NHTSA lists 296 complaints for the 2004 Ford Expedition, 48 of them mention a crash and 15 mention a fire. 35 complaints mention an injury, with 58 injuries and 1 deaths reported.
Data build 2026-10-08.
NHTSA lists this vehicle as FORD EXPEDITION.
Model-generated complaint tags: This model year has not been tagged.
Investigations
2 investigations; 0 open.
PE08070
Opened: 2008-12-09. Closed: 2009-04-15.
STEEL WHEEL FRACTURE
FORD SPECIAL SERVICE VEHICLE (SSV) EXPEDITIONS USE A STEEL FULL FACE WHEEL DESIGN SIMILAR TO THAT INVESTIGATED IN PE03009, RQ04007, EA04034 (CROWN VICTORIA POLICE INTERCEPTOR) AND PE03026 (GM PICKUPS AND SUVS).A TOTAL OF 8,251 SSVS (2.2% OF TOTAL PRODUCTION) WERE PRODUCED WITHIN MODEL YEARS 2004-2006 AND SOLD PRIMARILY FOR USE BY STATE, FEDERAL, AND MUNICIPAL LAW ENFORCEMENT (LE) AGENCIES.FORD STI
Systems: WHEELS.
Linked campaign numbers: None listed.
DP05005
Opened: 2005-09-22. Closed: 2006-01-04.
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 COMPLAINTS ON THE SUBJECT VEHICLES WHERE THE COMPLAINANT, OR THE DEALER REPAIRING THE VEHICLE, REPORTED THAT A SPARK PLUG DETACHED FROM THE CY
Systems: ENGINE AND ENGINE COOLING.
Linked campaign numbers: None listed.
Manufacturer communications
91 manufacturer communications.
Communications by system| System | Count |
|---|
| POWER TRAIN | 19 |
|---|
| ELECTRICAL SYSTEM | 14 |
|---|
| ENGINE AND ENGINE COOLING | 10 |
|---|
| EQUIPMENT | 7 |
|---|
| VISIBILITY | 7 |
|---|
| STRUCTURE | 6 |
|---|
| SUSPENSION | 6 |
|---|
| SERVICE BRAKES, HYDRAULIC | 5 |
|---|
11005305
Date: 2024-07-24. Type: Service Bulletin/Repair Instructions. Systems: WHEELS.
This article supersedes TSB 22-2219 to update the Parts List and Service Procedure to clarify applicable steps by vehicle application. 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 a
10235153
Date: 2023-04-04. Type: Service Bulletin/Repair Instructions. Systems: 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. Most modules on these affe
10214754
Date: 2022-06-21. Type: Service Bulletin/Repair Instructions. Systems: 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). To correct this condition, follow the Service Procedure
10181917
Date: 2020-10-16. Type: Service Bulletin/Repair Instructions. Systems: ELECTRICAL SYSTEM, EQUIPMENT, WHEELS.
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). To correct this condition, follow the Service Procedur
10177863
Date: 2020-07-13. Type: Service Bulletin/Repair Instructions. Systems: 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. Panel replacement is
10155551
Date: 2019-02-07. Type: Service Bulletin/Repair Instructions. Systems: 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. Follow the Service Procedure steps to correct the condition
10156863
Date: 2019-02-07. Type: Service Bulletin/Repair Instructions. Systems: EQUIPMENT, 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. Follow the Service Procedure steps to correct the condition
10109070
Date: 2016-09-21. Type: Service Bulletin/Repair Instructions. Systems: ENGINE, ENGINE AND ENGINE COOLING.
The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate when reading these PIDs and cannot display quickly enough to
10028736
Date: 2009-05-01. Type: Service Bulletin/Repair Instructions. Systems: 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
10023943
Date: 2007-10-01. Type: Service Bulletin/Repair Instructions. Systems: 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