2004 Ford Expedition Engine Problems

The contact owns a 2004 Ford Expedition. The contact recently purchased the vehicle and stated that while driving at an undisclosed speed, the transmission hesitated before upshifting with the accelerator pedal depressed. Additionally, while stopped at a traffic light, the vehicle rolled backwards when the accelerator pedal was depressed before responding as needed. There was no warning light illuminated. The contact attempted to return the vehicle to the independent dealer where the vehicle was purchased; however, the dealer declined to assist. Recently, the vehicle stalled, and it was towed to an independent mechanic to be diagnosed. The mechanic retrieved fault codes for the engine and stated that the TCM needed to be replaced. The vehicle was not repaired. The manufacturer was not informed of the failure. The failure mileage was unknown.

NHTSA ID

11722224

Incident

Feb 25, 2026

The contact owns a 2004 Ford Expedition. The contact stated while driving at 40 MPH, the vehicle shut down completely, and the warning messages indicated check gage and check service engine. The contact was able to pull over on the side of the road. The dealer was not contacted. The manufacturer was not made aware of the failure. The failure mileage was 127,708.

NHTSA ID

11488840

Incident

Oct 11, 2022

Mileage

127,708 mi

The contact owns a 2004 Ford Expedition. The contact stated that while her daughter was driving at an undisclosed speed, the vehicle was jerking. The contact stated that one spark plug exploded and then another spark plug exploded and went through the cylinder head. The contact called the local dealer but the vehicle was not diagnosed or repaired. The vehicle was taken to an independent mechanic where the spark plug was replaced. The manufacturer was notified and referred the contact to the NHTSA for assistance. The failure mileage was approximately 87,000.

NHTSA ID

11465508

Incident

May 14, 2022

Mileage

87,000 mi

The contact owns a 2004 Ford Expedition. The contact stated while driving at various speeds, the vehicle lost motive power without warning and the steering wheel became difficult to steer on several occasions. The vehicle was taken to an independent mechanic, but the failure could not be replicated. The throttle was replaced however, the failure recurred. The manufacturer was not made aware of the failure. The failure mileage was 216,000. The Vin was not available.

NHTSA ID

11425528

Incident

Jul 12, 2021

Mileage

216,000 mi

VEHICLE LOST POWER FOR 3-5 SECONDS AT HIGHWAY SPEEDS APPROXIMATELY 65 MPH ON THREE SEPARATE EVENTS. VEHICLE SLOWED DOWN DUE TO POWER LOSS WHILE IN HEAVY TRAFFIC. THREE OTHER TIMES AT IDLE SPEED IN DRIVE AND IN PARK ENGINE STALLED AND IMMEDIATELY RESTARTED. LOSS OF POWER STEERING DUE TO ENGINE NOT RUNNING WHEN STALL EVENT HAPPENED. I PERFORMED INSPECTION OF FUEL PUMP RELAY WHICH IS INTERNAL TO PASSENGER SIDE FUSE BLOCK. FOUND INADEQUATE SOLDER JOINT ON INTEGRATED RELAY PRINTED CIRCUIT AND BURN MARKS ON OUTSIDE OF FUEL PUMP RELAY. LOCATED SALVAGE FUSE BLOCK SAME MAKE AND MODEL AND INSPECTED. SAME DAMAGE ON SALVAGE FUSE BLOCK ASSEMBLY. REPLACED WITH AFTERMARKET FUSE BLOCK WITH REVISED SOLDER JOINT AND UPDATED RELAY.

NHTSA ID

11377472

Incident

Oct 13, 2020

Mileage

158,612 mi

TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. THE CONTACT STATED WHILE VEHICLE WAS IN A STAND STILL THE VEHICLE WAS LEAKING OIL ON THE MUFFLER SYSTEM AND STARTER. THE CONTACT ALSO STATED WHILE DRIVING 25 MPH, A BURNING ODOR WAS DETECTED COMING FROM THE MUFFLER AREA. THE CONTACT STATED THE CHECK ENGINE WARNING LIGHT WAS ILLUMINATED. THE CONTACT STATED A LOCAL DEALER WAS CONTACTED HOWEVER THE FAILURE HAD NOT BEEN DIAGNOSED OR REPAIRED. THE CONTACT STATED THAT HEAD GASKET WOULD NEED TO BE REPLACED. THE CONTACT STATED THAT THE FAILURE OCCURRED AT 75,000 MILES AND HE REPLACED THE HEAD GASKET. THE MANUFACTURER HAD BEEN INFORMED OF THE FAILURE AND REFERRED THE CONTACT TO NHTSA. THE FAILURE MILEAGE WAS APPROXIMATELY 210,000.

NHTSA ID

11330124

Incident

Jun 15, 2020

NHTSA ID #10017888/10018745/10023943/10004051/10010731/10012977/#10014086/10018069/10014100/10028736

NHTSA ID

11035567

Incident

May 31, 2017

CAN NOT DRIVE CAR POWER TRAIN AND ENGINE BLEW OUT DONT DRIVE DRIVE FAR ONLY IN MY CITY AND UP TO MAINTENCE AND ALL OF SUDDEN GIRLS STOP SHIFTING ONE DAY WHILE ON ROAD VERY SCARY HAD TO PULL OVER IN MIDDLKE OF INTERSECTION AFTER THT\AT DAY BOUGHT ANOTHER TRANSMISSION AND SAME THING HAPPENED DIDNT LAST MONTH SPENT SO MUCH MONEY ON TRANS THAT CANNOT AFFORD NEW AGIN

NHTSA ID

11035566

Incident

May 30, 2017

TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE RANDOMLY STALLED AT ANY RATE OF SPEED. THE VEHICLE WAS ABLE TO RESTART. TWO DEALERS (DOWNTOWN FORD, 1-866-899-7296) AND (FUTURE FORD OF SACRAMENTO, 916-547-2285) WERE UNABLE TO REPLICATE AND DIAGNOSE THE FAILURE. THE VEHICLE WAS NOT INCLUDED IN NHTSA ACTION NUMBER: DP5005 (ENGINE AND ENGINE COOLING). THERE WERE NINE TSBS FOR ENGINE AND ENGINE COOLING, TWO TSBS FOR THE FUEL SYSTEM, AND THIRTEEN TSBS FOR THE ELECTRICAL SYSTEM. NEITHER DEALER PROVIDED DIAGNOSTIC TESTING. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS NOT AVAILABLE.

NHTSA ID

11024879

Incident

Feb 1, 2012

TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 75 MPH, THE VEHICLE LOST POWER WITHOUT WARNING. THE VEHICLE WAS PULLED OVER TO THE SIDE OF THE ROAD AND TOWED TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE ENGINE DID NOT GET FUEL FROM THE FUEL PUMP. THE TECHNICIAN RECOMMENDED THAT THE FUSE PANEL BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND STATED THAT THERE WAS NO RECALL. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 169,900.

NHTSA ID

11003158

Incident

Jul 3, 2017

Mileage

169,900 mi

ALSO LIKE MANY OTHER COMPLAINTS I HAVE SEEN, THE 2004 FORD EXPEDITION I HAVE HAS SHUT OFF ON ME SEVERAL TIMES WHILE DRIVING AND I WAS TOLD TO SWITCH OUT THE ENTIRE FUSE BOX. I CALLED THE DEALER AND THEY SAID TO REPLACE IT, IT WOULD BE ABOUT $500 FOR IT. IT'S RIDICULOUS FORD HASN'T ISSUED A RECALL BECAUSE THIS SEEMS LIKE A PROBLEM MANY PEOPLE ARE HAVING AS WELL. WE HAVE ALMOST GOTTEN INTO A COUPLE OF ACCIDENTS BECAUSE OF THIS ISSUE! WE CAN'T KEEP HAVING TO RELY ON ONE LESS VEHICLE, BUT WHAT OTHER ALTERNATIVE DO WE HAVE IF IT'S GOING TO COST US, THE CONSUMER, A LOT OF MONEY TO REPLACE FOR SOMETHING THE MANUFACTURER SHOULD BE RESPONSIBLE FOR.

NHTSA ID

11000740

Incident

Jun 12, 2017

Mileage

82,000 mi

TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE STALLED WITHOUT WARNING AND WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE THE ISSUE COULD NOT BE DUPLICATED; HOWEVER, THE FAILURE RECURRED ON SEVERAL OCCASIONS. THE MANUFACTURER WAS NOTIFIED OF THE ISSUE. THE FAILURE MILEAGE WAS APPROXIMATELY 100,000.

NHTSA ID

10956151

Incident

Aug 5, 2016

Mileage

100,000 mi

SPARK PLUG BLEW OUT OF BLOCK: OUT OF NOWHERE, MY SPARK PLUG BLEW OUT OF THE BLOCK ON MY 2004 FORD EXPEDITION. MY CAR DROVE PERFECTLY FINE COMING HOME FROM WORK. I PARKED IT IN THE DRIVEWAY AND A SHORT TIME LATER WENT OUT, STARTED IT TO LEAVE AND IT POPPED AND HAD A LOW RUMBLING SOUND AND A BURNING SMELL. THREADS POSSIBLY STRIPPED.

NHTSA ID

10928687

Incident

Nov 29, 2016

Mileage

140,000 mi

WITHOUT WARNING AND WHILE DRIVING, ENGINE JUST QUITS, LOSS OF POWER STEERING, BRAKES AND TRAFFIC, VERY DANGEROUS. SECOND TIME....PROBLEM NOT FOUND.

NHTSA ID

10903182

Incident

Sep 1, 2016

Mileage

115,000 mi

WHILE DRIVING IN THE CITY ON LOCAL STREETS, THE ENGINE JUST STOPS WITH NO ABILITY TO DRIVE. I AM AN INSTANT SAFETY PROBLEM ON THE ROAD. THIS HAPPENED 3 TIMES IN ONE DAY. FORTUNATELY, NO ONE WAS INJURED. AFTER A FEW MINUTES, THE CAR STARTS UP AGAIN. MY MECHANIC CAN'T DUPLICATE THE PROBLEM. ANYONE HELP BEFORE THERE IS A MAJOR LIFE-THREATENING ACCIDENT!! THANKS!

NHTSA ID

10884825

Incident

Jul 14, 2016

Mileage

115,000 mi

OUR 2004 FORD EXPEDITION EDDIE BAUER SUDDENLY TURNS OFF WHILE WE ARE DRIVING AT ANY SPEED. IN A YEAR'S TIME, IT HAS TURNED OFF FOUR OR MORE TIMES. MOST OF THOSE TIMES, WE WERE TRAVELING AT SPEEDS OF ABOUT 60MPH. ALL OF THE POWER SHUTS OFF, STEERING AND BRAKES INCLUDED. WE TURN THE KEY OFF AND IT DOES RESTART. LUCKILY WE HAVE NOT BEEN IN ANY TERRIBLE ACCIDENTS!

NHTSA ID

10875319

Incident

Jan 15, 2015

Mileage

200,000 mi

TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 50 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE CONTACT STATED THE FAILURE OCCURRED SPORADICALLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 156,000.

NHTSA ID

10748782

Incident

Aug 14, 2012

Mileage

156,000 mi

TL*THE CONTACT OWNS A 2004 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, THE VEHICLE STALLED. THE FAILURE OCCURRED ON MULTIPLE OCCASIONS. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO DIAGNOSED THAT THE RELAY NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 198,000.

NHTSA ID

10682602

Incident

Sep 2, 2014

Mileage

198,000 mi

I HAVE A 2004 FORD EXPEDITION WHICH RANDOMLY SHUTS OFF WHILE DRIVING. THIS HAS BEEN HAPPENING WITH MORE FREQUENCY. I HAVE TAKEN THE VEHICLE TO TWO MECHANICS WHO TESTED AND ATTEMPTED TO DIAGNOSE HOWEVER THEY WERE NOT ABLE TO REPLICATE THE PROBLEM. UPON READING AND RESEARCHING ONLINE, THERE HAVE BEEN MULTIPLE POSTS ABOUT THIS BEING A COMMON PROBLEM WITH THE FORD EXPEDITION LINE. I CONTACTED FORD AND EXPLAINED OF THIS MAJOR SAFETY CONCERN AND THEY ONLY ADVISED THAT THE VEHICLE HAS NO RECALL AND THEY COLLECTED MY INFORMATION TO PROVIDE TO NHTSA. MY SON USES THIS VEHICLE FOR SCHOOL AND THE VEHICLE HAS A SAFETY CONCERN WHICH CAN NOT BE DIAGNOSED BY CERTIFIED MECHANICS AND FORD HAS TAKEN IS NOT TAKEN ANY RESPONSIBILITY OR ATTEMPTED TO RECTIFY. I HOPE SOMEONE DOES NOT HAVE TO DIE DUE TO THIS GROSS NEGLIGENCE, ESPECIALLY MY SON. *TR

NHTSA ID

10673113

Incident

Jan 12, 2015

Mileage

130,000 mi

WHILE DRIVING ON A 3 LANE HIGHWAY WHERE THE SPEED LIMIT IS 65, I BEGAN MY TRANSITION TO THE RIGHT LANE TO EXIT. WE WERE TRAVELING APPROXIMATELY 60MPH. AS I BEGAN TO CHANGE LANES THE VEHICLE NOTICEABLEY BEGAN TO ACCELERATE. AT FIRST I THOUGHT THE CRUISE CONTROL HAD BEEN ACTIVATED, BUT WHEN J ATTEMPTED TO STOP, THE CAR KEPT TRYING TO ACCELERATE. AS I ENTERED THE EXIT RAMP THE CAR DID NOT SLOW DOWN THE WAY IT SHOULD HAVE AND THE BRAKES DID NOT FEEL SURE. AS I WAS ABLE TO COME TO A SAFE ROLL, I PLACED THE CAR I TO NEUTRAL AT WHICH TIME THE CAR ACCELERATED VIOLENTLY. I FELT FOR THE GAS PEDAL WHICH SEEMED TO TO DEPRESSED AS IF THE CRUISE CONTROL WAS ON. HOWEVER, I WAS STOPPED. THE ENGINE DID FINALLY SLOW TO WITHIN NORMAL RPM. I WAS SOMEWHAT CONVINCED THAT SOMETHING MAY HAVE BEEN STUCK, BUT SOON REALIZED THAT THE GAS PEDAL IS HINGED FROM ABOVE AND NOT INTO THE FLOOR, NOR WAS THERE ANYTHING ON THE FLOOR. *TR

NHTSA ID

10663743

Incident

Dec 11, 2014

Mileage

164,000 mi

I WAS PULLING OFF FROM A STOP SIGN AND BEFORE I GOT ACROSS THE INTERSECTION MY CAR MAKE A POP AND THEN THE ENGINE SOUNDED LIKE IT BLEW. I PULLED OVER AND A SPARK PLUG POPPED OUT OF THE HEAD CAUSING A SMALL FIRE THAT MELTED HOSES. ESTIMATED DAMAGE IS A MINIMUM OF 1500 FOR JUST THIS PLUG BUT I WAS TOLD THE OTHERS WOULD FOLLOW SUIT. READING ON THE INTERNET THIS SEEMS TO BE A SERIOUS ISSUE WITH THE FORD 5.4 TRITON MOTORS. IF I WAS NOT ABLE TO STAY CALM AND STEER MY VEHICLE CORRECTLY THIS COULD HAVE RESULTED IN A SERIOUS ACCIDENT. THE VEHICLE LOST POWER AS IF IT HAD STALLED, AND AS I STATED BEFORE THERE WAS A SMALL FIRE WHEN I LIFTED THE HOOD TO SEE WHAT HAD HAPPENED. *TR

NHTSA ID

10627347

Incident

Aug 21, 2014

Mileage

158,420 mi

THE FIRST INCIDENT WITH MY FORD WHILE DRIVING AT ABOUT 25MPH THE SPARK PLUG WAS BLOWN OUT. IHAD THE SPARK PLUG ISSUE REPAIRED. MY SECOND ISSUE WITH MY FORD NOW IS THAT IT SHUTS OFF WHILE DRIVING AT SPEED. IT HAS HAPPEN 4 TIMES NOW. I HAVE READ SOME BLOGS THAT STATE IT MIGHT BE THE BAD PLACEMENT OF FUEL PUMP DRIVER MODULE OR FUEL PUMP RELAY. THIS MAY CAUSE A CRASH. PLEASE RESEARCH!!!! *TR

NHTSA ID

10617822

Incident

Jun 3, 2013

WHILE SLOWLY BRAKING TO A STOP BEHIND TRAFFIC STOPPED FOR A RED LIGHT, THE ENGINE SUDDENLY ACCELERATED WITH MY RIGHT FOOT STILL ON THE BRAKE PEDAL. I PRESSED HARDER ON THE BRAKE AND WHEN I REALIZED THE ENGINE WAS STILL REVVING (AT OVER 3,000 RPM), I PUT THE TRANSMISSION INTO NEUTRAL AND NOTICED THE ENGINE SPEED ERRATICALLY BOUNCING UP AND DOWN IN ROUGHLY THE 2500 TO 3500 RPM RANGE. I STILL HAD MY RIGHT FOOT FIRMLY PRESSED ON THE BRAKE PEDAL. I FINALLY SHUT THE IGNITION OFF AND PUT THE TRANSMISSION INTO PARK. I WAITED A A FEW SECONDS AND RESTARTED THE ENGINE. THIS ENTIRE TIME I NEVER LIFTED MY RIGHT FOOT OFF THE BRAKE PEDAL. THE ENGINE STARTED AND IDLED AT A NORMAL 600 RPM OR SO. I CAREFULLY PUT IT INTO DRIVE SO I COULD GET OUT OF TRAFFIC. AT EACH SUBSEQUENT STOP, I WOULD PUT THE TRANSMISSION INTO NEUTRAL JUST IN CASE OF ANOTHER INCIDENT. I PROMPTLY DROVE STRAIGHT HOME WHICH FORTUNATELY WAS ONLY 2 MILES AWAY. I CHECKED THE FLOOR MAT TO SEE IF THE ACCELERATOR PEDAL COULD HAVE GOTTEN STUCK BUT THERE WAS PLENTY OF CLEARANCE. THE FLOOR MAT IS ANCHORED TO THE FLOOR SO DOESN'T MOVE. THIS IS THE FIRST TIME SOMETHING LIKE THIS HAS HAPPENED TO THIS OR ANY OTHER VEHICLE I'VE OWNED OR DRIVEN. *TR

NHTSA ID

10595433

Incident

Jun 1, 2014

Mileage

72,061 mi

TL* THE CONTACT OWNED A 2004 FORD EXPEDITION. THE CONTACT STATED THAT HER VEHICLE WAS PARKED AND SMOKE EMITTED FROM UNDER THE HOOD. THE VEHICLE THEN BECAME ENGULFED IN FLAMES. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE AND CURRENT MILEAGES WERE UNKNOWN.

NHTSA ID

10584646

Incident

Apr 18, 2014

TL* THE CONTACT OWNS A 2004 FORD EXPEDITION. THE CONTACT WAS DRIVING 80 MPH WHEN THE CHECK SERVICE WARNING LAMP ILLUMINATED. THE VEHICLE THEN STALLED. THE VEHICLE WAS SAFELY MERGED FROM THE HIGHWAY AND RESTARTED. THE FAILURE BECAME A CONSTANT RECURRENCE AND THE VEHICLE WAS TOWED BECAUSE IT COULD NOT BE RESTARTED. THE VEHICLE WAS NOT TAKEN FOR DIAGNOSIS OR REPAIRS. THE MANUFACTURER WAS NOTIFIED OF THE INCIDENT. THE APPROXIMATE VEHICLE FAILURE MILEAGE WAS 189000.

NHTSA ID

10536715

Incident

Aug 17, 2013

Mileage

189,000 mi