Spark plugs blow out of cylinder head at highway speed.

- Bonita Springs, FL, USA

My Ford Expedition is equipped with a 5.4L Triton engine and like many other engines of the same family, it blew a spark plug out of the head while driving down the interstate. This allowed fuel to escape and almost created a fire under the hood. Luckily, I was able to contain it without any damage. However, I am mechanically savvy, so others may not know what to do in such an event. However, the reason is because the spark plug came out of the engine without assistance and being that I have never installed spark plugs in it, the failure was not due to my negligence. Being that this has happened to many other people and the nature of it being potentially fatal, I do not understand why this has not been addressed and considered for a recall to remedy this issue.

- Christiansburg, VA, USA

Spark plug ejection! I just experienced a problem with my Ford Triton motor where the spark plug will eject from the aluminum cylinder head. I have a 2003 Ford Expedition that experienced this on Saturday. I was driving home from wal-mart with my family in the truck, we turned a corner and my heart stopped! it sounded like I was involved in machine gun fire. I pulled over immediately and my looked. Couldn't initially see anything. My husband checked under the truck thinking it was exhaust related. We were luckily 2 blocks from home, so we were able to get it home and into the driveway. My husband began trying to diagnose the problem and I took to the internet. He took the engine cover off and discovered the spark plug missing and the coil wire broken off and sparking. Long story short it seems that we have experienced the situation where the cylinder head has stripped on the one spark plug. We have begun looking into ways to fix the situation, but it seems Ford has not deemed this to be an issue. Truly don't understand how so many people can report the exact same happenings and no one will do anything about it..... merry stinkin christmas!!! we are reaching out to our local Ford dealer but am pretty sure they are going to tell us we are crap out of luck and will fall on us to repair if we choose.

- Dover, DE, USA

The contact owns a 2003 Ford Expedition. While driving at an unknown speed, the vehicle stalled without warning. The vehicle was able to be restarted; however, the failure recurred several times. After inspecting the vehicle, the contact noticed that one of the fuse relays was melting into the fuse box. As a result, the fuse box and the power control module relay needed to be replaced. The manufacturer was not made aware of the failure. The VIN and failure mileage were unknown.

- Seguin, TX, USA

We were driving with the kids headed home, going about 45mph and loud noise and smell of fuel, we pull over lifted the hood and saw my coil pack busted off, we drove the rest way home to ark it, and looked again. The spark plug arched inside the head and busted the coil pack bolt and all. Shame that we tried an insert to repair it and doesnt work. I have been stressing this considering im a single mom of two that have disabilities and we have these appointments left and right and its hard walking across town all the time. This problem needs fixed by Ford. I researched and its a known problem cause the cheap aluminum heads. We really need our vehicle...

- Chambersburg, PA, USA

The contact owns a 2003 Ford Expedition. While driving at 60 mph, the engine stalled without warning. The vehicle failed to restart. The vehicle was towed to the contact's residence where an independent mechanic diagnosed that the fuse box failed and needed to be repaired. The vehicle was repaired, but the failure recurred. The manufacturer was not made aware of the failure. The failure mileage was 130,000.

- Lockeford, CA, USA

I was driving at 45mph and a spark plug blew out on my 2003 Ford Expedition XLT with the 5.4L V8.

- Lanesville, IN, USA

Transmission slipping @ 30-50 mph.

- Louisville, KY, USA

The contact owns a 2003 Ford Expedition. The contact stated that while driving approximately 60 mph, the vehicle stalled without warning. The contact was able to restart the vehicle after waiting for several minutes. The dealer was unable to diagnose the failure. The manufacturer was notified of the failure. The VIN was unavailable. The approximate failure mileage was 200,000.

- Santa Clara , CA, USA

My 03 Ford Expedition started cutting off every time U put it N drive unless U keep the gas pushed a little this is happening every time U put it in gear.

- Easley, SC, USA

I was traveling at 70 mph on the interstate. The car popped, sputtered and died. Has steadily gotten more and more frequent. Engine dies at idle, dies at slow speeds as well as faster speeds. Very dangerous! have replaced the PCM, wiring harness, and fuel pump. Is not repaired. Power mirrors readjust themselves when the keyless entry is used. Several warning lights stay on, door ajar, check fuel cap, advatrac will not turn on. Rear window will not work. Back up sensor will not work. Interior lights as well as exterior lighting will not power off when car is turned off. You must manually turn them off or the battery drains.cd player will not eject cd's loud popping sound in the front end and grinding sound when stopping. I have had this in the shop since June of 2014 and they cannot find the problem. Have already spent $1000 trying to repair. This vehicle is dangerous and can very likely cause an accident. It is not safe to drive. Ford auto shop wants to charge me $100 an hour to diagnose the problem then they are not sure if they can find the problem, they are telling me it could cost between $500-$1000 just to find the problem. I have checked several web sites and see that there are many, many people with the same problems with the same type of vehicle. This should be looked into before someone is injured or killed in an accident caused from the car stalling!!!

- Lowell, AR, USA

After accelerating from a stop, a loud bang was heard. What had happened? a spark plug blew out of the aluminum head, taking the threads with it. I was not aware that fuel would continue to blow out of the spark plug hole which could have been ignited by the ignition coil or exhaust manifold. Ford is aware of this issue, but has not recalled the defective aluminum heads, but rather offered a repair kit to fix the stripped threads when this issue occurs. This could have been a very different ending if the fuel would have ignited.

- Ephrata, PA, USA

The contact owns a 2003 Ford Expedition. The contact stated while driving approximately 65 mph the vehicle suddenly stalled. The contact indicated that after restarting the vehicle it began to function normally however, the failure recurred. The vehicle was taken to the dealer who was unable to diagnose the failure. The manufacturer was not notified of the failure. The failure mileage was 132,000.

- Lithonia, GA, USA

Driving down state highway when the battery gauge went to "L" and the ABS light came on. The engine was still running. Pulled into apartment complex parking lot and the engine shut off. All lights and bells were still working. Aaa was called and performed a diagnostic and determined the starter was going bad. The starter is less than 2 years old as is the battery. Was told it was safe to drive home. Took vehicle to local repair shop where another diagnostic test was performed and was told it was not the starter nor the battery and another diagnostic should be performed to determine cause. Engine has not shut off while driving since but am apprehensive to drive very far from home. Will wait for 3rd diagnostic test.

- Jacksonville, FL, USA

The contact owns a 2003 Ford Expedition. The contact stated while driving various speeds the engine stalled without any warning. The contact was able to restart the vehicle each time however, the failure recurred intermittently. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure and informed the contact that there were no recalls for the vehicle. The approximate failure mileage was 154,000. Updated 02/27/14 updated 02/27/14

- Manassas, VA, USA

Was driving the 2003 Expedition on interstate 10 near pensacola, when the vehicle shut off. The car coasted to a stop, luckily I did not cause a wreck and my family and I was safe. It has happened several times, at least 10 so far. We have replaced the fuel pump, fuel pump relay switch, the fuel filter, had the injectors inspected and it still does it. I did some research into the problem and it turns out the right side front passenger window leaks down onto the interior fuse panel and is causing the electrical system to short out. In all cases once the vehicle cools down, the car starts right back up again. I have taken it to 4 garages and now I have it at the Ford dealership in pensacola. Where they are looking at it. It turns out that the P0231 code keeps re-appearing in the system (fuel pump relay circuitry) which shows the problem could be the fuse panel since the fuses are soldered to the board and not plugged in. Hopefully Ford recognizes this problem and will order a recall soon.

- Pensacola, FL, USA

We moved it around in our shed at about 10pm on 6/16/12 and we awoke at 4 am to our shop, machine shed, and chicken coop engulfed in flames. We lost over $100,000 in property. The fire marshall determined that our Ford Expedition was to blame and that it started under the hood, somewhere in the electrical. We only had liability only on 2 of the 3 vehicles in the shop along with our motorcycle and trailer so they were not covered by insurance. I think Ford should of compensated us for the items we did not get paid for. They should do a recall on this vehicle, and compensate the people that had fires with this vehicle.

- Grove City , MN, USA

The contact owns a 2003 Ford Expedition. The contact stated that the vehicle stalled without warning. The contact took the vehicle to the dealer where the fuses and the computer were replaced. The contact stated that the failure recurred one week later. The vehicle was not further repaired. The failure mileage was 180,000.

- Donalsonville, GA, USA

I was traveling home to philadelphia from charlotte. As I got closer to my house suddenly there was loud pop and a sound as if something was popping in the engine. I parked the truck on the corner of my block afraid to drive it any further. I looked under the hood and I saw a spark plug sitting on top of my battery. After looking this problem up on the net I found out that Ford has had this problem consistently with the Triton engines. No recalls have been issued and to me Ford needs to own up to this issue..

- Philadelphia , PA, USA

Was driving on with family at posted 70 mph speed. Car lost all power with no warning light or error codes. I had no power steering or power brakes. I managed to pull steering wheel to get off hwy. I turned key off. The car started right back up with no problem. Drove another 2 miles with same results. It was night and out of town. The car started right back up with still no error codes. Drove home with no problems. Took in to mechanic next day with no help. Was told to bring in when service engine light comes on. They can't fix with no idea why and still no error codes. Left there drove towards home died again on way home in town. No error codes.

- Azle, TX, USA