Thought it was muffler(s). Got under car to look nothing wrong there, proceeded to go back home. ( less than 5 blocks away) driving on (coasting) only using gas pedal to make it into driveway. Got under hood and seen spark plug laying on engine, coil looing like it had caught fire. Replaced wire, plug and put a helix coil on it. Drove for about a month. Same thing happened again. Had mechanic "rethread" the head and use "sleeve". This lasted about another month. Had to replace it 3 more times (always the same plug that popped out) until August 2 when it didn't even make it out of my driveway before it popped again. Now it is sitting in my driveway, a 5100 pound "lawn ornament" not looking forward to replacing the head.

Vehicle ran perfect during the day. Stopped for about 1 hour around 9 pm, went to restart the engine around 10 pm, heard a loud "pop" followed by very loud flapping noise from under the hood as the engine continued to run but very rough (sounded like "blap, blap, blap. . . . . . "). On investigation, found #6 spark plug had been blown completely out laying on the top of the manifold and the coil broken off its mount. The spark plug was not broken, but the threads looked a little rounded, but otherwise ok. Tried to reinstall the plug, but it never would seat and when pulled out vertically it felt like the threads were stripped in the head. Had the vehicle towed to a local Ford dealership in wichita.

Exhaust manifolds leaking and fumes entering vehicle.

Dealer wants $800 to change spark plugs as they will break off in engine. Because a dis similar metal was used. Exhaust manifold bolts break and cause loud exhaust leak at the rear of the exhaust manifold dealer wants $850 to fix.

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The contact owns a 2006 Ford Expedition. The contact stated that the vehicle would only shift into reverse. Upon examining the vehicle, the contact noticed that a wiring harness within the engine melted against the exhaust manifold. The vehicle was taken to an authorized dealer and the contact was informed that the wiring harness needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and offered no assistance. The failure mileage was 90,000.

Plastic intake manifold failure resulting in repairs in excess of $1500.

See all problems of the 1998 Ford Expedition 🔎.

Oil leaking from head gasket on passenger rear of head. . . . . Leaks onto manifold where a fire can start. Ford mechanics know that there is a problem. The mechanics say that there is a flaw in the casting in the head. There are numerous complaints of this happening.

I have a 2003 Ford Expedition with the triton 5. 4l engine. I had the spark plug eject from the #7 cylinder. In my case the garage that I took it to had to remove the cylinder head to helicoil the cylinder. It took 5 weeks to get my truck back and cost over $1200 to fix. I had to replace 2 coil packs, a spark plug, the head gasket, intake and exhaust manifold gaskets, oil pan gasket, valve cover gasket and timing chain gasket.

While driving my 2003 Ford Expedition down the freeway @55 mph noticed a loud pop and a weird noise. Stopped vehicle, popped hood and inspected. Found #5 coil hanging by harness and #5 plug sitting on manifold. Plugs are original as the truck has on 76,000 miles. No other damage noted. Will helicoil the hole using a kit for this specific problem.

Heard a knocking noise coming from the engine department, took said vehicle to a dealership to be checked out, was told that it was a leaking exhaust manifold, I then checked what I was told and did not find any problems with the exhaust, then three weeks later without warning the no. 3 cylinder spark plug ejected from its port and breaking the ignition coil assembly, as of now, we are trying to figure out how to fix said problem because I have researched the issue and see that Ford does not have to fix said problem.

My 2003 Ford Expedition blew a spark plug out of the engine today. After reading about events leading up to this failure, my auto was acting exactly like all the others. A slight ticking sound while the engine idles. While driving 20mph, a slight loud bam occurred and the engine began to idle hard. The car was towed 70 miles to a repair center near my home and I now am to decide on a new manifold or a coil repair that is risky. How a company can operate with critical engine part that are so poorly designed is beyond my imagination. The internet is filled with complaints of spark plugs popping out of engines in f150s and explorer/expeditions. It is a shame that such a simple thing as engineering a thread deep enough to hold a spark plug in place for the life of a car is too challenging for a car company. This repair should be the responsibility of the manufacturer. They were able to handle replacing millions of firestones and should be held to a standard close to their reputation as a tough vehicle. Without recourse, Ford will find it acceptable to cut corners and engineer sub par part.

2002 Ford Expedition - back passenger side spark plug blew out. Car was pushed to mechanic who was luckily close by at time of blow out. Spark plug was completely blown out, the coil was broken and the intake manifold had to be removed to facilitate repair. Total bill: over $1300. Ford knows about this problem - it is widely reported on the internet - but yet they do nothing to help their consumers.

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My wife was almost to the end of the off ramp to the 210 freeway and heard a loud pop and then an awful noise. It sound like she blew a hole in the exhaust manifold. It turned out to be the #3 spark plug being ejected from the engine. We purchased the vehicle from the dealer and have never changed plugs. We were fortunate that it happened local and not on the road for vacation. The truck was towed and repaired and a tune up down. An expensive day and needless time off work for a problem that seems to due to bad engineering. A tapered spark plug and 1/4 thread lock in the head is not a safe and Smart design. A 3/4 thread lock would be much better.

I was driving on the freeway at 10pm, and heard a loud pop, then what sounded like I had no muffler from the engine. I looked in the engine, and could not really see anything because it was dark. I had to the vehicle towed because I thought I blew a rod, or a head. Once at the mechanic's, they saw that I shot out 2 spark plugs- the no. 3 and 4 still attached to the wires, and that there were no threads left. I am having them pull the head, and have plugs put in, so far the cost to date is $1200. If the plugs do not hold, or other ones blow- which could happen at any time, I will have to replace the entire engine . This will about $3000 this is a very common problem with Ford engines. Please do something about. Ford needs to take responsibility!!!!!.

1997 Ford Expedition--aluminum heads are engineered incorrectly. The problem is the spark plug recess bore is to thin, the spark plug does not have enough material to properly seat in the head and after awhile the plug will back out. The pressure from the combustion will eventually blow the plug out. This will lead to costly damage to fuel injection damage, piston, intake manifold, etc. The problem is ranging from 96' to 2005 triton engines. Ford will not help you nor will the engine manufacturer until someone dies! repairing this problem. . . . . . Low cost-heili coil insert $100 to $1000 depending on your service tech. Or a complete head replacement (steel heads) $3000 to $5000.

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The contact owns a 2006 Ford Expedition. While driving between 25-55 mph, the vehicle began to vibrate and shake violently, the engine light illuminated, and smoke appeared from the tail pipe. The vehicle could not be driven greater than 60 mph. The higher the speed, the more the vehicle would shake and vibrate. The failure occurred everytime the vehicle was driven. The dealer has had the vehicle since June 24, 2008, but they still cannot determine the cause of the failure. The current and failure mileages were unavailable. Updated 09/29/08. The dealer replaced the converter. Updated 09/29/08.

I was getting a loud noise from the passenger side when I would accelerate. I took it to the shop and found that all of the nuts and studs holding the exhaust manifold to the engine had rusted away. The tech said it is a common problem he finds with Fords. I also talked with a guy and he had the same year truck and had the same problem. I have a friend who is also a auto mechanic and he sees it often as well.

Recurring engine noise which is more noticeable during cold weather. Under load the engine , particularly at 2000 rpm, sounds like there is a manifold leak or a valve ticking. I have been to my dealer twice(out of business) and two other dealers three times with no satisfactory results.

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Spark plug on my 97 Ford Expedition blow out. The engine is a triton 5. 4l. It happened while I was driving on residential street at 30 miles per hour.

The contact owns a 1997 Ford Expedition. The dealer informed the contact that the manifold bolts have rusted out and need to be rebuilt and re-drilled. The vehicle was not included in any recalls. The contact heard a ticking sound coming from the passenger side of the motor due to the manifold rusting. The noise ceases when the vehicle heats up. The current mileage is 190,000 and failure mileage was 188,000.

The events leading up to the failure included startup of the vehicle and on the second occurrance merely driving the vehicle - a 2000 Ford Expedition eddie bauer 5. 4 ltr triton v8 with 90000 miles. The failure was of 2 separate spark plugs being blown from the cylinder head (both on the drivers side) a total of 3 times. The consequences was having the vehicle towed to a repair shop. The most recent repair was a recurrance of the same blown plug which happened in 2005. To correct the issues, the spark plugs were replaced and reinserted with repair kits to hopefully prevent future blowouts. Additional consequences are that I no longer trust Ford or my vehicles reliability. In researching this issue online, this is not a rare occurance and there have been vehicle fires where the spark plug has ruptured the fuel rail which sits directly above the spark plug holes. Consumeraffairs. . Read more...

We owned a 02 Ford Expedition which gave me no problem and I loved and owned it out right. In August of 07 the Expedition blew out a spark plug from the engine while stopped at a stop light. When I took it to the mechanic they speculated right away what the problem might be and upon checking it out found there speculation to be true. I phoned other mechanics who immediately said they were aware of the problem with that year engine and those surrounding it. It has obviously happened enough times for several mechanics to be aware of the problem and state that Ford was doing nothing about it. My husband went to speak to the Ford dealership who responded that it was not a problem and they were only aware of a few incidents and were going to do nothing about our problem. We ended up heli coiling the plug and having a temporary fix. We no longer have the vehicle because I could not trust that it would not blow a spark plug again and we have children and need a reliable vehicle. I'm very discouraged by the fact that I now have a car payment when I didn't before. I don't know if any other complaints have been made but the mechanics here seem to believe it is happening far to often and nothing is being done about it. Again I owned the Expedition out right and am very upset about the fact that I had to buy another vehicle because of something that never should have happened. Vehicles don't just blow a spark plug from the engine. Thank you tanya bishop.

: the contact stated the vehicle was leaking antifreeze onto the intake manifold behind the engine. An independent mechanic determined the upper part of the engine needed to be removed to repair the leak.

Leaking right head gasket due to faulty manufacturing. Oil leak is dripping on the muffler potential fire hazard and pollution.

: the contact stated when taking the vehicle in for normal routine service, a leak in the head gasket was discovered. The vehicle is currently at the dealership awaiting repairs.