I was driving on a busy road with my three children during rush hour. I heard a loud pop followed by the what sounded like machine gun fire. I immediately pulled over to the side of the road and shut down the vehicle. I was fearful of the safety of my children and had them leave the car. I then had the vehicle towed. A Ford repairman looked at the car and stated that the #3 passenger side spark plug blew out. He stated that this a known problem and Ford refuses to acknowledge the issue. He said that they see many of these each week and that it is usually the #3 spark plug on the passenger side. He stated that it would be $2500-$5000 to repair the vehicle. We were told by another Ford dealer that he could fix it for $300-$500. We had the vehicle towed there and despite informing him which spark plug it was, upon inspecting the vehicle he claimed it would be difficult to repair and increased the repair price to $2100. When we objected he offered to purchase the vehicle for $200-$300. We feel as if the Ford dealers are using this issue to run a bate and switch. We have investigated the matter on the internet and have found many others complaining of the same issue and Ford's failure to take responsibility. Someone is going to get injured if they fail to correct their design defect.

- Pleasanton, CA, USA

Loud pop then loss of vehicle power, continual popping sounds until I stopped engine. Spark plug was ejected from engine. I believe this investigation should be reopened as this should be a defect recall.

- Westville, NJ, USA

1999 Ford Expedition, 88K miles, spark plug ejected from passenger side of engine. This occurred in heavy traffic while in left lane of smoketown road in prince william county, Virginia. The vehicle stalled after I let off the gas pedal right after a loud bang and popping sound was heard in engine. I was able to restart vehicle, but had to keep the RPM's up to keep from stalling. After cutting off several cars in center and right lane, the vehicle was pulled into a parking lot on right side of road. I detected a strong smell of gasoline present when hood was raised. Not once did the "check engine" light come on; unlike all the other times it came on when nothing was wrong with the truck. The vehicle was towed to a Ford dealer and a $3400 head replacement performed because head was ruined by stripped spark plug ejecting. Upon checking internet, I found that this is an ongoing increasing problem. It appears that an inquiry done by your Agency concluded in January of 2006 that this is a rarely occurring incident of little to no danger. I beg to differ. A simple google query will show thousands if not tens of thousands of complaints regarding Ford Triton engine spark plug problems posted on various message boards. It is a matter of time before someone gets hurt or killed either directly or indirectly from this obvious problem. I'm just glad I was alone driving and not my wife and children. My wife would have remained in the stalled vehicle while sitting in the passing lane. Considering the enormous number of potentially affected vehicle this issue involves, I will also be bringing this matter to the attention of every elected official I can send an email to.

- Manassas, VA, USA

On August 2, 2006, while traveling in Michigan, a spark plug suddenly blew out of my 1999 Ford Expedition. There was no prior warning or indication of any problem. I had to have it towed to bay city, mi, where a Ford dealer told me that it would cost approx. $3500 to repair the problem. He said it was a recurring problem with Ford Expedition. My car had approximately 120000 miles on it at the time. I kept the spark plug and coil attachment, and it doesn't look like the grooves on the plug gave way or were stripped.

- Worthington, OH, USA

: the contact stated the check engine light illuminated. The vehicle was taken to an independent repair shop where they determined the oxygen sensor needed to be replaced. Although repair was made, the check engine light illuminated a second time. The vehicle was taken to the dealership this time where they determined the oxygen sensor needed to be replaced therefore causing a need to replace the engine.

- Hazel Park, MI, USA

Driving at 25 mph in residential area of cleveland oh spark plug #3 blew out of head, leaving me stranded for 2 days waiting to get repairs finished. 5.4 Triton engine, properly maintained with 59,000. Miles on it.

- Hendersonville, TN, USA

Spark plug blowing from cylinder head.

- Manassas, VA, USA

In Feb of 2005 my 1999 Ford Expedition with the 5.4 V-8 blew the passenger side 3rd spark plug right out of the head. The car had apox. 95,000 miles on it and Ford said warranty would not cover it. It would take 3,500 $ to fix. So I towed it away from grass vallley Ford, a decided to have a mecanic fup a heli coil. That lasted little over a year and in June of 2006 the same plug shot out. I think this is Ford problem and needs to be dealed with.

- Chicago Park, CA, USA

While driving a loud "pop" was heard followed by an exhaust-type sound emanating from engine compartment. Vehicle was driven 4 blocks to our home where inspection revealed the blown plug.

- Litchfield, MN, USA

For the second time in 6 months I had an engine spark plug ejection in my 1999 Expedition. The spark plug detached from the cylinder and was ejected from the engine. I heard a loud pop while driving, the vehicle followed by a loud, repetitive clicking or popping sound. I also lost some power while driving, the vehicle did not stall. I did smell gas when the incident occurred. I was able to slowly drive the vehicle to the repair shop.

- Sun Prairie, WI, USA

Approximately at 8 am, my wife was driving to work when she heard a loud bang under the hood of the car. She was driving a 1999 Ford Expedition. The engine started making a very loud popping noise. After arriving and starting the car to hear what was going on, I knew what the problem was. 5 years ago I drove a 1999 F250 Ford with a V10 and it did the same thing. The local dealership agreed a spark plug had blown out of the engine on the Expedition on the #3 cylinder. They repaired it by putting a plug insert (heli-coil) in. They put the insert in while the head was still on the vehicle. Now three weeks later the rods on #3 and #7 pistons are bent and the vehicle is inoperable. The dealership only option to us was to replace the engine at a cost of nearly $4,500.

- Osage Beach, MO, USA

I am a school teacher that drives a 1999 Expedition V8. I was on my way to school two weeks ago and heard a loud bang come from under my hood. It then started to sound like a john deer tractor. I had my spark plugs replaced last year and thought that it would be the same again. I took it to the same mechanic that replaced spark plugs last year and told me that the plug blew my thread out and that it might need some serious engine repairs because of it. He also told me that this is a common problem with these Ford vehicles. Apparently it is going to cost me 3,000 to fix. I am a teacher and find it ridiculous to have to pay for this when there has been so many complaints over the same engineering problem! Ford needs to do something about this. After seeing so many complaints online, it really makes me upset and feel emotional stress. The need to recall these aluminum engines.

- San Marcos, TX, USA

I had just left a stop light when I heard a loud pop. It sounded like something blew up! the car was really loud and ran rough after that. I had it towed to the shop. They said we blew a spark plug and stripped the threads that hold it in place. At a cost of $1,600 to repair we are having a friend look at it. He thinks he might be able to order a kit called timesert to possibly fix it. I hope it works because it will save us a great deal of money. After investigating the problem online, it definitely is a big problem for Ford. They must issue a recall immediately.

- Fort Wayne, IN, USA

Head gasket is leaking.

- Minneapolis, MN, USA

Leaking right head gasket due to faulty manufacturing. Oil leak is dripping on the muffler potential fire hazard and pollution.

- Forestdale, MA, USA

My 99 Ford Expedition's spark plug ejected from the head. This has caused emotional distress, not being able to get to and from work and other places. I had it repaired for a price of $300 dollars. This was ridiculous, Ford should pay all expenses. Then I was driving today and another plug blew. My truck is sitting on the side of the road right now. This is terrible!

- Clifton, VA, USA

: the contact stated while driving there was a loud bang in the engine. The vehicle immediately lost power and was uncontrollable. The contact pulled the vehicle to the side of the road. It was towed to an independent repair shop and the spark plugs were replaced. One month later another spark plug blew out of the engine. The vehicle was taken again to an independent repair shop were the spark plugs were replaced.

- Massapequa, NY, USA

Pulling out from a stop sign in neighborhood when suddenly smoke smell and loud rhythmic banging from under hood. I immediately pulled over and had the vehicle towed to shop. They discovered a spark plug had blown through the head, requiring a head replacement. Subsequently I discovered this is a problem with Ford vehicles with the Triton engine-design defect in that their are only 5-6 threads holding spark plugs in leaving them susceptible to this type of failure during normal operation. Ford would not assist me with repairs stating there was no recall dealing with this issue.

- Houston, TX, USA

1999 Ford Expedition - blow spark plug out of number 3 cylinder. Result is loss of power and very poor drivability at low speeds. Also, gas smell from leading injector in now open cylinder. Fortunately I was not towing when the plug blew, or the loss of power could have resulted in an unsafe situation. Ford dealer recommends replacing the cyl. Head ($3,000), doesn't acknowledge any defect that Ford has authorized. Several other mechanics indicate this is a common problem on this engine, deals with insufficient number of threads to hold the plug in the aluminum head.

- Lakeville, MN, USA

Driving down the interstate highway heard a loud pop, then a continious huffing sound from the engine compartment accompanied by a severe vibration. Pulled vehicle into the nearest rest stop and checked engine, found the second spark plug on the right bank (passenger side) had forceabily ejected taking the threads with it. The engine is a Triton 5.4L. The engine was repaired at a dealer (Ford country in henderson nv) by replacement of the head.

- Manhattan, KS, USA