Engine
4.6L 8-cyl
Fault profile
Complaint-component records on this vehicle, grouped by family. A complaint naming two systems counts once in each.
Complaints are owner-reported and not verified by the agency.
Known issues
The component families with the most complaint records against this vehicle. Counts, crash and fire figures belong to the whole family, not to any single named issue. Parts listed are related system parts, not a diagnosis.
Engine & cooling
140 complaint records27 fire reports1 crash report
"NO NEED FOR LONG DRAWN OUT SENTENCES, BLOWNOUT SPARK PLUGS AND FORD WONT OWN UP TO IT, IT'S REAL GREAT TO BE AN AMERICAN. *TR..."- one owner's federal complaint about this system; it may not describe the issue named above
Parts
No specific part is named for this issue. Browse engine & cooling parts in the directory →
Electrical system
123 complaint records25 fire reports
"VEHICLE PARKED FOR APPROX. 22 HOURS, CC QUIT WORKING 1 WEEK PRIOR, ONE DAY BEFORE VEHICLE FIRE WOULD NOT GET OUT OF PARK..."- one owner's federal complaint about this system; it may not describe the issue named above
Parts
No specific part is named for this issue. Browse electrical system parts in the directory →
Speed control
100 complaint records42 fire reports11 crash reports
"WHEN COMING TO A STOP ENGINE REVS AND VEHICLE JUMPS FORWARD EVEN WITH CONSUMER PRESSING ON BRAKES. VEHICLE WILL NOT STOP. *AK..."- one owner's federal complaint about this system; it may not describe the issue named above
Parts
No specific part is named for this issue. Browse speed control parts in the directory →
Federal defect investigations
Formal investigations opened by the federal safety agency into this vehicle. An investigation is the step between a complaint pattern and a recall; not every one results in one.
| Investigation | Status | Component | Subject |
|---|---|---|---|
| EA05015 opened Oct 2005 | closed Dec 2006 | Visibility | WINDSHIELD LEAK CAUSES ELECTRIC FAILURES CONSUMERS ALLEGED THAT WHEN IT RAINED OR SNOWED, WATER LEAKED INTO THE VEHICLE AROUND THE WINDSHIELD.MOISTURE FLOWING THROUGH THE SEAL THAT SURROUNDS THE FRONT WINDSHIELD FOLLOWS A PATH THROUGH THE SEAL INTO THE GENERIC ELECTRONIC MODULE (GEM) AND FUSE BOX,... |
| DP05005 opened Sep 2005 | closed Jan 2006 | Engine And Engine Cooling | SPARK PLUG EJECTION FROM CYLINDER HEAD ON SEPTEMBER 6, 2005, ODI RECEIVED A PETITION REQUESTING THAT THE AGENCY INVESTIGATE ALLEGATIONS OF ENGINE SPARK PLUG EJECTION IN CERTAIN MODEL YEAR 1997 THROUGH 2004 FORD VEHICLES WITH TRITON V-8 AND V-10 ENGINES.ODI RECEIVED A TOTAL OF 474 NON-DUPLICATIVE... |
| PE05033 opened Jun 2005 | closed Oct 2005 | Visibility | ELECTRICAL SYSTEM FAILURE ODI HAS RECEIVED 39 REPORTS ALLEGING THAT WATER LEAKS AROUND THE WINDSHIELD CAUSING ELECTRICAL FAILURES, INCLUDING BUT NOT LIMITED TO THE WINDSHIELD WIPERS AND THE HEADLAMPS.FORD REPORTS THAT WATER ENTERING THE VEHICLE CAN WET THE POWER DISTRIBUTION BOX (PDB)... |
| EA05005 opened Mar 2005 | closed Aug 2006 | Vehicle Speed Control | ENGINE COMPARTMENT FIRES - led to recall 08V025000 EA05-005 IS CLOSED WITH FORD?S ACTIONS IN RECALLS 05V-017, 05V-388, AND 06V-286, RECALLING APPROXIMATELY 6.7 MILLION VEHICLES EQUIPPED WITH TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCHES (SCDS).THE BRAKE SYSTEMS IN THESE RECALLED VEHICLES GENERATE A... |
| EA05004 opened Feb 2005 | closed Jul 2005 | Seat Belts | FRONT SEAT BELT BUCKLE ASSEMBLY DURING THE INITIAL RECALL CAMPAIGN IN 2001, THE SUBJECT VEHICLES WERE INSPECTED BY FORD DEALERSHIPS USING A TEST TOOL THAT WOULD DETECT A DEFECTIVE FRONT SEAT OUTBOARD SEAT BELT BUCKLE ASSEMBLY.APPROXIMATELY ONE MILLION VEHICLES PASSED THE INSPECTION TEST FOR... |
| RQ04011 opened Oct 2004 | closed Feb 2005 | Seat Belts | FRONT SEAT BELT BUCKLE ASSEMBLY UNDER RECALL CAMPAIGN (01V227), FORD RECALLED APPROXIMATELY 1.3 MILLION VEHICLES TO INSPECT AND IF NECESSARY REPLACE THE FRONT DRIVER AND/OR PASSENGER SEAT BELT BUCKLE.APPROXIMATELY 1.1 MILLION OWNERS RESPONDED BY TAKING THEIR VEHICLES TO A DEALER FOR... |
Recall campaigns
Safety-recall remedies are normally provided at no charge. Under US federal law the mandatory free remedy applies when the vehicle was no more than 15 years old at the time the defect was determined; manufacturers often cover older vehicles voluntarily. Canadian rules differ. Confirm eligibility with the manufacturer using the VIN. Each campaign number links to the federal record.
| Campaign | Component | Summary | Remedy |
|---|---|---|---|
| 05V388000 | Vehicle Speed Control | ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES EQUIPPED WITH SPEED CONTROL, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT, SMOKE, OR BURN. | Normally free |
| 03V094000 | Structure | CERTAIN PICKUP TRUCK, VAN, AND MINI VAN CONVERSIONS EQUIPPED WITH SOUTHERN COMFORT BUILT RUNNING BOARDS THAT CONTAIN CERTAIN COURTESY LIGHTS MANUFACTURED BY AMERICAN TECHNOLOGY COMPONENTS, INC. | Normally free |
| 01V258000 | Visibility | VEHICLE DESCRIPTION: PASSENGER CARS, SPORT UTILITY VEHICLES, AND LIGHT AND MEDIUM DUTY PICKUP TRUCKS. | Normally free |
| 01V227001 | Seat Belts | VEHICLE DESCRIPTION: PASSENGER AND SPORT UTILITY VEHICLES, PICKUP TRUCKS, AND MINIVANS. EQUIPPED WITH SEAT BELTS SUPPLIED BY TRW. | Normally free |
| 01V082000 | Air Bags | VEHICLE DESCRIPTION: PASSENGER AND SPORT UTILITY VEHICLES. THE INFLATOR CANISTER IN THE DRIVER AIR BAG MODULE MAY HAVE AN INADEQUATE WELD NEAR THE IGNITER. | Normally free |
| 00V396000 | Equipment | VEHICLE DESCRIPTION: CERTAIN SPORT UTILITY VEHICLES, PICKUP TRUCKS, AND PASSENGER VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FMVSS 225, "CHILD RESTRAINT ANCHORAGE SYSTEMS." THE AFFECTED EXPEDITION/NAVIGATOR OWNER... | Normally free |
Transport Canada recalls
Recalls issued under Canadian law for this model year, from Transport Canada's Vehicle Recalls Database. Matched by model name, so a Canadian-market variant may appear here that was sold under another name in the US. Units are Canadian vehicles affected.
| Recall | System | Units (CA) | Summary |
|---|---|---|---|
| 2005028 2005-02-14 | Electrical | 304,417 | On certain vehicles, the speed control deactivation switch may overheat, smoke, or burn, potentially resulting in an underhood fire. The condition may occur either when the vehicle is parked or when it is in operation. |
| 2004164 2004-05-18 | Steering | 305,024 | On certain vehicles, Ford has issued a scheduled maintenance guide update which specifies that every 20 000 kms, the steering linkage, which includes tie-rod ends, should be inspected. |
| 2001204 2001-08-13 | Other | 83,005 | Certain passenger cars, sport utility vehicles, and light and medium duty pickup trucks. A switch located in the plastic cover of the wiper motor gear case could malfunction and overheat, potentially resulting in loss of intermittent wiper... |
| 2001194 2001-07-16 | Seats And Restraints | 78,402 | Certain passenger and sport utility vehicles, pickup trucks, and minivans equipped with seat belts supplied by TRW. It is possible that the driver's and/or front passenger's outboard seat belt buckle may not fully latch. |
| 2001069 2001-03-16 | Seats And Restraints | 18 | On certain vehicles, the inflator canister in the driver airbag module may have an inadequate weld near the igniter. In the event of a vehicle crash, the driver airbag may not deploy as intended. |
Service bulletins and warranty extensions
Manufacturer communications to dealers on file with the federal agency: repair instructions, service campaigns, and warranty extensions. A warranty extension means the manufacturer may pay for a repair the recall table does not cover.
| Bulletin | Type | Component | Summary |
|---|---|---|---|
| TSB 20-2233 Jul 2020 | Structure | This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. | |
| TSB 19-2026 Feb 2019 | Structure | Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. | |
| 07212 Oct 2007 | Engine And Engine Cooling | SOME 1997-2008 VEHICLES EQUIPPED WITH A 4.6L 2V, 5.4L 2V, OR 6.8L 2V ENGINE--SPARK PLUG THREAD REPAIR PROCEDURE--NOT COVERED UNDER NEW VEHICLE LIMITED WARRANTY. *NJ THIS INCLUDES F-53 MOTORHOME CHASSIS. UPDATED 2/23/10. *PE | |
| 041601 Nov 2005 | Engine And Engine Cooling | WDS COP KIT DIAGNOSTIC TIP - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING. *TT | |
| 042421 Jun 2005 | Seat Belts | SAFETY BELT RETRACTION SPEED. *TT | |
| 05618 Apr 2005 | Power Train | REAR AXLE NOISE REPAIR. *TT | |
| 0554 Mar 2005 | Engine And Engine Cooling | USE OF STAINLESS STEEL EXHAUST STUDS IN SERVICE FOR 5.4L 2V ENGINE. *TT | |
| 05417 Mar 2005 | Engine And Engine Cooling | INTERMITTENT ROUGH IDLE - NON-COMMANDED EGR (EXHAUST GAS RECIRCULATION VALVE) FLOW. *TT | |
| 050618 Jan 2005 | Suspension | REAR AXLE NOISE REPAIR. *SC | |
| 0471 Dec 2004 | Electrical System | WARNING INDICATORS-PARKING AID-REVERSE SENSING SYSTEM (RSS) AND FORWARD SENSING SYSTEM (FSS)-FALSE ACTIVATION OF WARNING TONE-SERVICE TIPS. *MJ UPDATE. *TT | |
| 04251 Dec 2004 | Structure | ALUMINUM CORROSION - SERVICE TIP. *TT | |
| 04189 Dec 2004 | Visibility | REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR. *TT | |
| 042107 Dec 2004 | Power Train | GENERAL (PCM) POWER TRAIN CONTROL MODULE PROGRAMMING PROCEDURES. *TT | |
| 18217 Oct 2004 | Fuel System | MULTIPLE VEHICLES - FUEL LEVEL INDICATION CONCERNS - SERVICE TIP. VARIOUS MODELS INCLUDING 2005 SUPER DUTY F-SERIES, EXCURSION, EXPEDITION, EXPLORER, MOUNTAINEER AND AVIATOR. *TT | |
| 04174 Sep 2004 | Electrical System | MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - SYSTEM LEAN DIAGNOSTIC TROUBLE CODES (DTC'S) - SERVICE TIPS. VARIOUS MODELS INCLUDING 2004 F-SERIES. *TT | |
| 04L19 Sep 2004 | Steering | CUSTOMER MAINTENANCE REMINDER - LITERATURE PROGRAM 04L19 - TIE ROD INSPECTION PROCEDURE. *TT | |
| 031404 Aug 2004 | Engine And Engine Cooling | ENGINE MISFIRE OR RUNNING - COIL ON PLUG (COP) IGNITION SYSTEMS - WDS COP KIT DIAGNOSTIC TIPS. TO INCLUDE VARIOUS 2005 MODELS. * AR THIS ARTICLE 04161 SUPERSEDES TSB 03-14-04. | |
| 041514 Aug 2004 | Visibility | REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR. *TT | |
| 031501 Jul 2004 | Visibility | INOPERATIVE ELECTRIC REAR WINDOW DEFROSTER (HEATED BACKLITE) GRID LINES, INTEGRAL ANTENNA CONCERNS. *TT | |
| 04111 Jun 2004 | Electrical System | STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MALFUNCTION INDICATOR LAMP (MIL) ON AND DIAGNOSTIC TROUBLE CODES (DTCS) P0401, P0402, P1400 OR P1401. ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY. *TT | |
| 02M01 Jun 2004 | Engine And Engine Cooling | CUSTOMER SATISFACTION PROGRAM 02M01 SUPPLEMENT #4. CERTAIN FORD 2000 THROUGH 2003 VEHICLES EQUIPPED WITH A TUBE-MOUNTED EGR PRESSURE SENSOR - ADDITIONAL EGR PRESSURE SENSOR WARRANTY COVERAGE. *TT SUPPLEMENT #3. *MJ SUPPLEMENT #6. *TT | |
| 17720 Apr 2004 | Electrical System | AIRBAG WARNING LAMP ON WITH DIAGNOSTIC TROUBLE CODE (DTC) B1994/B1998 ON VEHICLES WITHOUT SIDE AIR BAGS. *TT | |
| 0454 Mar 2004 | Suspension | AIR SUSPENSION COMPRESSOR NOISE. *TT | |
| 0457 Mar 2004 | Visibility | POP/THUMP NOISE AT END OF WINDOW MOVEMENT AND/OR DRIVER'S WINDOW BOUNCE BACK AND REVERSE TO MID-POSITION. *TT | |
| 03223 Jan 2004 | Electrical System | STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MALFUNCTION INDICATOR LAMP ON AND DIAGNOSTIC TROUBLE CODES (DTCS) P0401, P0402, P1400 OR P1401. ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY. *TT | |
| 17459 Jan 2004 | Interior Lighting | COURTESY RAIL LAMPS DO NOT OPERATE CORRECTLY OR CAUSE A BATTERY DRAW. *TT | |
| 03256 Dec 2003 | Engine And Engine Cooling | ENGINE-ROMEO BUILT 4.6L 2V-TICK NOISE FROM ENGINE-ENGINES BUILT BEFORE 9/17/2003. *MJ | |
| 99263 Nov 2003 | Wheels | CORRECT LUG NUT TORQUE SPECIFICATIONS - INCREASE WHEEL NUT AND STUD SIZE - SERVICE TIP. *TT | |
| 17316 Nov 2003 | Fuel System | FUEL SIGNAL TO INSTRUMENT CLUSTER SERVICE TIP. *TT | |
| 17320 Nov 2003 | Engine And Engine Cooling | BROKEN EXHAUST MANIFOLD STUDS. *TT |
Showing 30 of 145 distinct bulletins on file for this vehicle.
Before you buy this vehicle
A test-drive checklist generated from this vehicle's own complaint and recall record.
- Cold-start it yourself and listen for the first thirty seconds.Knocking, ticking that fades as it warms, or blue or white smoke on startup are the sounds of this vehicle's engine cluster. Check the oil level and the coolant color, and ask whether the engine or its head gaskets have ever been out.
- Sit in it with the engine off and test everything that has a switch.Windows, locks, lights, the cluster, the radio. Electrical faults are this vehicle's story and the hardest to see on a drive: an intermittent no-start waits for the second week of ownership. Ask for the battery's age and whether any control module has been replaced.
- Test the throttle response and the cruise control on an open road.A surge, a hang in engine speed after lifting off, or cruise that will not set or cancel cleanly are the speed-control complaints on this vehicle.
- Run the VIN against open recalls before you negotiate.This vehicle has 6 recall campaigns on file. An open recall needs VIN-specific confirmation. Many are quick, no-charge fixes and worth negotiating over; an unresolved do-not-drive advisory, or a remedy the manufacturer has not yet made available, should stop the purchase until it is resolved.
- Ask for the service history in writing, then read it against this page.The complaint families above are where owners of this vehicle report trouble. Repairs in exactly those systems are evidence the car had the problem; no such repairs could mean it never developed it, or that it was never fixed. The test-drive items above are how you tell those apart.
Parts search directory
The generic parts list for this vehicle has its own page: a search launcher for every system, filtered by fuel type and era but not by engine, trim, or brake type. It is not a diagnosis and not a fitment guarantee.
Open the parts directory for this Ford Expedition →