2001 Ford Expedition

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, AND MAY CAUSE THE ELECTRICAL COMPONENTS IN THE VEHICLE TO MALFUNCTION.OVERALL, THE NUMBER OF REPORTS ALLEGING WIPER FAILURES AND LIGHTING FAILURES IS RELATIVELY SMALL.IN REVIEWING A LARGE SAMPLE OF THE 1503 COMPLAINTS FOR WINDSHIELD LEAKS, ODI'S ANALYSIS REVEALS THAT 0.04% OF THE TOTAL VEHICLE POPULATION REPORTED IMPROPER WINDSHIELD WIPER OPERATION AND 0.01% OF THE TOTAL VEHICLE POPULATIONREPORTED LIGHTING FAILURES.THE WARRANTY CLAIMS REVEAL THAT APPROXIMATELY 0.10% OF THE POPULATION HAS BEEN SERVICED FOR WIPER MALFUNCTIONS AND 0.08% FOR LIGHTING MALFUNCTIONS AS A RESULT OF WINDSHIELD LEAKING. ODI'S ANALYSIS OF THE FIELD PERFORMANCE STATISTICS AND AVAILABLE TECHNICAL INFORMATION HAS NOT ESTABLISHED THAT A DEFECT TREND EXISTS IN THE MALFUNCTION, FAILURE OR INTERMITTENT OPERATION OF THE FRONT WINDSHIELD WIPERS OR HEADLIGHTS.SEE THE ATTACHED SUMMARY REPORT.

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 COMPLAINTS ON THE SUBJECT VEHICLES WHERE THE COMPLAINANT, OR THE DEALER REPAIRING THE VEHICLE, REPORTED THAT A SPARK PLUG DETACHED FROM THE CYLINDER AND/OR EJECTED FROM THE ENGINE.AS OF DECEMBER 8, 2005, ODI IS NOT AWARE OF ANY ALLEGATIONS WHERE THE ALLEGED DEFECT RESULTED IN A LOSS OF VEHICLE CONTROL, A CRASH, AN INJURY, OR A FATALITY IN ANY OF THE 10,319,810 SUBJECT VEHICLES.IN ADDITION, ODI IS AWARE OF ONLY TWO INCIDENTS WHERE THE VEHICLE STALLED WITHOUT RESTART.INFORMATION CONTAINED IN THE ODI CONSUMER COMPLAINTS AND OBTAINED FROM 72 TELEPHONE INTERVIEWS WITH COMPLAINANTS SHOWED THE FOLLOWING:(1) 99% OF THE COMPLAINTS WERE ON MY 1997 TO 2002 SUBJECT VEHICLES.(2) MOST THE COMPLAINANTS REPORTED HEARING A LOUD POP WHILE DRIVING OR UPON STARTING UP THE VEHICLE FOLLOWED BY A LOUD, REPETITIVE CLICKING OR POPPING SOUND.(3) MANY OF THE COMPLAINANTS REPORTED THAT THE POPPING SOUND WAS ACCOMPANIED BY SOME LOSS OF VEHICLE POWER; HOWEVER, IN 99% OF THE INCIDENTS REPORTED, THE VEHICLE DID NOT STALL.IN THE VERY FEW INCIDENTS WHERE THE VEHICLE DID STALL, MOST VEHICLES COULD BE RESTARTED.(4) ONLY A SMALL PERCENTAGE OF THE COMPLAINANTS CITED THAT THEY SMELLED GAS OR A SLIGHT BURNING SMELL WHEN THE INCIDENT OCCURRED.(5) IN ALL BUT A VERY FEW INCIDENTS, VEHICLE DAMAGE WAS LIMITED TO THE ENGINE.IN ONE INCIDENT, THE COMPLAINT REPORTED THAT THE FUEL RAIL WAS DAMAGED AND REPLACED AFTER ONE OF THE SPARK PLUGS EJECTED FROM THE ENGINE; HOWEVER, THE COMPLAINANT REPORTED THAT THE DAMAGE DID NOT RESULT IN ANY TYPE OF FUEL LEAK OR FIRE.IN ANOTHER INCIDENT, THE ONLY INCIDENT WHERE A FIRE WAS ALLEGED, THE COMPLAINANT REPORTED THAT NO FLUID LEAK WAS OBSERVED, BUT THAT A FIRE RESULTED AFTER THE SPARK PLUG HAD EJECTED FROM THE ENGINE AND HE HAD RESTARTED THE VEHICLE AND DRIVEN TO ANOTHER LOCATION.NONE OF THE COMPLAINANTS REPORTED ANY DAMAGE TO THE VEHICLE HOOD.(6) ONLY TWO COMPLAINANTS REPORTED THAT THEY OBSERVED WHAT APPEARED TO BE SOME DROPS OF FUEL COMING FROM THE CYLINDER WHERE THE SPARK PLUG HAD FAILED OR ON THE SPARK PLUG ITSELF; HOWEVER, EACH OF THESE COMPLAINANTS REPORTED THAT THERE WAS NO SMOKE OR FLAMES AS A RESULT OF HIS INCIDENT.AS THE PETITIONER NOTED, AND ODI?S ANALYSIS SHOWED, IT IS POSSIBLE FOR A SPARK PLUG TO DETACH FROM THE ENGINE CYLINDER THREADS IN THE SUBJECT VEHICLES.HOWEVER, ODI?S ANALYSIS OF 474 COMPLAINTS DESCRIBING SUCH INCIDENTS FOUND ONLY A VERY FEW ALLEGED ANY SAFETY-RELATED CONSEQUENCES.NONE OF THESE SHOWED ANY EVIDENCE OF A SERIOUS SAFETY CONSEQUENCE.GIVEN THE LARGE POPULATION AND RELATIVELY LONG EXPOSURE TIME OF THE SUBJECT VEHICLES, THE COMPLAINT ANALYSIS INDICATES THAT THE RISK TO MOTOR VEHICLE SAFETY FROM THE ALLEGED DEFECT IS VERY LOW.IN VIEW OF THE FOREGOING, IT IS UNLIKELY THAT NHTSA WOULD ISSUE AN ORDER FOR THE NOTIFICATION AND REMEDY OF THE ALLEGED DEFECT AT THE CONCLUSION OF THE INVESTIGATION REQUESTED IN THE PETITION.THEREFORE, IN VIEW OF THE NEED TO ALLOCATE AND PRIORITIZE NHTSA?S LIMITED RESOURCES TO BEST ACCOMPLISH THE AGENCY?S SAFETY MISSION, THE PETITION IS DENIED.

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) AND THE GENERIC ELECTRONIC MODULE (GEM).THESE COMPONENTS CONTROL VARIOUS ELECTRICAL SYSTEMS IN THE VEHICLE.THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS, EA05015, TO ALLOW FURTHER INVESTIGATION OF THE ISSUE AND TO ASSESS THE NATURE OF THE POTENTIAL SAFETY CONSEQUENCE.

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 VACUUM THAT CAN POTENTIALLY CAUSE THE SCDS TO FAIL AND, IN CERTAIN SWITCH INSTALLATION ORIENTATIONS, CATCH FIRE.FORD IS ALSO INCLUDING THE ENTIRE POPULATION OF 1998 EXPLORERS.FORD HAS INFORMED ODI THAT TESTING TO DETERMINE THE CAUSE OF FAILURES IN THE 1998 EXPLORERS WILL CONTINUE AFTER THIS INVESTIGATION IS CLOSED.ODI BELIEVES THAT THE VEHICLES EXHIBITING THE FACTORS CAUSING SCDS FAILURE DESCRIBED IN THIS REPORT CORRELATE WELL WITH THE OBSERVED FAILURE RATES ON THESE VEHICLES BY MODEL AND MODEL YEAR.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST IN THE NON-RECALLED VEHICLES MANUFACTURED WITH SCDS THAT ARE NOT INCLUDED IN FORD?S RECALLS.ODI WILL CONTINUE TO MONITOR THE NON-RECALLED POPULATION FOR INCIDENCE OF ENGINE COMPARTMENT FIRES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE ATTACHED CLOSING REPORT FOR DETAILS.

Air Bags did not deploy Impact directly to drivers side of vehicle the other car was going 55 MPH caused me the driver to hit my head on the window hard. I was informed the air bags should have deployed by officer on site.

NHTSA ID

11713268

Incident

Dec 11, 2025

Front brake hose metal crimp completely rusted causing brake hose separation and failure. Design has rubber boot over crimp which actually retains moisture over many years. Boot may be intended to reduce stress at joint of metal to hose but actually enhanced failure mode. Drivers side came apart after minor bump during service, have photos of passenger side still intact but clearly fragile.

NHTSA ID

11586111

Incident

Apr 27, 2024

Driver seatbelt- Randomly releases from buckle when driving. Happened about 3-4 times already.

NHTSA ID

11582277

Incident

Apr 10, 2024

On the second row seat, passenger side door will not open using the door handle with the child safety switch in lock or unlock position. It will open from the outside handle. This is a safety concern. In case accident happen or fire in the vehicle occurs, the second and third row passengers can not get out of the vehicle fast enough for their safety. This has not work for over a year now.

NHTSA ID

11531805

Incident

Jun 1, 2022

Vehical burst into flames seems on passenger side under the hood...Had been parked all day. No one around or injured. Vehical is a total loss.

NHTSA ID

11503217

Incident

Nov 20, 2022

I gave a friend a ride to Wal mart in my 2001 Expedition to buy some power steering fluid, luckily I parked over by the automotive section. I turned it off and waited in vehicle till he returned, about 7 or 8 minutes. I started the engine, grabbed the brake and dropped it in reverse when engine revved sending us backwards completely out of control with both feet on the brakes, spinning rear wheels and I turned ignition key off as quick as possible but violently slammed into a truck semitrailer only, parked alongside Wal mart tire shop. Completely totalled out the entire rear passenger liftback, taillights, tailgate, rear hatch window, left rear luever window, left tailpipe, tow hitch package and rear bumper. With only min. coverage, I'm now w/o a vehicle after completely replacing entire front and rear suspension, steering and tires plus alignment less than 6 months prior, with 275000 miles. Thank you very much Ford Motor Co. This was NOT an issue of driver error !.. I WILL find a way to legally hold you responsible for my loss, making FORD liable for repairing or replacing my vehicle ! This happened on Aug 29th, 2022 approx. 4pm at Wal mart property, in Ukiah, CA. 95482

NHTSA ID

11482139

Incident

Aug 29, 2022

VEHICLE CAUGHT ON FIRE DUE TO AN INCORRECTLY INSTALLED HEAD LIGHT DUE TO A CRACKED PLUG ASSEMBLY. VEHICLE WAS IN A FAST-FOOD DRIVE THROUGH WHEN THE SMOKE AND SUBSEQUENT FLAMES WERE SEEN. DUE TO AGE OF THE VEHICLE THE TASK OF CHANGING THE LIGHT BULB WAS FARMED OUT TO LOCAL OIL CHANGE SHOP. WHILE CHANGING THE PLACING THE NEW BULB INTO THE PLUG ASSEMBLY THE THIN PLASTIC BROKE KEEPING THE BULB FROM SEATING PROPERLY. TESTED OKAY ON REASSEMBLY BUT ONCE NIGHT CAME THE LIGHT WAS ON FOR ONLY 15 MINUTES AND IGNITED THE INNER HEAD LAMP ASSEMBLY AND SUBSEQUENTLY MORE OF THE ENGINE COMPARTMENT. FORTUNATELY, THE FAST-FOOD RESTAURANT CAME OUT WITH AN EXTINGUISHER AND PUT OUT THE FIRE. THANKFULLY, NO ONE WAS HURT HOWEVER, HAD THE FIRE OCCURRED ON THE HIGHWAY, IN A PARKING LOT UNATTENDED, OR IN THE HOMES GARAGE, THE OUTCOME WOULD HAVE BEEN FAR WORSE.

NHTSA ID

11366759

Incident

Oct 24, 2020

Mileage

192,000 mi

MY VEHICLE YEAR,MAKE,AND MODEL HAS MULTIPLE MANUFACTURER RECALLS PERTAINING TO MY SPECIFIC VEHICLES VIN NUMBER. I HAVE 0 UNREPAIRED RECALLS THAT HAVE NOT BEEN ASSESSED AND HAS HAD ZERO COMPONENTS REPLACED UNDER RECALLS FOR SPECIFIC COMPONENTS. EACH AND EVERY RECALLED COMPONENTS ASSOCIATED WITH MY VEHICLES YEAR, MAKE, AND MODEL PERTAINING TO MY VEHICLES VIN NUMBER ARE A SAFETY RISK AT FAULT AND ANY PROBLEMS CREATE UNSAFE CONDITIONS FOR OPERATION OF VEHICLE ON THE ROAD. MY ASSESSMENT OF MY VEHICLES SAFETY RISK IS HIGH DUE TO THE 0 UNREPAIRED RECALLS MY VEHICLE HAS NOT BEEN REPLACED WITH NEW COMPONENTS TO AVOID THESE SAFETY RISKS FROM COMPONENT FAILURE.

NHTSA ID

11349753

Incident

Aug 16, 2020

Mileage

214,800 mi

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. Panel replacement is recommended.

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. Follow the Service Procedure steps to correct the condition

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. Follow the Service Procedure steps to correct the condition

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

WDS COP KIT DIAGNOSTIC TIP - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING. *TT

SAFETY BELT RETRACTION SPEED. *TT