2005 Ford Expedition Fuel System Problems

MY SUV WAS PARKED IN PARKING LOT OF A STORE. SMOKE STARTED COMING OUT FROM MY VEHICLE. THEN IT STARTED TO CATCH ON FIRE. FIRE FIGHTERS SAID THE FIRE STARTED FROM THE FUEL INJECTORS.

DRIVING UP A SMALL INCLINE AND THE VEHICLE LOST POWER. I HAD ELECTRICAL POWER JUST NO FUEL GETTING TO THE ENGINE. I WAS ABLE TO PULL OFF TO THE SIDE OF THE ROAD. THE FUEL TANK WAS JUST BELOW A 1/4 TANK. ADD A GALLON OF GAS AND TRIED TO RESTART THE CAR. IT WOULD NOT RESTART. CALLED FOR THE TOW TRUCK TO TAKE TO THE GARAGE. THE GARAGE HAD TO DROP THE FUEL TANK AND TOLD ME THE FUEL PUMP CONTROL MODULE WAS BAD. THEY HANDED ME THE MODULE UPON PICKING UP MY VEHICLE AND I CAN TELL YOU WHY THE MODULE WENT BAD. IT HAS A HOLE IN IT FROM CORROSION. I HAVE SAID MODULE IF ANYONE FROM FORD OR NHTSA WOULD LIKE TO EXAMINE THE MODULE. *TR

WHILE DRIVING HOME DOWN A SLIGHT DECLINE, I HEARD A BEEP AND THE MESSAGE ON THE DASH READ (CHECK ELECTRONIC THROTTLE CONTROL) WHICH I THEN MENTALLY ADDED TO MY LIST OF THINGS TO DO. NOT UNTIL A NEEDED TO START ACCELERATING AGAIN DID I REALIZE THAT MY THROTTLE WAS COMPLETELY INOPERABLE. LUCKILY, A WORD USED FREQUENTLY BY OTHER OWNERS TO DESCRIBE THIS SAME ISSUE, I WAS ABLE TO COAST TO A STOP WHILE OTHER VEHICLES WENT AROUND ME. TURNING OFF THE VEHICLE AND RESTARTING IT SEEMED TO "RESET" THE THROTTLE CONTROL. I DO NOT TRUST THAT IT WILL BE SAFE TO USE, PARTICULARLY WITH THE WINTER DRIVING CONDITIONS THAT I ENCOUNTER. I HAVE AN APPOINTMENT SCHEDULED FOR MONDAY. WITH ALL THE COMPLAINTS I HAVE SEEN REGARDING THIS SAME ISSUE, I AM SHOCKED THAT MORE ACTION (RECALL) HAS NOT BEEN TAKEN. DOES A CRASH, FIRE, INJURY, OR FATALITY NEED TO OCCUR BEFORE THIS CAN BE TAKEN SERIOUSLY? I AM BAFFLED THAT A WARNING MESSAGE CANNOT BE DISPLAYED IN ADVANCE OF COMPLETE THROTTLE FAILURE CONSIDERING THE POTENTIAL CATASTROPHIC OUTCOMES. THIS VEHICLE WAS INSPECTED/SERVICED NOVEMBER 2013. *TR

TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT WHILE TRAVELING 60 MPH, THE VEHICLE SUDDENLY STALLED. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC WHERE IT WAS FOUND THAT THE DRIVER FUEL MODULE NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOT CONTACTED ABOUT THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 108,000.

WAS DRIVING WHEN CHECK ELECTRONIC CONTROL SENSOR CAME ON AND WITH OUT WARNING VEHICLE DIED IN MIDDLE OF ROAD. *TR

TL* THE CONTACT OWNS A 2007 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE FAILED TO START. THE VEHICLE WAS TOWED TO THE DEALER WHERE IT WAS ADVISED THAT THE FUEL PUMP HAD FAILED. THE CONTACT WAS INFORMED BY THE DEALER THAT THE REPAIR WOULD TAKE THREE MONTHS BECAUSE THE FUEL PUMP WAS ON BACK ORDER AND THERE WAS NO AFTER MARKET FUEL PUMP THAT WOULD WORK ON THE 2005 MODEL YEAR. THE FAILURE AND THE CURRENT MILEAGES WERE 74,000 *TR

WHILE I WAS DRIVING DONE THE INTERSTATE, MY FORD EXPEDITION LOST ALL POWER AND COMPLETELY STALLED. LUCKILY, I WAS ABLE TO GET IT OFF THE ROAD TO THE SHOULDER WITHOUT ANY INCIDENT. THIS IS THE THIRD TIME IT HAS HAPPENED TO ME. PREVIOUSLY, I HAD MY FUEL PUMP SENSOR CHANGED BECAUSE MY CHECK ENGINE LIGHT CAME ON AND THAT IS WHAT IT INDICATED; HOWEVER, THE PROBLEM STILL EXITS AND MY MECHANICS ARE BAFFLED. VERY DANGEROUS! *TR

WHILE TRAVELING DOWN THE FREEWAY AT 70 MPH, THE VEHICLE DIED. IT WOULD NOT RESTART. AFTER 1 HOUR VEHICLE THE VEHICLE STARTED AND THEN DIED WITHIN SECONDS. THE FUEL FILTER AND FUEL PUMP WERE REPLACED BECAUSE ALL INDICATIONS LEAD TO BELIEVE THAT THE FUEL PUMP WAS BAD. AFTER REPLACEMENT OF THE FUEL PUMP, VEHICLE WOULD NOT START. LOOKING ON THE INTERNET FOR POSSIBLE SOLUTIONS FROM OTHERS, I FOUND ONE PERSON WITH THE SAME PROBLEM AND FOLLOWED THEIR ADVISE ON HOW TO FIX IT. I FOUND THE "DRIVERS MODULE" ON THE BACK TOPSIDE OF THE FRAME. WHEN THE MODULE WAS REMOVED, IT WAS FOUND TO HAVE TWO LARGE SECTIONS OF CORROSION ABOUT 1/4 INCH THICK. WHEN THE CHUNKS WERE KNOCKED OFF, UNDER THEM WERE TWO HOLES THROUGH THE SIDE OF THE MODULE AND THE CIRCUIT WAS BURNT, THE PLUG WAS ALSO STARTING TO CORRODE. THE PLACEMENT FOR THE MODULE IS A TERRIBLE SPOT. IT IS ALUMINUM ATTACHED TO A STEEL FRAME, WITH NOTHING SEPARATING THEM. WHEN THE NEW MODULE ARRIVED, IT NOW HAS A RUBBER GASKET TO KEEP THEM SEPARATE. THIS LOOKS LIKE A DESIGN FLAW ON FORD'S PART AND A RECALL SHOULD BE ORDERED. FORD SHOULD FURTHER REFUND THE COST OF THE FUEL PUMP BECAUSE ALL INDICATIONS SHOW THAT THE FUEL PUMP IS BAD, WHEN IN TRUTH IT IS THE MODULE AND NOT THE FUEL PUMP. *TR

VEHICLE STOPED RUNNING ON FLAT LEVEL READ AT 65 MILES PER HOUR.VEHICLE WOULD NOT RESTART. VEHICLE HAD BEEN STALLING PRIOR. MECHANIC CANT PINPOINT PROBLEM BUT FEELS FUEL PUMP, FUEL PUMP MODULE, FUES BOX MALFUNCTION ARE THE CAUSE. TO MANY STORIES OF THIS PROBLEM SURFACING. MY FAMILY IN DANGER WITH VEHICLE STOPPED ON MAJOR HIGHWAY, CAUSED BY A WELL KNOWN PROBLEM FORD IS AWARE OF. *TT

2005 FORD EXPEDITION HAS EXPERIENCED APPROXIMATELY 5 EPISODES WHERE IT HAS STALLED WITH NO NOTICE OR PRIOR INDICATION OF A PROBLEM. THE PROBLEM STARTED AROUND 50K MILES AND HAPPENED MOST RECENTLY AS ABOUT 120K MILES. ON AT LEAST 2 OCCASIONS THE CENTER DASH INDICATED ENGINE FAILSAFE MODE. EACH TIME, THE TRUCK COULD BE IMMEDIATELY RESTARTED AND WOULD OPERATE NORMALLY. THE ONLY COMMON CIRCUMSTANCE IS THAT THE TRUCK WAS COASTING TO A LOWER SPEED AT THE TIME OF THE FAILURE. NO CODES ARE RECORDED, SO NO TROUBLESHOOTING CAN BE PERFORMED. REPLACED THE THROTTLE POSITION SENSOR, BUT FAILURE HAS OCCURRED TWICE SINCE. THE NEXT STEP IS TO REPLACE THE THROTTLE BODY ASSEMBLY. *TR

VEHICLE HAS BEEN STALLING FOR ALMOST A YEAR. VEHICLE SHUT OFF ON BUSY HIGHWAY AND TOWED TO NEARBY REPAIR SHOP. MECHANIC FOUND FUEL PUMP CONTROL MODULE COMPLETELY CORRODED FROM BEHIND AND CIRCUIT BOARD EXPOSED TO MOISTURE. THE FPCM FRIED AND SHORTED OUT ONE LEG OF THE FUEL PUMP. BOTH PIECES HAD TO BE REPLACED. NEW FPCM INSTALLED WAS OBVIOUSLY REDESIGNED SO MODULE WOULD NOT SUFFER THIS FLAW AGAIN. I AM FINDING AN ALARMING AMOUNT OF COMPLAINTS ON THE INTERNET OF FORD EXPEDITION OWNER EXPERIENCING THE EXACT SAME PROBLEMS UNDER MORE DANGEROUS CONDITIONS. *KB

TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THE FUEL PUMP DRIVER MODULE FAILED. THE CONTACT STATED WHILE DRIVING 65 MPH THE VEHICLE STALLED WITHOUT WARNING. THE FUEL PUMP DRIVER MODULE WAS LOCATED IN THE REAR OF THE VEHICLE NEAR THE FUEL TANK. THE FAILURE DESTROYED THE FUEL PUMP AND BLEW THE 15 AMP FUSE THAT ALLOWS THE FUEL PUMP TO FUNCTION. THE DEALER INFORMED THE CONTACT THAT THE PART WAS CURRENTLY ON BACK ORDER. THE FAILURE AND CURRENT MILEAGES WERE 103,000.

THE REPORTED MODEL WAS CRUISING AT 65 MILES AN HOUR ALONG NORTH BOUND I-795 @ NC RTE 42, WILSON, NC (STATE POLICE RESPONDED TO THIS DISABLED VEHICLE CALL) VEHICLE ACTED LIKE IT RAN OUT OF GAS. ELECTRICAL PROVEOUT INDICATORS WERE NORMAL. IGNITION SYSTEM WAS FUNCTIONAL, AS WERE ALL OTHER FACETS OF THE ELECTRICAL SYSTEM SEEMED FINE DURING THE ENGINE POWER FAILURE, HOWEVER , LOSS OF STEERING POWER AND BRAKING POWER WAS EVIDENT AND PROMINENT. AFTER SAFELY COASTING OFF ONTO THE SHOULDER JUST PAST THE SAID INTERSECTION THE VEHICLE WOULD NOT START AND WAS TOWED TO A REPAIR FACILITY. A FINAL DIAGNOSIS WAS PERFORMED AND WAS DETERMINED OF A RELAY CONTACT FAILURE. THIS RELAY IS AN INTEGRAL PART OF THE MAIN POWER DISTRIBUTION PANEL / FUSE BLOCK RIGHT OF THE PASSENGER FOOT WELL. MAKING THIS PART INTEGRAL TO THE POWER BLOCK MAKES IT EXTREMELY EXPENSIVE TO REPAIR AND MAKES THE VEHICLE UNSAFE AS FAR AS A REASONABLE REPAIR TO A CRITICAL SYSTEM AND PLACES OTHER SYSTEMS AT RISK BY THE NATURE OF REPLACING THE ENTIRE POWER BLOCK TO REPAIR THE PROBLEM.. IE: THE FUEL PUMP. WHEN THIS RELAY CONTACT FAILS, POWER IS LOST TO THE FUEL PUMP DRIVER MODULE LOCATED UNDER THE DRIVER'S REAR WHEEL WELL. THIS MODULE SUPPLY POWER TO THE FUEL PUMP MOTOR IN THE FUEL TANK. THE FUEL PUMP CONTROL MODULE ITSELF SHOULD BE SCRUTINIZED HENCE IT'S LOCATION MAKES IT VULNERABLE TO WEATHER AND QUICK CORROSION. *TR

TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT WAS DRIVING APPROXIMATELY 10 MPH WHEN THE ENGINE STALLED WITHOUT PRIOR WARNING. THE ENGINE FAILED TO RESTART AND THE VEHICLE WAS TOWED AN AUTHORIZED DEALER WHERE THE FUEL PUMP DRIVER MODULE WAS REPLACED. THE FAILURE MILEAGE WAS 66,859. UPDATED 05/05/11*LJ THE CONSUMER STATED WHEN THE ENGINE FAILED, HE LOST POWER STEERING. HE WAS ON STEEP HILL AND WAS ABLE TO STOP BY PLACING THE TRUCK INTO PARK AND APPLYING THE EMERGENCY BRAKE. UPDATED 07/01/11

WHILE DRIVING MY 2005 FORD EXPEDITION UNDER NORMAL DRIVING CONDITION AT APPROXIMATELY 35 MILES PER HOUR, THE "CHECK ELECTRONIC THROTTLE CONTROL" INDICATOR APPEARED ON THE DASH CONSOLE AND THE ENGINE SHUT OFF. I PUT THE VEHICLE IN NEUTRAL GEAR AND COASTED TO A STOP ON A SIDE ROAD. THE VEHICLE RESTARTED WITH NO ISSUE AND I WAS ABLE TO CONTINUE ON MY TRIP. THIS HAS HAPPENED ENUMERABLE TIMES WITH THIS VEHICLE. MY WIFE, SON AND I ALL KNOW THE DRILL. WHY HASN'T FORD PUT A SERVICE BULLETIN OUT ON THIS ISSUE? *TR

MY 2005 FORD EXPEDITION HAS BEEN EXPERIENCING INTERMITTENT PROBLEMS AND THE ONLY MESSAGE YOU RECEIVE IS "CHECK ELECTRONIC FUEL THROTTLE." TRAVELING AT ANY SPEED THE CAR LOSES POWER IN THE SENSE LIKE IT HAS BEEN SHIFTED INTO NEUTRAL. WHEN THIS OCCURS YOU CAN STEP ON THE GAS PEDAL BUT ITS LIKE IT ISN'T ACKNOWLEDGED. YOU SHUT THE CAR OFF WAIT A FEW MINUTES AND RESTART IT AND EVERYTHING IS FINE. YOU MAY GO DAYS OR IT MAY BE WEEKS BEFORE IT HAPPENS AGAIN. IT IS A VERY SCARY SITUATION WHEN THIS HAPPENS. I HAVE BEEN SO LUCKY NOT TO HAVE BEEN INVOLVED IN AN ACCIDENT DUE TO THIS PROBLEM.

I OWN A 2005 FORD EXPEDITION. THIS YEAR MODEL EXPEDITION HAS A KNOWN THROTTLE CONTROL ISSUE THAT CAUSES THE VEHICLE'S ENGINE TO DEFAULT TO "FAILSAFE MODE," WHICH IS A REDUCED POWER MODE. THIS IS A VERY SIGNIFICANT SAFETY ISSUE BECAUSE "FAILSAFE MODE" CAN BE ACTIVATED ANYWHERE AT ANY TIME WITHOUT WARNING. IMAGINE THE IMPLICATIONS OF SUDDENLY LOSING MOST OF YOUR ENGINE'S POWER AT INTERSTATE OR HIGHWAY SPEEDS. NOW, IMAGINE THE SAME SCENARIO WITH YOUR FAMILY ON BOARD AND A BOAT IN TOW, A VERY COMMON USE FOR THIS TYPE OF VEHICLE. THE INTERNET IS FULL OF FAILED THROTTLE BODY COMPLAINTS, YET FORD HAS DONE NOTHING TO ADDRESS THIS POTENTIALLY LIFE THREATENING DEFECT. THIS IS MUCH MORE THAN A NUISANCE ISSUE THAT THREATENS ONLY THE OWNERS' POCKETBOOKS. THIS IS A MAJOR SAFETY HAZARD AND FORD NEEDS TO DO SOMETHING ABOUT IT. THEIR NEGLIGENCE IS SHAMEFUL. *TR

THIS IS THE FIFTH INCIDENT REGARDING THIS VEHICLE. IN EACH CASE, THE CAR WAS TRAVELING AT A NORMAL RATE OF SPEED UNDER ORDINARY TRAFFIC CONDITIONS. WITHOUT WARNING, THE CAR EITHER LOST POWER AND SHUT OFF SUDDENLY OR LOST THE ABILITY TO ACCELERATE AND SLOWED TO A STOP. IN EACH CASE THE DASHBOARD MESSAGE CENTER WARNING "CHECK ELECTRONIC THROTTLE CONTROL" (OR SOMETHING SIMILAR) APPEARED. IN EACH CASE THE DRIVER TURNED THE IGNITION SWITCH TO THE OFF POSITION, WAITED SEVERAL MINUTES, AND THEN STARTED THE CAR. THE WARNING MESSAGE NO LONGER APPEARED AND THE CAR RAN FINE WITHOUT ANY FURTHER IMMEDIATE INCIDENT. IN THIS PARTICULAR CASE (INCIDENT #5), THE CAR WAS TRAVELING AT APPROXIMATELY 25 MPH SOUTH ON 14TH ST NW IN WASHINGTON, DC, WHEN THE CAR LOST THE ABILITY TO ACCELERATE, AND THE "CHECK ELECTRONIC THROTTLE CONTROL" WARNING APPEARED IN THE DASHBOARD MESSAGE CENTER. DUE TO TRAFFIC AND STREET PARKING CONDITIONS, THE DRIVER WAS UNABLE TO MOVE THE CAR OUT OF THE ACTIVE TRAFFIC LANE, THEREBY TEMPORARILY BLOCKING TRAFFIC. THE DRIVER TURNED OFF THE IGNITION, WAITED APPROXIMATELY 3 MINUTES, AND THEN STARTED THE CAR. THE DASHBOARD WARNING LIGHT WAS NO LONGER ILLUMINATED, AND THE CAR WAS ABLE TO ACCELERATE NORMALLY. INCIDENTS SIMILAR TO THIS HAVE BEEN REPORTED ON VARIOUS WEBSITES. *TR

THIS IS THE FOURTH INCIDENT REGARDING THIS VEHICLE. IN EACH CASE, THE CAR WAS TRAVELING AT A NORMAL RATE OF SPEED UNDER ORDINARY TRAFFIC CONDITIONS. WITHOUT WARNING, THE CAR EITHER LOST POWER AND SHUT OFF SUDDENLY OR LOST THE ABILITY TO ACCELERATE AND SLOWED TO A STOP. IN EACH CASE THE DASHBOARD MESSAGE CENTER WARNING "CHECK ELECTRONIC THROTTLE CONTROL" (OR SOMETHING SIMILAR) APPEARED. IN EACH CASE THE DRIVER TURNED THE IGNITION SWITCH TO THE OFF POSITION, WAITED SEVERAL MINUTES, AND THEN STARTED THE CAR. THE WARNING MESSAGE NO LONGER APPEARED AND THE CAR RAN FINE WITHOUT ANY FURTHER IMMEDIATE INCIDENT. IN THIS PARTICULAR CASE (INCIDENT #4), THE CAR WAS TRAVELING AT APPROXIMATELY 10 MPH AND WAS TURNING RIGHT INTO A SUPERMARKET PARKING LOT IN CHEVY CHASE, MARYLAND. AS THE CAR PULLED INTO THE PARKING LOT, THE CAR LOST THE ABILITY TO ACCELERATE, THE "CHECK ELECTRONIC THROTTLE CONTROL" WARNING APPEARED IN THE DASHBOARD MESSAGE CENTER. THANKFULLY, THE CAR HAD ENOUGH MOMENTUM TO SAFELY PULL INTO A PARKING SPACE WITHOUT FURTHER INCIDENT. THE DRIVER TURNED OFF THE IGNITION, WAITED APPROXIMATELY 5 MINUTES, AND THEN STARTED THE CAR. THE DASHBOARD WARNING LIGHT WAS NO LONGER ILLUMINATED, AND THE CAR WAS ABLE TO ACCELERATE NORMALLY. *TR

DRIVING AT 50MPH IN 2005 FORD EXPEDITION LMTD. WHEN LOST ALL THROTTLE CONTROL AND HAD TO TRY AND GET TO THE SIDE OF THE ROAD SAFELY. "CHECK THROTTLE CONTROL" WARNING CAME ON DURING INCIDENT. THIS WAS THE FIRST TIME AT 108,500 MILES. IT SEEMS THIS IS HAPPENING A LOT ON THIS VEHICLE MODEL. NOT A VERY SAFE DEFECT FROM FORD. FORD NEEDS TO THINK OF THEIR CONSUMER SAFETY AND RECALL AND CORRECT THIS ISSUE. MEANWHILE MY NEXT CAR THAT WAS GOING TO BE A FORD WILL BE SOMETHING DIFFERENT. *TR