Manifold/header/muffler/tail Pipe Problems of Ford Expedition - part 2

Towing trailer and exhaust manifold studs broke. This caused a loss of power climbing a steep grade. Car behind almost hit us.

See all problems of the 1997 Ford Expedition 🔎.

The vehicle was running rough, and the service engine light appeared. Took vehicle to the dealer, and they said manifold was cracked.

See all problems of the 2000 Ford Expedition 🔎.

The car was under normal city driving conditions when the #3 spark plug was violently ejected from the engine. Although there was not a fire, with fuel air vapors being expelled from the empty spark plug hole and the plug and wire visible arcing in the engine compartment, there certainly was a possibility of a fire. I have contacted Ford motors customer relations directly to report this as a potentially dangerous design flaw, they flatly deny that there is any problem. Unfortunately, the cost of this repair can run between $3000 and $6000, which is probably why Ford has chosen to take the coarse of denial. At the same time they are denying that this is a hazardous design flaw, the have corrected the problem in replacement parts and in later model years.

See all problems of the 1998 Ford Expedition 🔎.

Oil leak from right side cylinder head gasket. Oil leaks onto exhaust manifold and under certain conditions it could start a fire.

See all problems of the 1999 Ford Expedition 🔎.

Consumer will describe the problem related with the exhaust intake manifold. Dealer and manufacturer has been notified. The leaf and twig litter would collect on the skid plate when driven off of the road. This was in close proximity to hot pipes which caused smoldering and a fire hazard.

See all problems of the 2004 Ford Expedition 🔎.

On my 1999 Ford Expedition I noticed the smell of hot oil. When I would stop and park the vehicle the smell became stronger and smoke would come up around the hood of the vehicle. I also noticed some oil drops on the ground. Upon taking the vehicle to the local Ford dealer I was informed the the head gasket was leaking oil on the rear of the right head. Cost to repair was $1,295. 04. I then found on the internet that this was a know problem and was widespread. Apparently there was a manufacturing defect in the head which would cause an oil leak in the right rear or left front of the head. Again this was a know problem by Ford but no recall has been issued and if your vehicle was not under warranty the owner had to absorb the repair cost. To me this was a safety issue and should have been addressed by Ford. The oil was leaking onto the exhaust pipe and could have caused a fire.

1998 Ford Expedition eddy bauer losses power when accelerated over 3000 rpms, on what seems to be a misfire, I've taken it to different mechanics, I've had the coils and spark plugs replaced, I've spent over $2000 and problem still persists. I went to two different Ford dealers just to encountered the worst dealer serviced I've ever received in my life. . . They are no help. I am stuck with a car that I paid over $30,000 for that has defect problems that Ford is aware of but is completety unwilling to accept. This is definitely the worst investment I've ever made in my life, can anybody help me?. . . Please.

Upon starting the vehicle, large amount of oil smoke came out from the tail pipe. Vehicle was serviced 4 times by the dealership, in which a diagnostic test was performed. No failure code was found. Dealership indicated that this was a normal characteristic of the vehicle.

See all problems of the 2003 Ford Expedition 🔎.

99 Ford Expedition spark plug blow out right cylinder # 2. This occurred 10,000 miles after having Ford dealership tune my vehicle up. My local mechanic claim it was a defective spark plug and that Ford should remedy problem. That hasn't happened as of yet. My vehicle had 97,000 at time of blow out. I personally have put 60,000 highway miles on vehicle last year alone. This vehicle has a service bulletin on coolant hose clamp as well as insufficient threads on heads.

Fire hazard! manufacturers defect causes head gasket failure resulting in severe pressurized oil leak onto hot exhaust manifold, creating a dangerous fire hazard.

I have a 1999 Ford Expedition with 95,000 miles. At 31,000 it had warranty work performed to repair an oil leak between the cylinder head and the block. The warranty work was performed prior to the first technical service bulletin (011202) dated 6/12/01. The vehicle now has the leak again in the same area. The technical bulletin has this as the issue: some vehicles equipped with the romeo built 4. 6l 2v engine or 5. 4l supercharged engine may exhibit an oil leak or oil weepage from the cylinder head gasket at the right hand rear or the left hand front of the engine. Oil weepage is not considered detrimental to engine performance or durability. An oil leak may be caused by metal chip debris lodged between the head gasket and the block, chip debris between the cylinder head and the head gasket, or by damage to the cylinder head sealing surface that occurred during the manufacturing process. I believe that this is a manufacturer issue not a consumer issue.

While driving at 8,900 miles gasket blew. Took vehicle to dealer for repairs. Again at 22, 000 miles the gasket blew again. Also, vehicle was leaking oil. All gaskets had been replaced. Little white dot on headlight switch doesn't light up. Switch assembly replaced.

The tail pipe separated from the muffler & fell off. Dealer referred owner to muffler shop. They welded pipe on & it fell off sometimes later again.

While driving consumer states' the vehicle's tail pipe was shooting out metal. Consumer witness flames in the rear seat, pulled over and vehicle caught fire. Cause is still unknown. Please provide any further information.