2003 Ford Expedition Complaint Log

WE OWN A 2003 FORD EXPEDITION EDDIE BAUER. IN JANUARY 2009, WE HAD A "MISFIRE" IN THE #6 SPARK PLUG AND WAS ADVISED TO CHANGE ALL OF THE SPARK PLUGS - WHICH WE DID. SINCE THAT TIME, WE'VE HAD 3 OTHER "MISFIRES" IN THE #6, #8 AND #7 SPARK PLUGS. EACH TIME A REPAIR IS MADE, THERE IS A MISFIRE IN ANOTHER SPARK PLUG WITHIN 3 MONTHS OF THE REPAIR. ON 4/19/2010, THE NUMBER 4 SPARKPLUG BLEW COMPLETELY OUT OF THE ENGINE UPON STARTING THE CAR. WE HAVE HAD THE VEHICLE SERVICED REGULARLY AT THE FORD DEALER AND ALL REPAIRS HAVE BEEN MADE BY THE FORD DEALER. WE'VE BEEN TOLD THAT FORD KNOWS OF THE DESIGN DEFECT IN THEIR ENGINES AND IT IS A REGULAR PROBLEM WITH THE V8 ENGINES IN THE FORD TRUCKS AND THEY ARE CHOOSING TO DO NOTHING ABOUT IT. WE HAVE SPENT WELL OVER $3000 TOTAL TO FIX ALL OF THESE ISSUES. WHY ISN'T FORD STANDING BEHIND THEIR PRODUCT - ARE THEY WAITING FOR A INJURY OR WORSE, A FATALITY IN ORDER TO ISSUE A RECALL? *TR

I OWN A 2003 5.4L FORD EXPEDITION ED BAUER WITH 63,000 MILES. MY 2003 FORD EXPEDITION VERY RECENTLY BLEW THE #3 SPARK PLUG IN MAY 2010. I PURCHASED THE EXPEDITION IN 2006 WITH ONLY 14,000 MILES. THE SPARK PLUGS ON THE VEHICLE ARE THE ORIGINAL SPARK PLUGS FROM THE FACTORY AND HAVE NOT BEEN REPLACED. THE EXPEDITION STARTED MAKING A KNOCKING SOUND. ON MAY WAY HOME FROM WORK, AS I TUNED INTO THE FREEWAY ENTRANCE, THE ENGINE MADE A LOUD POPPING SOUND FOLLOWED BY A RATTLING SOUNG. I CONTINUED TO OPERATE THE VEHICLE FOR APPROXIMATELY 3 MILES AND THEN EXIT THE FREEWAY. THERE WAS ALSO A SMELL OF GASOLINE COMING FROM THE ENGINE. SINCE I WAS NOT FAR FROM THE FORD SERVICE CENTER (GALPIN FORD IN NORTH HILLS, CA.), I CONTINUED TO OPERATE THE VEHICLE TO THE SERVICE CENTER FOR REPAIR. A DAY LATER I RECEIVED A CALL FROM THE SERVICE TECHNICIAN INDICATING THAT THE #3 SPARK PLUG BLEW OUT OF THE HEAD. THE TECHNICIAN MENTIONED THAT THE ENGINENE NEEDED A NEW HEAD SINCE THEY COULD NOT REPAIR THE PROBLEM. TOTAL PARTS AND LABOR...$3834.00. AFTER READING COMMENTS FROM THIS WEBSITE, THIS IS CLEARLY A MANUFACTURER DEFECT THAT SHOULD NOT CONTINUE TO BE OVERLOOKED BY FORD. *TR

SPARK PLUG HAD BLOWN OUT OF ITS PLACE IN THE ENGINE. AT FIRST, I HAD THE CHECK ENGINE LIGHT ON AND I HAD PROMPTLY TAKEN TO THE SHOP (ASE CERT.) BUT THE LIGHT DIDN'T COME ON ANY MORE. AFTER THE SERVICE MAN RAN THE TEST SOME TIME LATER, NOTHING APPEARED TO BE WRONG. A DAY OR SO LATER, I WAS HEARING A "CLICKING" SOUND UNDER THE HOOD, LATER, I HAD LOST A SPARK PLUG. WHICH BY THE WAY IS A HORRIBLE NOISE! I WAS TOLD BY THE SERVICE TECHNICIAN THAT IT WAS A PROBLEM WITH FORD VEHICLES. *TR

SPARK PLUG EJECTED FROM THE ENGINE CAUSING THE COIL TO BRAKE AS WELL, AND THE WHOLE CAR TO SMELL OF GAS. THIS HAPPENED ONCE IN APRIL, AND AGAIN THE OTHER DAY (MAY 17TH), ON A DIFFERENT PLUG. IT HAS CAUSED ME TO LOSE WORK, AND MY MECHANIC INSTALLED A REPAIR KIT WITH A NEW SPARK PLUG. IT WAS $200-$300 FOR EACH REPAIR. FORD SAYS ITS NOT A PROBLEM, BUT MY MECHANIC HAS HAD OTHER CASES LIKE THIS, AND STATED FORD ISSUED A SERVICE BULLETIN ON HOW TO FIX THE PROBLEM. I HAVE CONTACTED FORD, ASKING THEM TO AT LEAST CHECK MY OTHER PLUGS TO MAKE SURE THEY ARE TIGHT, BUT THEY WERE UNHELPFUL. THERE WAS NO WARNING IN EITHER CASE. THE TRUCK DRIVES FINE, AND THEN SUDDENLY STARTS MAKING A LOUD NOISE AS ITS DRIVEN, AND THE WHOLE TRUCK SMELLS OF GAS. THESE ARE THE ORIGINAL PLUGS, AND THE TRUCK HAS 78K MILES ON IT. I BELIEVE THE HEAD NEEDS TO BE REPLACED SO IT DOESN'T KEEP HAPPENING. I WENT ON DIFFERENT CAR PROBLEM WEBSITES, AND THIS SEEMS TO BE A PROBLEM WITH THIS MODEL TRUCK. *TR

A DEER CAME ONTO THE HIGHWAY AS I WAS SWITCHING LANES AND I SWERVED TO PREVENT HITTING. HIT THE DEER AND DRAG IT APPROX 60 FT. SPARKS AND FLAMES WERE COMING FROM THE VEHICLE AS WE FLIPPED. VEHICLE BEGAN TO FLIP 6-8 TIMES PER PASSENGER (DAUGHTER) AND A TRACTOR TRAILER DRIVER. AIR BAGS NEVER DEPLOYED. THIS IS THE FIRST TIME FOR THE FAILURE OF THE BAGS. THE EXPEDITION WAS TOTALED BECAUSE THE FRONT AND REAR WINDOW CAME OUT, THE DRIVER AND PASSENGER WINDOW IN THE FRONT ROW WERE SHATTERED, THE ASHTRAY DISCONNECTED AND WENT OUT THE WINDOW. THE MIRRORS ON THE EXPO WERE DAMAGED AND THE BODY OF THE VEHICLE WAS TERRIBLY DAMAGED. A NEW VEHICLE WAS BROUGHT A COUPLE OF WEEKS LATER. *TR

TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 65 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE CONTACT WAS ABLE TO RESTART THE VEHICLE AS IT OPERATED AS NORMAL. THE FAILURE RECURRED APPROXIMATELY 5 MONTHS LATER. WHILE ATTEMPTING A TURN AT APPROXIMATELY 20 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE CONTACT WAS ABLE TO RESTART THE VEHICLE AFTER TWENTY MINUTES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC BUT THE FAILURE COULD NOT BE DUPLICATED AND THE MECHANIC WAS UNABLE TO PRODUCE ANY FAILURE CODES. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 120,000 AND THE CURRENT MILEAGE WAS 127,000.

MY 2003 FORD EXPEDITION WILL BE DRIVING FINE, THEN ALL OF A SUDDEN IT WILL DIE IN TRAFFIC AND HAVE HAD SEVERAL CLOSE CALLS OF BEING REAR ENDED. ONE OTHER TIME IT DIED AND WHILE COASTING AFTER IT DIED, IT STARTED AGAIN CAUSING VEHICLE TO LUNGE AND MY WIFE ALMOST REAR ENDED SOMEONE ELSE. THE VEHICLE IS AT THE REPAIR SHOP AND IT IS DIAGNOSED AS A PCM THAT IS AND NOW HAS A HARD FAILURE. *TR

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. *TR

MY 2003 FORD EXPEDITION THREW A SPARK PLUG. *TR

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. *TR

BRAKE LINES RUSTED AND LEAKED CAUSING SUDDEN LOSS OF MOST BRAKING. I BOUGHT THIS FORD NEW IN JULY OF 2003. AFTER THE BRAKE FAILURE, THE VEHICLE WAS TOWED. I HAD ALL BRAKE LINES REPLACED, AND STILL HAVE THE PIECE WHICH LEAKED. THE SHOP SAID IT IS BECAUSE THE BRAKE LINES ARE ROUTED ON TOP OF THE FRAME RAILS, AND SALT BUILDS UP. BUT I'VE LIVED IN THIS AREA ALL MY LIFE (I'M 66) AND HAD MANY OLDER OR HIGHER MILEAGE VEHICLES, BUT NEVER HAD THIS HAPPEN BEFORE. I UNDERSTAND THAT YOU ARE INVESTIGATING CHEVY BRAKE LINE FAILURE, AND THINK YOU SHOULD INCLUDE FORDS. *TR

TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. WHILE DRIVING AT SPEEDS OF 35 MPH FOLLOWING ANOTHER VEHICLE, THE CONTACT DEPRESSED THE BRAKE PEDAL AS THE PRECEDING VEHICLE INDICATED A TURN. THE PRECEDING VEHICLE DID NOT COMPLETE THE TURN AND AS A RESULT, THE CONTACT CRASHED INTO THE VEHICLE. THE AIR BAGS DID NOT DEPLOY AND HE SUSTAINED INJURIES TO HIS LEFT HAND AND A FRACTURED STERNUM. THE VEHICLE WAS DESTROYED. THE DEALER WAS NOT CONTACTED AND THERE WERE NO REPAIRS MADE TO THE VEHICLE. A POLICE REPORT WAS FILED. THE FAILURE AND THE CURRENT MILEAGES WERE 128,000.

I WAS STOPPED AT A LIGHT. I WENT TO GO AND I HEARD A POP,SO I WENT UNDER THE HOOD AND I COULD SEE THE LAST SPARK PLUG IN THE REAR ON THE PASSENGER SIDE FIRING. *TR

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. *TR

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.

MY HUSBAND WAS DRIVING HIS 2003 FORD EXPEDITION ON THE WAY HOME FROM WORK ON FEB.4,2010. HE HEARD A BANG AND SMELLED A SMALL VAPOR OF GAS ALONG WITH THE TRUCK NOT RUNNING VERY WELL. HE MADE IT HOME SAFELY TO FIND THAT SPARK PLUG BLEW THROUGH THE HEAD!! WE WENT ONLINE TO SEE ABOUT THIS PROBLEM,AND WHAT COULD BE DONE. HE HAS ONLY 69,000 MILES ON IT AND HE IS THE ORIGINAL OWNER AND TAKES CARE TO KEEP UP ON EVERYDAY MAINENTANCE. I HAVE MADE PHONE CALLS TO NO AVAIL--FORD CISTOMER RELATIONSHIP CENTER TOLD ME TO TAKE IT TO THE DEALER OR REPUTABLE SERVICE CENTER. THIS IS NOT COVERED UNDER ANY WARRANTY AT ALL!! SO I AM GOING FURTHER WITH THIS BECAUSE IF YOU GO TO GET IT FIXED--(A) IT COULD HAPPEN AGAIN AND (B) A FIRE COULD START, AND (C) VERY EXPENSIVE TO GET FIXED. WE HAVE READ MANY OTHER CONSUMERS HAVE HAD THIS SAME PROBLEM BUT FORDS DOES'NT WANT TO HELP OUT. THIS IS A SAFETY ISSUE THAT NEEDS TO BE ADDRESSED BEFORE WORSE SCENARIOS HAPPEN WITH POSSIBLE DEATHS. TO MAKE MATTERS WORSE, I OWN A 2004 F-150 AND HAVE READ STORIES OF IT HAPPENING IN THOSE ENGINES TOO!

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] *TR

MY FORD EXPEDITION HAS LESS THAN 90,000 MILES AND THE SPARK PLUG FOR #3 CYLINDER FELL INTO THE CYLINDER CHAMBER THUS THE PISTON WAS HITTING THE SPARK PLUG ,THIS REPAIR CAN COST AS MUCH $1800.00...FOR A SPARK PLUG THAT COST AROUND $5.00 ON A SUV THAT COST $50,000.00... THIS COULD HAVE CAUSED A FIRE SINCE THE PISTON WAS PUSHING INTO THE ENGINE COMPARTMENT, A FUEL AIR MIXTURE, PLUS, THE PRESENCE OF ELECTRICAL SPARK ARE A PERFECT MIXTURE FOR A FIRE... !!! I WAS CHARGED $ 689.00 FOR A TOW BACK TO MY HOME. I WANT THIS PROBLEM TO BE ADDRESSED BY FORD ASAP BEFORE SOMEONE LOSES THEIR LIFE!!!! A RECALL IS IN ORDER! I WANT FORD TO PAY FOR MY REPAIR AND TOWING BILL BECAUSE THIS IS AN ENGINEERING FLAW AND IT IS EXTREMELY HAZARDOUS!!! CONTACT ME PLEASE! I HOPE THIS CAN HELPS OTHER EXPEDITION OWNERS. *TR

MY 2003 FORD EXPEDITON WAS MAKING A SLIGHT TAPPING NOISE ALL DAY AS I DROVE AROUND TOWN. WHEN I HIT MY HOME TOWN I WAS A .10 OF A MILE FROM MY HOUSE AND A HUGE BANGING NOISE OCCURED. THE VEHICLE LOST POWER AND I COULD SMELL GASOLINE VAPORS. FROM INSPECTION UNDER THE HOOD I NOTICED THE COIL ASSEMBLY ABOVE IN THE RIGHT REAR CYLINDER WAS BROKEN AND THE SPARK PLUG WAS LAYING ON THE MOTOR. IT HAD BLOWN A SPARK PLUG. I HAD PURCHASED AN EXTENDED WARRANTY WHEN I PURCHASED THE VEHICLE. I HAD THE CAR TOWED AND WAS TOLD THEY WOULD INSPECT FOR REPAIRS. THE CAR WAS SUB-LETTED OUT TO A FORD DEALER. THE FORD DEALER SAID THAT A HELICOIL REPAIR WAS WHAT WAS ONCE ACCEPTED BUT THEIR DEALERSHIP NO LONGER PERFORMED THAT PROCEDURE BECAUSE IT WAS ONLY A TEMPORARY FIX. FORD PUT OUT A SERVICE BULLETIN THAT SAID THE BEST REPAIR IS TO REPLACE THE HEAD BUT A HELICOIL TYPE REPAIR WOULD SUFFICE. BECAUSE OF THIS TEMPORARY FIX ANNOUNCEMENT AND FORD'S INABLILTY TO ADMIT THERE IS SOMETHING WRONG WITH THE TRITON MOTOR BUILT BETWEEN 1997 AND 2008 MY EXTENDEDE WARRANTY COMPANY WILL NOT MAKE THE BEST RECOMMENDED FIX. FORD NEEDS TO BE HELD ACCOUTABLE. I DO NOT WANT TO PUT MY FAMILY OF FIVE AT RISK OF BREAKING DOWN AND POSSIBLE ENGINE FIRE BECAUSE OF THIS DEFECT. *TR

2003 FORD EXPEDITION 5.4L V-8 ENGINE BLEW A SPARKPLUG OUT OF THE CYLINDER HEAD. *TR

2003 FORD EXPEDITION SPARK PLUG BLEW OUT OF CYLINDER HEAD. APPARENTLY A COMMON PROBLEM THAT NEEDS TO BE READDRESSED. *TR

I WAS DRIVING DOWN THE FREEWAY WHEN MY EXPEDITION MADE A NOISE, THE INSIDE DASH LIGHTS FLICKERED AND THE TRANSMISSION STARTED ACTING UP. I PULLED OVER AT A HOTEL. I CALLED A TOW TRUCK WHO CAME TO PICK IT UP A FEW DAYS LATER. WHEN HE STARTED IT THE WIRING HARNESS CAUGHT UNFIRE. THE ENTIRE WIRING BURNED UP ON THE LIFT SIDE OF THE VEHICLE. THE MECHANIC TOLD US WE WERE LUCK TO HAVE STOPPED. IF WE CONTINUED DOWN THE HIGHWAY MY FAMILY AND I WOULD HAVE BEEN IN GREAT DANGER. I BELIEVE THE FIRE WAS THE FAULT OF BAD WIRING. I CHECK THE RECALL SITES AND MY VEHILCE WAS NOT PART OF THE FAULTY WIRING RECALL. *TR

TL*THE CONTACT OWNS A 2003 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 25 MPH ON THE HIGHWAY IN RAINY CONDITIONS, THE VEHICLE FISHTAILED AND ALMOST SLIPPED ON A RAMP UNTIL HE REGAINED CONTROL. HE ALSO NOTICED A VIBRATING NOISE. HE TOOK THE VEHICLE TO A REPAIR SHOP BUT THERE WERE NO DEFINITE ANSWERS AS TO WHAT THE CAUSE FOR FAILURE WAS. HE HAD NOT SPOKEN WITH THE MANUFACTURER OR TAKEN THE VEHICLE TO THE DEALER TO-DATE. THE VEHICLE HAD NOT BEEN REPAIRED AT THE TIME OF THE COMPLAINT. THE CURRENT MILEAGE WAS APPROXIMATELY 105,000. THE FAILURE MILEAGE WAS APPROXIMATELY 102,000.

ONE OF THE SPARK PLUGS BLEW OUT OF THE HEAD WHILE I WAS DRIVING ON THE HIGHWAY. THERE WAS NO EXTERNAL DAMAGE, HOWEVER INTERNAL DAMAGE TO THE ENGINE IS UNKNOWN. THIS COULD HAVE STARTED A FIRE UNDER THE RIGHT CIRCUMSTANCES AS RAW FUEL WAS BEING BLOWN THROUGH THE SPARK PLUG HOLE. THIS VEHICLE HAS THE ORIGINAL SPARK PLUGS, SO THIS IS NOT A CASE OF SOMEONE PUTTING TOO MUCH TORQUE ON REPLACEMENT PLUGS. THIS IS A SERIOUS ISSUE AND AFTER READING THE POSTS ON THE INTERNET FROM OTHER FORD OWNERS THAT HAVE HAD THE SAME PROBLEM, I AM CONVINCED THAT FORD NEEDS TO DO A RECALL. *TR

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.

ON OCT 23 WHILE DRIVING I NOTICED A THUMPING NOISE. UPON INSPECTION I DISCOVERED THE LEFT REAR TIRE HAD A LARGE BUBBLE STICKING OUT ON THE INSIDE OF THE TIRE BETWEEN THE TREAD AND THE SIDEWALL. THIS IS THE EXACT SAME FAILURE THAT I EXPERIENCED ON THE INSIDE OF THE RIGHT REAR TIRE IN AUG. IN BOTH CASES I HAD BEEN DRIVING FOR A SHORT PERIOD ON THE INTERSTATE AND WAS PREPARING TO REJOIN THE INTERSTATE. I WAS EXTREMELY FORTUNATE THAT BOTH WERE DISCOVERED PRIOR TO AN EXPLOSIVE FAILURE AND TREAD SEPARATION AT HIGH SPEED ON THE HIGHWAY. THE FIRST TIRE THE DEALER CLAIMED IT MAY OF BEEN SOME SORT OF IMPACT, WHICH I DOUBTED SINCE THE VEHICLE WAS MAINLY USED FOR HIGHWAY DRIVING. HOWEVER AFTER THIS SECOND TIRE, IT IS APPARENT TO ME THAT THE TIRE IS FAILING BETWEEN THE TREAD AND SIDEWALL. IT APPEARS TO BE SEPARATING WHERE THE TREAD JOINS THE INSIDE BELTING. *TR

TL*THE CONTACT OWNS A 2003 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 70 MPH AT NIGHT, THE HEADLIGHTS SUDDENLY TURN OFF AND BACK WITHOUT WARNING. THE HEADLIGHT RELAY MADE A NOISE AS WELL. THE FAILURE OCCURRED SEVERAL TIMES. THE CONTACT CALLED THE MANUFACTURER WHO STATED THAT THERE WERE NO RELATED RECALLS. THE FAILURE MILEAGE WAS APPROXIMATELY 91,000.

2003 FORD EXPEDITION SPARK PLUG # 2 BLOWN OUT. *TR

MY 2003 EXPEDITION, WITH THE V8 5.4 TRITION ENGINE, IS BEING DECLINED TO BE FIXED BY LOCAL FORD DEALERSHIPS, DUE TO THE FACT OF THE "KNOWN" ISSUE, WITH THE SPARK PLUG, THEY WANT ME TO PAY FOR THE FIX OF THE HELI COIL WHICH ISN'T A GUARANTEE AND THEN HOPE IT WORKS, IF NOT IT WILL BE A REBUILT ENGINE, THE FIRST TIME THE SPARK PLUG BLEW IT WAS AT NIGHT, UPON STARTING, SOUNDED LIKE GUN FIRE, HAD VEHICLE TOWED AND THEN RESEARCHED IT ON THE INTERNET FOR SOLUTIONS, FOUND OUT WHAT IT WAS AND THEN REPLACED THE SPARK PLUG AND IGNITION COIL AND THEN HOPED IT WOULD STAY, UPON STARTING IT , IT DID IT AGAIN, BOUGHT MORE SPARK PLUGS AND IGNITION COILS, AND GOT IT TO SEAT BETTER, AND THEN 4 WEEKS TO THE DAY WHILE DRIVING IS WHEN IT MADE THE SAME SOUND LIKE GUN FIRE AND WE KNEW THEN WHAT IT WAS, PULLED OVER ON A HIGHWAY AND PROCEEDED TO LOOK AND SEE WHAT DAMAGE HAD BEEN DONE, ONCE AGAIN A SPARK PLUG AND A NEW IGNITION COIL, HOWEVER THIS TIME THE SPARK PLUG WAS VASTLY DISCOLORED AND BURNT IN APPEARANCE, 1 WEEK AND 1 DAY LATER UPON STARTING IT DOES IT AGAIN, AND THIS TIME NO SPARK PLUG CAN BE PUT IN, THERE ARE NO MORE THREADS IS WHAT I WAS TOLD BY MY MECHANIC, THEY TOLD BE THEY WILL HAVE TO REMOVE THE ENGINE TO PUT THE HELI COIL IN, AND THAT ISN'T A GUARANTEED FIX, ALSO THAT I SHOULD JUST REPLACE THE ENGINE, SINCE IT CAN AND PROBABLY WILL CONTINUE TO HAPPEN AGAIN, I HAD THE AUTO TOWED TO MY RESIDENCE AND I BEGAN TO RESEARCH MY OPTIONS, I CALLED ALL THE FORD DEALERSHIPS IN WHICH THEY SAID THEY COULD DO THE HELI AND THERE IS NOT A GUARANTEE FOR THIS TO WORK, SO AT WHAT COST IS A HUMAN LIFE TO FORD? PER THE INFO AND RESEARCH IT DOES SAY THAT IT CAN CATCH FIRE, AND EXPLODE.....OR PAY A FORTUNE FOR A CAR THAT CAN'T BE FIXED. WE DO HAVE SOME OF 6 THE SPARK PLUGS THAT HAVE "SHOT" OUT, I AM TOLD BECAUSE IT IS THE 3RD PLUG NEAR THE FIREWALL THAT THE ANGLE IS NOT APPROACHABLE....HELP NOW! *TR

TL*THE CONTACT OWNS A 2003 FORD EXPEDITION. THE CONTACT STATED UPON INSPECTION OF HER VEHICLE, SHE NOTICED THAT THE SPARK PLUG EJECTED FROM THE ENGINE HEAD ON THE PASSENGER SIDE NEAR THE FIREWALL. IF THIS OCCURRED WHILE DRIVING, THERE IS A HIGH RISK FOR A VEHICLE CRASH. THE VEHICLE IS IN THE PROCESS OF BEING TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING. THE MANUFACTURER WAS NOTIFIED, BUT SHE WAS NOT PROVIDED WITH ANY RECOURSE. THE FAILURE AND CURRENT MILEAGES WERE 105,000.

MY 2003 FORD EXPEDITION JUST BLEW A SPARK PLUG OUT OF THE CYLINDER HEAD. IT WAS THE SECOND TO LAST CYLINDER PASSENGER SIDE. THERE WAS RAW FUEL AND VAPORS COMING INTO THE ENGINE COMPARTMENT AND A FIRE COULD HAVE STARTED HAD A SPARK IGNITED THOSE FUMES. THESE ARE THE FACTORY PLUGS AND FACTORY HEAD AND THE FORD DEALER COMMENTED THAT THIS WAS A FAIRLY COMMON ISSUE BUT THAT FORD HAS NOT ISSUED A RECALL YET. NOW I AM OUT $2800 FOR WHAT SEEMS TO BE A DEFECT IN THE DESIGN OF THE HEAD. *TR

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. *TR

I HAVE PARK MY TRUCK AND WENT TO HAVE DINNER WITH MY FAMILY AND UPON MY RETURN WHEN I START MY TRUCK. THE ENGINE MAKE A LOUD SOUND AND SPARK PLUG BLOW OUT FROM THE ENGINE. *TR

I HAVE AN 2003 FORD EXPEDITION SUV, THE SPARK PLUG IN THE #3 CYLINDER HEAD POPS OUT EVERY 5-8K MILES. RESULTING IN A LOSS OF POWER, PER THE 3 DEALERSHIPS I HAVE SPOKEN TO AS WELL AS THE B.A.R FORD IS AWARE OF THIS PROBLEM AND REFUSES TO FIX IT. PER THE B.A.R. IT IS AN CASTING/MANUFACTURING DEFECT. IM WORRIED THAT I WILL BE ON THE FREEWAY AND LOOSE POWER, AND GET IN AN ACCIDENT DUE TO NOT BEING ABLE TO EXIT THE FREE WAY UNDER MY OWN POWER. THE PROBLEM GOES BACK TO THE 2000 MODEL YEAR. I HAVE HAD THE CAR WORKED ON AT THE FORD DEALERSHIP 2 TIMES TO CORRECT THIS ISSUE,AND IT IS CURRENTLY BROKEN AGAIN. THE DEALER SHIP REFUSES TO FIX IT AS AN WARRANTY ON THEIR REPAIR DONE ON 8/13/09 OR AS AN FACTORY DEFECT FROM FORD DIRECT. DON'T KNOW WHERE ELSE TO TURN, ANY HELP OR DIRECTION WOULD BE GREATLY APPRECIATED. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

IMMACULATE SIDE AIRBAG DEPLOYMENT BOTH SIDES WHICH DRIVING. NO BUMP OR ACCIDENT. *TR

1. EVENT: GASOLINE LEAKING ONTO PAVEMENT. 2. FORD DEALER INSPECTED AND FOUND A CRACK IN THE FILLER NECK ON TOP OF THE GASOLINE TANK. I, NOR A FOREIGN OBJECT, HAVE ACCESS TO THIS AREA. TANK WILL LEAK GAS ONTO PAVEMENT CONTINUOUSLY UNTIL BELOW CRACK LEVEL. IF AN IGNITER SUCH AS A CIGARETTE OR MATCH OR SPARK IS NEAR THE FLAME, A FIRE WILL START ON GROUND UNDER THE GAS TANK LEADING TO THE GAS TANK COATED WITH GAS RESULTING IN A VEHICLE FIRE OR EXPLOSION. 3. FORD DEALER ESTIMATED REPLACEMENT COST AT $1,350. FORD DEALER STATED THIS IS NOT A RECALL ITEM AND WOULD NOT DISCUSS THE FACT THAT THIS MIGHT BE A DEFECT IN THE INJECTION MOLDED GASOLINE TANK. I THEN CONTACTED FORD MOTOR COMPANY CUSTOMER CARE. FORD MOTOR COMPANY CUSTOMER CARE WOULD NOT GIVE ME THE NAME OF THE LOCAL FORD MOTOR COMPANY REPRESENTATIVE (REGIONAL MANAGER), A SUPERIOR CUSTOMER CARE REP TO TAKE MY CONCERN TO A HIGHER LEVEL AND DISMISSED MY CONCERN THAT THIS WAS A SAFETY DEFECT ISSUE. I WAS THEN INFORMED THAT THERE WAS NO FURTHER RECOURSE AND THERE WAS NOTHING ELSE FORD MOTOR COMPANY OR MY FORD DEALER COULD DO FOR MY SITUATION. THEREFORE, I HAVE NO FURTHER RECOURSE EXCEPT TO SUBMIT MY COMPLAINT. I CANNOT AFFORD A REPLACEMENT GAS TANK (TANK IS STILL INSTALLED ON MY VEHICLE). *TR

2003 FORD EXPEDITION 5.4L EJECTION OF FACTORY SPARK PLUG FORM CYLINDER HEAD. *TR

FOR NO REASON, WHILE DRIVING MY VEHICLE THE PASSENGER SIDE AIR BAG DEPLOYED. *TR

SPARK PLUG BLOW OUT ON 2003 FORD EXPEDITION 5.4 L ENGINE. *TR

TL*THE CONTACT OWNS A 2003 FORD EXPEDITION. THE VEHICLE HAS CONTINENTAL CONTITRAC SUV TIRES, SIZE P265/70R17. WHILE DRIVING APPROXIMATELY 70 MPH, THE REAR OF THE VEHICLE BEGAN TO SHIMMY AND SHAKE, FOLLOWED BY A CLICKING NOISE. THE DRIVER INSPECTED THE VEHICLE AND NOTICED THAT THE REAR DRIVER'S SIDE TIRE EXHIBITED TREAD SEPARATION. THE TIRE IS IN THE PROCESS OF BEING REPLACED. THE DOT NUMBER WAS UNKNOWN. THE FAILURE AND CURRENT MILEAGES WERE 68,000.

ON JUNE 19 2009, RETURNING HOME FROM A SHORT TRIP, THICK SMOKE ERUPTED WITH STRONG RUBBER SMELL FROM UNDERNEATH THE DRIVER SEAT. I IMMEDIATELY TURNED OFF THE IGNITION AND EXITED THE CAR. THE FOLLOWING DAY I CONTACTED FORD MOTOR CO. AND INFORM THEM OF THE SAFETY ISSUE, AFTER GOING BACK AND FORTH, FORD GENERAL CONSUL OFFICE MADE DECISION THAT THE ISSUE IS NOT SAFETY HAZARDS AND WILL NOT REPAIR THE VEHICLE. PAT MILLIKEN FORD HAS THE VEHICLE, AND INSPECTED THE DAMAGE, WHICH DECLARED TO BE VERY EXTENSIVE THE REPAIR COST MAY EXCEED $2000.00. FORD GENERAL CONSUL WAS INFORMED OF THE DAMAGE AND STILL WILL NOT CONSIDER IT AS SAFETY ISSUE BECAUSE THE VEHICLE DID NOT BURST ON FIRE. MY SMART AND QUICK REACTION TO TURN OFF THE VEHICLE AND CUT THE POWER OFF PREVENTED A DISASTER TO HAPPEN, AND YET AS A CONSUMER I'M LEFT WITH HEFTY REPAIR BILLS FOR A POSSIBLE MANUFACTURING DEFECT IN THE WIRING.*TR

WHILE DRIVING MY 2003 FORD EXPEDITION EDDIE BAUER ONE OF THE EIGHT SPARK PLUGS BLEW OUT OF THE ENGINE. *TR

WHILE DRIVING ON VACATION ON VANCOUVER ISLAND NEAR VICTORIA, THE DRIVER SIDE AIR BAG DEPLOYED FOR NO APPARENT REASON. WE WERE UNINJURED AND DROVE TO THE FORD DEALER IN VICTORIA. NO REASON WAS FOUND FOR THE DEPLOYMENT AND THE SYSTEM WAS DEACTIVATED BY THE DEALER. IT IS STILL INACTIVATED.

DRIVING ON SIDE ROAD DOING ABOUT 30 TO 35 MY SIDE AIR BAG CURTAINS DEPLOYED. SOUNDED LIKE A GUN WENT OFF AND WHITE POWDER CAME OUT,TOOK TO FORD SAID CANT FIND ANYTHING WRONG, BUT CHARGE ME 250 DOLLARS TO TELL ME THE CODE SHOW AIR BAG DEPLOY, ABOUT 5 MONTHS LATE THE SEAT BELT PRETENSIONER WENT OFF WHILE SITTING IN A PARKING LOT, SAME NOISE AND POWDER, FORD SAID NOT THEIR PROBLEM. *TR

MY WIFE AND I OWN A 2003 FORD EXPEDITION XLT 4WD SINCE 2004. EVERY SINCE WE OWNED THIS VEHICLE WE HAVE HAD PROBLEMS FROM THE REAR LSD BEING REPLACES TWICE, THE ELECTRICAL HARNESS REPLACEMENT, ALL POWER LOCKS REPLACED (DUE TO COMING OPEN BY THEMSELVES), AND RECENTLY THE TWO COIL PACKS BLOWING OUT OF THE MOTOR. WE SPENT OVER A THOUSAND DOLLARS TO GET VEHICLE TO PASS SMOG DUE TO OUTRAGEOUS SPARK PLUG PRICES ALONG WITH LABOR COST OF $400. I AM FED UP WITH FORD AND WANT EVERYONE TO KNOW HOW THEIR QUALITY IS SO SUB-STANDARD. THIS VEHICLE HAS BEEN IN THE SHOP AROUND 6-7 TIMES AND I HAVE TO WORRY EVERY TIME I DRIVE IT. PLEASE ISSUE A RECALL ON THE SPARK PLUG ISSUE AS FORD AGREES IT IS A DEFECT, THEY WILL NOT TAKE RESPONSIBILITY FOR THEIR SHABBY WORK- [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

I OWN A 2003 FORD EXPEDITION WITH A 5.4,AND WHILE DRIVING AROUND TOWN WE NOTICED THE VEHICLE STARTED RUNNING ROUGH,SO WE TOOK IT TO A LOCAL SHOP TO HAVE IT LOOKED AT AND UPON INSPECTION WE FOUND THAT THE NUMBER 7 PLUG HAD BLOWN OUT AND CAUSED DAMAGE TO THE COIL WHICH CAUSED THE ROUGH RUNNING,THE MECHANIC AT THE SHOP SAID THIS IS VERY COMMON WITH THESE TRUCKS AND MOTORS,SO AT THE COST $700 I GOT IT FIXED WITH THE UNDERSTANDING THAT THIS COULD HAPPEN AGAIN BECAUSE OF THE WAY THESE MOTORS ARE MADE. *TR

TL*THE CONTACT OWNS A 2003 FORD EXPEDITION. THE VEHICLE HAS CONTINENTAL CONTITRAC TR TIRES, SIZE P265/70 R17. WHILE DRIVING 65 MPH, THE CONTACT HEARD A LOUD NOISE COMING FROM THE REAR OF THE VEHICLE. FROM THE DRIVER'S SIDE REARVIEW MIRROR, HE NOTICED A LARGE PORTION OF THE REAR DRIVER'S SIDE TIRE SEPARATING. THE CONTACT PULLED THE VEHICLE OFF THE ROAD AND NOTICED THE TREAD OF THE TIRE IN THE MIDDLE OF THE ROADWAY. ROADSIDE ASSISTANCE ARRIVED AND REPLACED THE TIRE. THE CONTACT CALLED THE MANUFACTURER OF THE TIRES AND IS WAITING ON SOME PAPERWORK. HE BELIEVES THAT A RECALL SHOULD BE ISSUED. THE FAILURE MILEAGE WAS 126,000. UPDATED 07/28/09 *BF UPDATED 07/30/09.*JB

CRACKS ON 3 OF 4 TIRES. NO ACTION TAKEN. *TR

WHILE DRIVING ON A LOCAL ROAD IN CLEAR WEATHER MY 03 EXPEDITION SUDDENLY THREW PLUG #7. IN SO DOING IT DESTROYED THE COIL ASSEMBLY, BUT THE IMPACT OF THE COIL ASSEMBLY ON THE FUEL RAIL SAVED THE CAR'S HOOD FROM FURTHER DAMAGE (THE TOP OF THE COIL ASSEMBLY CLEARLY EVIDENCED THE IMPACT MARK FROM CONTACT WITH THE FUEL RAIL). GIVEN THE FACT THAT THE DAMAGED COIL INSULATION WAS NOW ARCING ITS SPARK ACROSS THE ENGINE HEAD AND THAT THE FUEL MIXTURE WAS SPEWING OUT OF THE SPARK PLUG HOLE IT'S SURPRISING THAT WE AVOIDED AN ENGINE FIRE UNDER THE PLASTIC SHROUD. I HAD THE CAR TOWED TO THE LOCAL INDEPENDENT SERVICE CENTER (PEP BOYS, LAUREL MD - THE SAME LOCATION THAT HAD CHANGED THE PLUGS A YEAR PRIOR). THEY EXAMINED ALL THE SPARK PLUG THREADS AND ADVISED THAT THEY APPEARED OK, WITH THE EXCEPTION OF THIS ONE CYLINDER. TO EFFECT REPAIRS THEY ADVISED TO HAVE THE VEHICLE TOWED TO ANOTHER OUTLET 36 MILES ($104 CHARGE) UP THE ROAD. THEY FURTHER ADVISED THAT THIS IS NOT AN UNCOMMON PROBLEM WITH THE 5.4 ENGINE AND THAT THIS MAY OCCUR IN OTHER CYLINDERS IN THE FUTURE. FORD CUSTOMER ASSISTANCE (800#) DISCLAIMS ANY KNOWLEDGE OF THIS BEING A COMMON PROBLEM AND REFERRED ME TO THE LOCAL DEALER FOR TECHNICAL ADVICE. AT THE LOCAL DEALER, THE MECHANIC WAS VERY FAMILIAR WITH THE ISSUE, PRONOUNCED IT RATHER COMMON AND ADVISED THAT FORD WOULD BE HAPPY TO REPAIR THE PROBLEM, HOWEVER HIS ESTIMATE WOULD COST ME MORE THAN TWICE THE ESTIMATED FEE FROM THE INDEPENDENT (INCLUSIVE OF THE ADDITIONAL TOW COSTS). SUBSEQUENT GOOGLE SEARCHES FOR "FORD EXPEDITION THROWN SPARK PLUG REVEAL 11,200 WEB PAGE HITS. THE WEBPAGES AT THE 1ST HIT ALONE, WWW.CONSUMERAFFAIRS.COM/AUTOMOTIVE/FORD_SPARK.HTML REVEALS A LITANY OF VERY SIMILAR COMPLAINTS OVER A NUMBER OF YEARS, SOME OF WHICH HAVE RESULTED IN MORE TRAGIC CONSEQUENCES. GIVEN THE DANGER REPRESENTED BY POTENTIAL ENGINE FIRES AND THE APPARENT FREQUENCY OF THE PROBLEM WHY HAS THERE NOT BEEN A RECALL TO EFFECT THE CORRECTION OF THIS APPARENT DEFECT. *TR

WE YOU MAKE A TURN YOU HER A NOISE FROM THE REAR END. *TR