Engine
4.6L 8-cyl
How to read this file. Complaint records are unverified owner submissions to the federal safety agency. Counts are raw, not adjusted for sales volume or vehicle age. Recall campaigns apply to the model; only a VIN check shows whether this car is affected or repaired. Parts shown are named by an editorial note or listed as a search directory; none is a diagnosis. Full methodology.
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.
When it fails
The timing of this vehicle's reported failures, from the complaint file itself. A cluster tells you what to expect and when; it is shaped by reporting behavior as well as by the vehicle.
Vehicle age when the failure occurred
Years between the model year and the owner's reported failure date. Based on 330 of 340 complaints with a usable failure date.
Odometer when the failure occurred
Owner-reported mileage at failure, in 20,000-mile bands. Based on 259 of 340 complaints reporting a plausible odometer (500 to 500,000 miles; unverified).
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
122 complaint records21 fire reports
"WHILE DRIVING THE VEHICLE MISFIRED AND STALLED. THE DEALER REWIRED AND RETORQUED THE FRONT END TO CORRECT THE PROBLEM. *YH..."- 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 →
Speed control
58 complaint records25 fire reports2 crash reports
"CRUISE CONTROL AND HORN FAILED. THE DEALER STATED THE CRUISE CONTROL CABLE WIRE OVERHEATED AND FUSED TOGETHER IN THE HARNESS. *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 →
Electrical system
47 complaint records22 fire reports
"VEHICLE UNEXPECTEDLY CAUGHT ON FIRE WHILE IT WAS PARKED. MANUFACTURER WAS CONTACTED BY OWNER, AND WAS AWARE OF THE PROBLEM.*AK *TT..."- 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 →
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 |
|---|---|---|---|
| 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... |
| 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... |
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 |
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. |
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 |
Show 55 more bulletins
| Bulletin | Type | Component | Summary |
|---|---|---|---|
| 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 | |
| 17905 Jul 2004 | Power Train | MULTIPLE VEHICLES USING FEHP REAR AXLE FLUID. FLUID USAGE CHANGE. *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 | |
| 17346 Nov 2003 | Steering | STEERING IDLER ARM NOISE. *TT | |
| 03181 Sep 2003 | Electrical System | REMOTE KEYLESS ENTRY (RKE) - SERVICE TIPS. *TT | |
| 03164 Aug 2003 | Engine And Engine Cooling | SOME VEHICLES, EQUIPPED WITH THE 4.6L 2V ENGINE, WITH AN ENGINE BUILD DATE PRIOR TO 8/29/03 MAY EXHIBIT AN ENGINE TICK NOISE THAT IS PRESENT AT ALL TEMPERATURES DURING IDLE. 2004 MODELS INCLUDED. *TT | |
| 031513 Aug 2003 | Steering | TIE ROD END INSPECTION PROCEDURE. *TT | |
| 03144 Jul 2003 | Engine And Engine Cooling | ENGINE MISFIRE OR ROUGH RUNNING CONDITION WITH COIL ON PLUG (COP) IGNITION SYSTEMS MAY BE MORE ACCURATELY DIAGNOSED USING THE OPTIONAL WORLDWIDE DIAGNOSTIC SYSTEM (WDS) COIL ON PLUG (COP) KIT. 2003 SUPER DUTY F SERIES INCLUDED. *TT | |
| 03148 Jul 2003 | Power Train | NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS. 2003 ESCORT AND SUPER DUTY F SERIES INCLUDED. *TT | |
| 0392 May 2003 | Suspension | REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES. *TT | |
| 0398 May 2003 | Fuel System | MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATION WITH DIAGNOSTIC TROUBLE CODES P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE P0457. *TT | |
| 0399 May 2003 | Steering | TIE ROD END INSPECTION PROCEDURE. *TT | |
| 16797 Apr 2003 | Electrical System | VEHICLES WITH KEYLESS ENTRY PAD MAY EXHIBIT DEAD BATTERY, NO START, INTERIOR LAMP/HEADLAMP SELF-ACTIVATION, OR INOPERATIVE KEYLESS ENTRY PAD. *TT | |
| 030709 Apr 2003 | Suspension | REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES. *TT | |
| 0361 Mar 2003 | Engine And Engine Cooling | MALFUNCTION INDICATOR LAMP ON WITH OR WITHOUT ROUGH RUNNING, LACK OF POWER, SURGE OR POOR FUEL ECONOMY WITH DIAGNOSTIC TROUBLE CODES P0401, P0402, P1400, P1401. *TT *JB | |
| 03610 Mar 2003 | Steering | TIE ROD END INSPECTION PROCEDURE. CANADA VEHICLES ONLY. *TT *JB | |
| 16683 Mar 2003 | Engine And Engine Cooling | FALSE FAILURE OF THE VAPOR MANAGEMENT VALVE (VMV). *TT *JB | |
| 0322 Feb 2003 | Engine And Engine Cooling | STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MALFUNCTION INDICATOR LAMP (MIL) ON AND DIAGNOSTIC TROUBLE CODES (DTCS) P0401, P0402, P1400 OR P1401, OR RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY, AND THE ABOVE LISTED DTCS WITHOUT MIL. *TT | |
| 0258 Nov 2002 | Power Train | INOPERATIVE OR INACURRATE SPEEDOMETER, 4X4 LAMP ILLUMINATD, AND / OR DIAGNOSTIC TROUBLE CODE P1635 OR P1639. *TT | |
| 02227 Nov 2002 | Engine And Engine Cooling | ENGINE-CYLINDER HEAD DECK LEAK-4.6 AND 5.4L ENGINES-NEW SERVICE-ONLY GASKET AND CYLINDER HEAD KITS AVAILABILITY. *MJ | |
| 16400 Nov 2002 | Power Train | REAR AXLE SEAL LEAK - CONTACT REQUEST. *MJ | |
| 16403 Nov 2002 | Engine And Engine Cooling | ENGINE-LIGHT TICK OR RATTLE TYPE NOISE FROM ENGINE AFTER COLD START. *MJ | |
| 02208 Oct 2002 | Equipment | CLIMATE CONTROL A/C SERVICE TECH TIPS. *EH | |
| 02193 Sep 2002 | Vehicle Speed Control | DRIVEABILITY-IDLE-HIGH IDLE SPEEDS-THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES-VEHICLES BUILT THROUGH 12/31/01 EQUIPPED WITH 4.6L ENGINE. *MJ | |
| 02176 Sep 2002 | Exterior Lighting | LAMP-BRAKE-INVADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK. *MJ | |
| 16170 Aug 2002 | Unknown Or Other | SOME VEHICLES EQUIPPED WITH A 4R100 TRANSMISSION AND BUILT BETWEEN JANUARY 1, 2001 AND MAY 1, 2002 MAY EXHIBIT FLASHING TRANSMISSION CONTROL INDICATOR LAMP AND ANY OR ALL TORQUE CONVERTER CLUTCH DIAGNOSTIC TROUBLE CODES P0740, P0741, P0743, P1744. *TT | |
| 16015 Jul 2002 | Suspension | SOME VEHICLES WITH AIR SUSPENSION MAY EXHIBIT AN INITIAL OR REPEAT COMPRESSOR DRYER FAILURE. *TT | |
| 16033 Jul 2002 | Power Train | SOME VEHICLES WITH ELECTRONIC SHIFT-ON-THE FLY MAY EXHIBIT AN INADVERTENT 4X4 LOW ENGAGEMENT WHILE DRIVING. *TT | |
| 16087 Jul 2002 | Unknown Or Other | SOME VEHICLES MAY EXHIBIT A FLASHING TRANSMISSION CONTROL INDICATOR LAMP (TCIL) AND DIAGNOSTIC TROUBLE CODES P0740, P0741, P0743, AND P1744 (TORQUE CONVERTER CLUTCH). *TT | |
| 02121 Jun 2002 | Equipment | WHITE FLAKES COMING FROM THE AIR CONDITIONER VENTS WHEN THE BLOWER MOTOR IS ENGAGED. *TT | |
| 02108 May 2002 | Engine And Engine Cooling | SOME VEHICLES EQUIPPED WITH THE 5.4L 2V ENGINE MAY EXHIBIT A WHISTLING NOISE FROMTHE FORMED NYLON TUBE INTHE IDLE-AIR BYPASS FLOW CIRCUIT. *TT | |
| 15897 May 2002 | Power Train | SUBJECT REGARDING DRIVELINE ANGLE-RELATED VIBRATION AT VARIOUS SPEEDS AND LOAD CONDITIONS. *TT |
Showing 60 of 101 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.
- 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.
- 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.
- Run the VIN against open recalls before you negotiate.This vehicle has 2 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 →