Problems · by component

2004 Ford Expedition engine and engine cooling problems

26 owner complaints to NHTSA about the 2004 Ford Expedition cite engine and engine cooling, 9% of all 297 complaints for this model year.

Complaints
26
9% of all complaints
Crashes
0
Reported by owners
Fires
3
Reported by owners
Injuries
1
Reported by owners
01 —Owner reports

What owners say about the engine and engine cooling

Verbatim from NHTSA complaints, newest first
“TL* THE CONTACT OWNS A 2004 FORD EXPEDITION EDDIE BAUER EDITION. THE CONTACT WAS DRIVING 45 MPH WHEN THE ENGINE FAIL SAFE WARNING LIGHT ILLUMINATED AND THE VEHICLE STALLED. THE VEHICLE WAS TOWED TO THE DEALER. THE MANUFACTURER WAS CONTACTED. THE VEHICLE WAS NOT REPAIRED AND THE VIN WAS UNAVAILABLE. THE FAILURE AND CURRENT MILEAGES WERE 74,000.”
Owner complaint to NHTSAFiled May 4, 2012Engine and engine coolingODI 10457485
“TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. THE CONTACT STATED THAT THE NUMBER THREE SPARK PLUG BLEW OUT OF THE HEAD GASKET. THE SPARK PLUG RIPPED THE TREADS IN THE SLOT WHERE THE SPARK PLUG WAS LOCATED. THE CONTACT SPOKE WITH THE DEALER AND WAS TOLD THAT THE FAILURE WAS A COMMON ISSUE. THE MANUFACTURER WAS ALSO CONTACTED BUT STATED THAT SINCE THE VEHICLE WAS NO LONGER UNDER WARRANTY, THE VEHICLE WOULD NOT BE REPAIRED AT THEIR EXPENSE. THE FAILURE AND THE CURRENT MILEAGES WERE 107,000.”
Owner complaint to NHTSAFiled Apr 23, 2012Engine and engine coolingODI 10456096
“TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. THE CONTACT WAS INFORMED BY A NEIGHBOR THAT HER VEHICLE WAS ON FIRE. THE FIRE DEPARTMENT WAS CALLED TO EXTINGUISH THE FIRE. THERE WERE NO INJURIES REPORTED. THE VEHICLE WAS NOT DESTROYED NOR WAS IT TAKEN FOR INSPECTION OR REPAIRS. THE CAUSE OF THE FIRE WAS UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 195,000.”
Owner complaint to NHTSAFiled Apr 18, 2012Engine and engine coolingFire reportedODI 10455677
“WHILE DRIVING DOWN THE ROAD, TAKING MY SON TO SCHOOL, I HAD A SPARK PLUG BLOW OUT. IMMEDIATELY HAD TO STOP THE VEHICLE AND MY SON WASN'T ABLE TO ATTEND SCHOOL BECAUSE I HAD NO RIDE. I HAVE BEEN READING ONLINE AND THIS IS AN ONGOING PROBLEM WITH FORD AND AM FURIOUS THAT NOTHING HAS BEEN DONE TO REMEDY THIS PROBLEM FOR FORD OWNERS. *TR”
Owner complaint to NHTSAFiled Mar 9, 2012Engine and engine coolingODI 10450855
“TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. AFTER STARTING THE VEHICLE, THE CONTACT NOTICED A KNOCKING SOUND COMING FROM THE ENGINE. MOMENTS LATER THE CONTACT NOTICED THAT THE VEHICLE HAD BEGAN TO VIBRATE ABNORMALLY. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE CURRENT AND FAILURE MILEAGES WERE 26,000.”
Owner complaint to NHTSAFiled Mar 6, 2012Engine and engine coolingODI 10450520
“THE REAR A/C ACTUATOR BEGAN MAKING A THUMPING NOISE AND THE REAR A/C NOW ONLY WORKS WHEN IT WANTS TO AND ALSO THE HEAT IN THE REAR. IF YOU TURN ON THE A/C SOMETIMES HEAT WILL COME OUT OF THE VENTS AND IF YOU TURN ON THE HEAT, SOMETIMES A/C WILL COME OUT OF THE VENTS. *TR”
Owner complaint to NHTSAFiled Nov 16, 2011Engine and engine cooling, VisibilityODI 10436025

Showing 6 of 26 reports. Read every report on NHTSA.gov.

Data from NHTSA Complaints API (owner reports, unverified) · synced Oct 30, 2026NHTSA vehicle page

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.