really awful
Crashes / Fires:
0 / 1
Injuries / Deaths:
1 / 0
Average Mileage:
57,681 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Ford Expedition engine problems

engine problem

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2004 Ford Expedition Owner Comments

problem #9

Dec 272010


  • miles


2003 Ford F250 and 2004 Ford Expedition. Consumer states right rear spark plug blew out of the cylinder head. This happened on both vehicles the consumer was informed an adapter was made as a temporary fix. About 500 miles later, the same problem happened again. The consumer took the vehicle to a repair shop where the mechanic stated the heads or engine would need to be replaced at a cost of $3000-$4000.

- Piscataway, NJ, USA

problem #8

Jun 062011

Expedition 8-cyl

  • 110,000 miles
On two separate occasions, while driving my 2004 Ford Expedition, a spark plug has been ejected from the engine. One time, at city speeds, a second time at 65 miles per hour. Both times, there was an instant loss of power and the smell of gasoline filled the passenger compartment. After the original failure, I took it to an auto mechanic who replaced the spark plug and installed a replacement coil on plug assembly. I have not yet repaired the second incident as it occurred last night. It seems to me that this is a very dangerous condition that initially didn't seem that significant, but after the tow truck operator said, that he thought there was a recall, it prompted me to research further. His tow service operates in the harrisburg, pa area and he claimed that he sees this happen nearly 1-2X/week with Ford 5.4L V8 engines. He said, that he's "seen so many of them, that they've got to have a recall.

- Columbia, MD, USA

problem #7

Nov 162010

Expedition 4WD 8-cyl

  • 109,000 miles
Engine hood insulator material began to smolder and smoke. Needed to remove before vehicle caught fire. Burned two fingers.

- Milford, MI, USA

problem #6

Apr 162010


  • 138,000 miles


Starting vehicle spark plug broke loose, damaging threads for spark plug and breaking coil pack. This is the second time this has occured. First time the vehicle was at freeway speeds and blew the spark plug out into the engine compartment. The spark plugs had never been changed before the first incident. In order to fix the problem the spark plug hole will have be repaired before a new plug can be put in.

- Las Vegas, NV, USA

problem #5

Oct 192009


  • 119,680 miles
The contact owns a 2004 Ford Expedition. While parked three sparks plugs/engine misfired. The failure caused $1700 worth of damage. The vehicle was towed to the Ford dealer and all of the wires under the cylinder head were repaired. The failure mileage was 119,680.

- Las Vegas , NV, USA

problem #4

Mar 112006

Expedition 4WD 8-cyl

  • Automatic transmission
  • 38,000 miles
My vehicle's engine has failed. The dealer will not honor the warranty claiming I didn't change the oil, they have no record of me coming in for maintenance, I change my own oil and brought receipts in. This was not good enough. They have had my vehicle for 18 weeks with no rental. I have contacted the company the BBB a news channel in my area and I also work for Ford which makes it even worse that they are denying my claim.

- Chesapeake, VA, USA

problem #3

Dec 272004

Expedition 4WD 8-cyl

  • Automatic transmission
  • 4,400 miles


2004 Ford Expedition. Since I took delivery, the vehicle has a rough idle in any gear once the vehicle has been brought up to operating temperature (approximately 15 minutes). The truck has been returned to original dealership twice for this problem. The original "solution" was stated that due to the change in gas types from summer to winter the difference in oxygen in the fuel was causing the problem. I was told to drive it using a mid-grade gas for approximately 30 days and if the problem was still present return it to the dealer. The vehicle now has about 5,900 miles on it and the rough idle continues after it warms up. The vehicle is only getting about 10.6 mpg which is significantly less than mfg stated and less than the 1997 4.6L Expedition I previously owned. I returned the vehicle to the dealer approximately 30 days from the original visit complaining of the same rough idle problem and reduced mileage. On the second visit the dealer said all "electronic" checks were in spec and there was nothing "wrong" with the vehicle. Said they would have to turn it over to Ford engineer. We are waiting to hear from Ford. The car idles rough and the mileage is poor. Still no resolution to original problem.

- Sandy, UT, USA

problem #2

Nov 162004

Expedition 4WD 8-cyl

  • Automatic transmission
  • 52 miles
2004 Ford Expedition. Since delivery day the truck has a rough idle in any gear once the temperature gauge reaches the mid point between C and H. the truck has been returned to three different dealershi[S for this problem. Two have changed different coil packs and spark plugs. One of them changed oil saying it displayed too much oil. The third dealership, which the truck was taken to twice said this was a charateristic of the 2004 4.6 engine. The truck now has 6,000 miles ane the rough idle continues after it warms up. No of these dealers have checked for a bad cooling sensor, bad head gasket, clogged or defective radiator or constricted cooling system.

- West Bloomfield, MI, USA

problem #1

Nov 012003

Expedition 4WD 8-cyl

  • Automatic transmission
  • miles
Gas mileage 6 mpg city and 11 mpg highway. Power windows make a loud scratching sound when operated.

- Oakley, KS, USA

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