2004 Ford Expedition Engine Problems

Which parts fail

• Engine
  9
• Exhaust system › Manifold/header/muffler/tail pipe
  1
• Engine › Gasoline
  1
• Exhaust system
  1
• Cooling system
  1

Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).

Mileage when the problem started

• Under 25k
  37%
• 25k–50k
  49%
• 50k–75k
  511%
• 75k–100k
  716%
• 100k–150k
  1432%
• 150k+
  1125%

Owner reports

Selected complaints filed with NHTSA by 2004 Ford Expedition owners, lightly cleaned up (personal details are redacted by NHTSA).

The contact owns a 2004 Ford Expedition. The contact stated that while her daughter was driving at an undisclosed speed, the vehicle was jerking. The contact stated that one spark plug exploded and then another spark plug exploded and went through the cylinder head. The contact called the local dealer but the vehicle was not diagnosed or repaired. The vehicle was taken to an independent mechanic where the spark plug was replaced. The manufacturer was notified and referred the contact to the NHTSA for assistance. The failure mileage was approximately 87,000.

The contact owns a 2004 Ford Expedition. The contact stated while driving at various speeds, the vehicle lost motive power without warning and the steering wheel became difficult to steer on several occasions. The vehicle was taken to an independent mechanic, but the failure could not be replicated. The throttle was replaced however, the failure recurred. The manufacturer was not made aware of the failure. The failure mileage was 216,000. The Vin was not available.

The contact owns a 2004 Ford Expedition. The contact stated while driving at 40 MPH, the vehicle shut down completely, and the warning messages indicated check gage and check service engine. The contact was able to pull over on the side of the road. The dealer was not contacted. The manufacturer was not made aware of the failure. The failure mileage was 127,708.

The contact owns a 2004 Ford Expedition. The contact recently purchased the vehicle and stated that while driving at an undisclosed speed, the transmission hesitated before upshifting with the accelerator pedal depressed. Additionally, while stopped at a traffic light, the vehicle rolled backwards when the accelerator pedal was depressed before responding as needed. There was no warning light illuminated. The contact attempted to return the vehicle to the independent dealer where the vehicle was purchased; however, the dealer declined to assist. Recently, the vehicle stalled, and it was towed to an independent mechanic to be diagnosed. The mechanic retrieved fault codes for the engine and stated that the TCM needed to be replaced. The vehicle was not repaired. The manufacturer was not informed of the failure. The failure mileage was unknown.

I have a 2004 Ford Expedition which randomly shuts off while driving. This has been happening with more frequency. I have taken the vehicle to two mechanics who tested and attempted to diagnose however they were not able to replicate the problem. Upon reading and researching online, there have been multiple posts about this being a common problem with the Ford Expedition line. I contacted Ford and explained of this major safety concern and they only advised that the vehicle has no recall and they collected my information to provide to NHTSA. My son uses this vehicle for school and the vehicle has a safety concern which can not be diagnosed by certified mechanics and Ford has taken is not taken any responsibility or attempted to rectify. I hope someone does not have to die due to this gross negligence, especially my son.

Tl* the contact owns a 2004 Ford Expedition. The contact stated that while the vehicle was parked, he smelled a burning odor and noticed smoke emitting from the hood area. Upon inspecting underneath the hood, the contact observed an excessive amount of smoke which originated from the engine oil reservoir. There were no flames. The contact allowed the engine to cool for a period of four hours before operating the vehicle. The vehicle was taken to an independent mechanic, who stated that the anti-lock brake module would need to be replaced. The vehicle was not repaired; however the anti-lock brake sensor was disconnected. The manufacturer was not made aware of the failure. The approximate failure mileage was 110,238.

Tl* the contact owns a 2004 Ford Expedition. The contact stated while vehicle was in a stand still the vehicle was leaking oil on the muffler system and starter. The contact also stated while driving 25 MPH, a burning odor was detected coming from the muffler area. The contact stated the check engine warning light was illuminated. The contact stated a local dealer was contacted however the failure had not been diagnosed or repaired. The contact stated that head gasket would need to be replaced. The contact stated that the failure occurred at 75,000 miles and he replaced the head gasket. The manufacturer had been informed of the failure and referred the contact to NHTSA. The failure mileage was approximately 210,000.

Vehicle lost power for 3-5 seconds at highway speeds approximately 65 MPH on three separate events. Vehicle slowed down due to power loss while in heavy traffic. Three other times at idle speed in drive and in park engine stalled and immediately restarted. Loss of power steering due to engine not running when stall event happened. I performed inspection of fuel pump relay which is internal to passenger side fuse block. Found inadequate solder joint on integrated relay printed circuit and burn marks on outside of fuel pump relay. Located salvage fuse block same make and model and inspected. Same damage on salvage fuse block assembly. Replaced with aftermarket fuse block with revised solder joint and updated relay.

I was pulling off from a stop sign and before I got across the intersection my car make a pop and then the engine sounded like it blew. I pulled over and a spark plug popped out of the head causing a small fire that melted hoses. Estimated damage is a minimum of 1500 for just this plug but I was told the others would follow suit. Reading on the internet this seems to be a serious issue with the Ford 5.4 triton motors. If I was not able to stay calm and steer my vehicle correctly this could have resulted in a serious accident. The vehicle lost power as if it had stalled, and as I stated before there was a small fire when I lifted the hood to see what had happened.

Also like many other complaints I have seen, the 2004 Ford Expedition I have has shut off on me several times while driving and I was told to switch out the entire fuse box. I called the dealer and they said to replace it, it would be about $500 for it. It's ridiculous Ford hasn't issued a recall because this seems like a problem many people are having as well. We have almost gotten into a couple of accidents because of this issue! We can't keep having to rely on one less vehicle, but what other alternative do we have if it's going to cost us, the consumer, a lot of money to replace for something the manufacturer should be responsible for.

NHTSA investigations

Engine complaints in other Expedition years