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 592 of 615 complaints with a usable failure date.
Odometer when the failure occurred
Owner-reported mileage at failure, in 20,000-mile bands. Based on 442 of 615 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
173 complaint records13 fire reports
"2003 FORD EXPEDITION SPARK PLUG BLEW OUT OF CYLINDER HEAD. APPARENTLY A COMMON PROBLEM THAT NEEDS TO BE READDRESSED. *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
105 complaint records16 fire reports3 crash reports
"COIL PACK WENT OUT ON MY 2003 FORD EXPEDITION @ 36,200 MILES, 200 MILES OUT OF WARRANTY. DEALER WOULD NOT MAKE EXCEPTION AND COVER. *NM..."- 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 →
Brakes
91 complaint records2 fire reports8 crash reports
"EXCESSIVE BRAKE DUST ACCUMULATION SINCE NEW. ROTORS HAVE BEEN TURNED ONCE AND NOW NEED TO BE REPLACED WITH PADS AT 23,600 MILES. *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 brakes 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... |
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 |
|---|---|---|---|
| 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 |
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 24-2188 Jul 2024 | Wheels | This article supersedes TSB 22-2219 to update the Parts List and Service Procedure to clarify applicable steps by vehicle application. | |
| SSM 51536 Apr 2023 | Structure | For 2000-2024 Ford and Lincoln vehicles, swapping a module from a vehicle for diagnosis purposes is likely to cause errors and is not recommended. It is also not recommended to order a replacement module using a vehicle identification number (VIN) from a different vehicle. | |
| TSB 22-2219 Jun 2022 | Power Train | Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 (non-Raptor) vehicles equipped with 4WD may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (IWE). | |
| TSB 20-2307 Oct 2020 | Electrical System | Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 vehicles equipped with TOD transfer cases may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (IWE). | |
| 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. |
Show 55 more bulletins
| Bulletin | Type | Component | Summary |
|---|---|---|---|
| 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. | |
| TSB-08-19-3 May 2009 | Power Train | FORD: SOME VEHICLES MAY EXHIBIT OIL SEPARATION FROM THE INTERNAL LUBE FOUND IN THE UNITIZED CARTRIDGE SEAL. OIL SEPARATION APPEARS TO BE AND IS OFTEN MISDIAGNOSED, AS AN AXLE LUBE LEAK. *PE | |
| 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 | |
| 0514 Jan 2006 | Service Brakes | BRAKE SHUDDER (ROTOR THICKNESS VARIATION) DUE TO THE NEW LOW DUST FRONT BRAKE LINING USED IN PRODUCTION, OR NEW LININGS THAT WERE INSTALLED PER TSB 04-05-02. *TT | |
| 06216 Jan 2006 | Power Train | LIMITED SLIP AXLE CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNING MANEUVERS. *TT | |
| 0637 Jan 2006 | Tires | LOW TIRE INDICATOR ON - TPMS SYSTEM SENSOR WAKE UP. *TT | |
| 041601 Nov 2005 | Engine And Engine Cooling | WDS COP KIT DIAGNOSTIC TIP - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING. *TT | |
| 0594 Oct 2005 | Seats | DRIVERS FRONT POWER SEAT WILL NOT MOVE FORWARD OR REARWARD. *TT | |
| 05198 Oct 2005 | Visibility | REAR WINDOW WIPER INOPERATIVE. *TT | |
| 18815 Sep 2005 | Power Train | A TINY CRACK, OR CRACKS, AROUND THE TRANSFER CASE DRAIN PLUG HOLE. *TT | |
| 04105 Jun 2005 | Power Train | AXLE SEAL LEAKS. LEAKS FROM REAR HALFSHAFT AXLE SEAL. SERVICE TIPS. *TT | |
| 042421 Jun 2005 | Seat Belts | SAFETY BELT RETRACTION SPEED. *TT | |
| 051610 Jun 2005 | Structure | CLUNK/GRIND/THUMP NOISE - FRAME REPAIR PROCEDURE. *TT | |
| 18478 May 2005 | Power Train | AXLE SEAL LEAKS. *EH | |
| 031207 Apr 2005 | Steering | STEERING WHEEL AT 65 MPH (105 KM/H) OR HIGHER. *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 | |
| 18466 Mar 2005 | Power Train | AXLE WHINE HOWL. THIS INCLUDES 1997-05 FORD VEHICLES. *EH | |
| 18506 Mar 2005 | Wheels | ALUMINUM ALLOY WHEELS PITTING AND OR PEELING CLEANING PROCEDURES. *EH | |
| 05310 Feb 2005 | Seat Belts | SAFETY BELT WEB STOP BUTTON SERVICE. *EH | |
| 0526 Feb 2005 | Visibility | WIPER BLADE CHATTER. *TT | |
| 18423 Feb 2005 | Power Train | AXLE WHINE HOWL SERVICE WITH INDIVIDUAL PARTS INSTEAD OF AN AXLE ASSEMBLY. *EH | |
| 18400 Feb 2005 | Suspension | FOUR CORNER LOAD LEVELING AIR SUSPENSION MAY EXHIBIT LEVELING CONCERNS, SUCH AS ONE FRONT CORNER DROPPING. INDIVIDUAL AIR SPRINGS AVAILABLE FOR SERVICE. *TT | |
| 18439 Feb 2005 | Power Train | TINY CRACK OR CRACKS AROUND THE TRANSFER CASE DRAIN PLUG. *EH | |
| 050618 Jan 2005 | Suspension | REAR AXLE NOISE REPAIR. *SC | |
| 052624 Jan 2005 | Wheels | VIBRATION DIAGNOSIS - TIRE/WHEEL RUNOUT. *TT | |
| 052308 Jan 2005 | Parking Brake | PARKING AID SYSTEM INOPERATIVE. *AK | |
| 052621 Jan 2005 | Service Brakes | UNINTENDED BRAKE ASSIST. *TT | |
| 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 | |
| 040704 Dec 2004 | Seats | CLIMATE CONTROLLED SEAT DIAGNOSIS - SERVICE TIPS. *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 | |
| 042116 Nov 2004 | Visibility | REVERSE TILT MIRROR SYSTEM DIAGNOSTICS AND REPAIR. *EH | |
| 18213 Oct 2004 | Power Train | GRINDING NOISE FROM FRONT AXLE WHEEL HUBS ON ACCELERATION IN 2WD - SERVICE TIP. VARIOUS MODELS INCLUDING 2005 EXPEDITION/NAVIGATOR. *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 | |
| 18228 Oct 2004 | Tires | TIRE FEATHERING AT LOW MILEAGE. OASIS. VARIOUS MODELS INCLUDING 2005 EXPEDITION. *TT | |
| 03198 Sep 2004 | Power Train | CHATTER, SHUDDER, A BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNS ON VEHICLES EQUIPPED WITH THE 9.75 INCH OR 8.8 INCH LIMITED SLIP REAR AXLE. *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 | |
| 18127 Sep 2004 | Electrical System | VARIOUS ELECTRIC CONCERNS. INTERIOR ILLUMINATION, QUARTER WINDOWS, MOONROOF FUNCTION, ACCESSORY DELAY, COURTESY LAMPS, ELECTRO CHROMATIC MIRROR, CLIMATE CONTROLLED SEATS, ELECTRONIC PARK BRAKE RELEASE, FLASHER RELAY, AUDIO SYSTEM, ELECTRONIC HIDDEN ANTENNA MODULE (EHAM), POWER... | |
| 18172 Sep 2004 | Electrical System | REVERSE SENSING SYSTEM DEFAULTING OFF, SETTING DIAGNOSTIC TROUBLE CODES, OR LOSING COMMUNICATION WITH DIAGNOSTIC SCAN TOOL. *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. | |
| 041511 Aug 2004 | Engine And Engine Cooling | MISFIRE AT IDLE WITH DIAGNOSTIC TROUBLE CODES P0300-P0308, P0316. *TT | |
| 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 | |
| 17881 Jun 2004 | Suspension | RIDE HEIGHT ISSUES ON AUTOMOBILES WITH AIR SUSPENSION. *TT | |
| 17693 Apr 2004 | Electrical System | DIAGNOSTIC TROUBLE CODE (DTC) P0320 (IGNITION ENGINE SPEED INPUT CIRCUIT MALFUNCTION). *TT | |
| 17732 Apr 2004 | Electrical System | CHECK AIR SUSPENSION MESSAGE WITH DIAGNOSTIC TROUBLE CODE (DTC) C1724, C1873, AND/OR C1889. *TT | |
| 17738 Apr 2004 | Electrical System | CHARGING SYSTEM WARNING INDICATOR INTERMITTENTLY ON WITH POSSIBLE DIAGNOSTIC TROUBLE CODE (DTC) P0620. *TT | |
| 17755 Apr 2004 | Power Train | AXLE WHINE AT HIGHWAY SPEEDS (40-60 MPH). *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 | |
| 0459 Mar 2004 | Equipment | INTERMITTENT LOSS OF COOLING OR AIRFLOW FROM A/C SYSTEM AT HIGHWAY DRIVES. *TT |
Showing 60 of 151 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.
- Brake hard once from speed on an empty road.A pull to one side, a pulsing pedal, a pedal that sinks at a stop, or an ABS light that stays lit are the brake complaints on this vehicle presenting themselves.
- Run the VIN against open recalls before you negotiate.This vehicle has 1 recall campaign 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 →