Electrical fire today. Vehicle was parked outside garage. A clicking noise was heard and noticed the mirror was trying to move/click and car was filled with smoke. Mirror switches didn't work when tried. Knocked mirror off and fire stopped. Wiring Harness around the emergency brake area melted. Fire melted a hole in the dash corner by windshield. Vehicle was last driven about 25 hrs. earlier with no issues. Approx. 128K miles. Glad it wasn't in garage and the clicking was heard or garage/house would have burned. We haven't done anything to it yet.

- Palmer, AK, USA

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.

- Denton, TX, USA

The gas gauge never works and sometimes the vehicle thinks that it doesnt have gas when it does.

- Lakewood, CO, USA

While driving a 2004 Ford Expedition 178,000 kept stalling on the highway and streets. I had it towed several times because it won't start back on the next day it would turn on. Had the fuel pump replaced and still having the same problems it turn off on my 18 year old son like 5 times going to school and work where it almost got to the point where we felt it wasn't a reliable due the fact it stalls while on the road or even just turning and almost caused my sons life. Finally we found out it's the relay gets hot and it causes for the car to stop and I'm aware that Ford knows about this very frustrating and disappointing they have not done a recall on this the relay can not be change by its self has to be the whole circuit board

- Mesquite, TX, USA

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.

- Pinegrove, CA, USA

When driving home from seattle wa. To walla walla wa. At a speed of 70 mph the vehicle died and I had to get off the road, it then restarted and did it to me 3 more times. When I took it to the shop the mechanic stated that it was in the fuse box. He had just did a replacement on the same type vehicle that had caught fire. It is the fuel relay in the fuse box that malfunctions and catches fire. I feel this is a safety issue.

- Walla Walla, WA, USA

My vehicle, without any warning at any speed, including highway speeds, shuts off completely, without any warning or indication that it is about to do this. Always on a straight road with almost a full tank of gas. The cause a relay switch which is soldiered into the memory board that controls the vehicle's brain box that shorts out. After doing research on the internet, I am both shocked and disgusted that the nhsta has not investigated this faulty design by Ford and made them recall all of the 2003- 2008 Expedition. You only have to pull it up on you-tube or google to see the 1000's upon 1000S of complaints from Expedition owners concerning this constant and dangerous problem, which clearly endangers every Expedition owner and their family. The worst part of this, the Ford dealerships want you to spend $1000 of dollars needlessly to try and diagnose this same, old problem, before they finally deal with replacing the entire fuse block panel, just for the relay switch, which is the cause, the shorting out relay switch. The internet shows again and again, that this problem is so rampant, that it isn't if it happens, but when, because it was a faulty and defective design, which endangers all Expedition owners made these years. The faulty fuse block's fuel pump relay switch burns out and between that and the thin wires grounding out under the hood, drivers, unsuspectingly are left in panic modes on the highway, scrambling to get out of harms way, as a result of your vehicle turning off at all speeds, ie, 70 mph. Imagine a semi is behind you and you don't have the safe means of escaping the dangerous predicament you are now left in to get over to the side of the road? a recall is needed asap before too many people are needlessly killed as a result. Expedition's are family vehicle's and usually have lots of children in them! this is too dangerous to keep overlooking.

- Boiling Springs, SC, USA

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.

- Las Vegas, NV, USA

The contact owns a 2004 Ford Expedition. While driving 35 mph, the side air bags deployed without warning. The battery, engine, and low oil indicators illuminated after the air bag deployment. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The passenger sustained neck injuries while seated in a child safety seat located in the rear of the vehicle. Medical attention was not required. A police report was filed under complaint number: 170606882. The manufacturer was notified of the failure, but did not offer any assistance. The failure mileage was 149,904.

- Midland, TX, USA

The contact owns a 2004 Ford Expedition. While driving at various speeds, the vehicle stalled without warning. The vehicle was restarted and taken to a dealer and an independent mechanic; however, the cause of the failure was unable to be determined. The contact mentioned that the alternator, battery, transmission, fuel pump, and fuel bypass switch were replaced; however, the failure recurred. The manufacturer was notified of the failure. The failure mileage was 126,000.

- Valley Grove, WV, USA

This has occurred a three times in last month...first being in July. I park my vehicle, turn ignition off and pull out key and the air conditioner is still blowing and radio is still going for a couple seconds after key is pulled out...only a couple seconds and immediately shuts itself off. This is definitely an electrical or ignition issue.I do know radio will stay on until door opened, thats a feature of the vehicle, but this is different, air stays blowing"? not sure if this is related to above issue but also having an problem with electrical(") under the hood, at times the vehicle while sitting at a light or drive thru tries to die so much so that you can see the instrument panel lights trying to go out as the car attempts to die. I have put a brand new battery in a couple months ago but its not that, its a weird issue like while holding brake down, it just attempts to die and this is only at times, not every time. When on gas, never an issue at all. Car runs great but seems to have an electrical problem somewhere.

- Weatherford, TX, USA

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.

- Delano, MN, USA

I am the 2nd owner of this vehicle. Had problem w/ drivers seat & mirror fuse blowing out since I purchased truck in August 2011. Some time in 2012 I started having additional problems w/ my truck like radio &/or heating/air not coming on when started. Check engine light going on & off & back windshield wiper stopped working. Then it was the vehicle was dying quickly by leaving the radio on for 10 min after vehicle was turned off. We replaced the battery & terminals that connect at the positive & negative. We had plenty of other issues like the entire brake lines needing replacing due to rusting. There is now rusting on other parts of the truck. Blew fuse to air conditioner 2X. Things seem to be ok after battery was replaced until the truck shut off several times while driving it over the past year. Sometimes if you waited 5-10 minutes it would restart. Vehicle has been in shop & nothing comes back on diagnostic test. We have had the alternator & fuel pump tested. The cables to the battery were just found rotted & replaced but something is still killing my battery. The fuse box has been making loud click noises when the truck struggles to start. Today it wouldn't start again until jumped & now the radio wouldn't go on. At the shop again & the mechanic is stumped but working on it! from research it seems to be either a fuel pump relay that is apparently sodder into the fuse box & almost impossible to replace w/ replacing the whole box or it is the fuse box itself. I am also seeing claims of water leaking down windshield & getting into fuse box. All I know is Ford should acknowledge & recall before someone gets killed! my children were in the car several times now when it staled while I was driving or stuck in parking lot & even a severe thunderstorm when it won't start. And now I'm reading the fuse box has caught fire in some of these cars! I rely on this vehicle!

- Atco, NJ, USA

The contact owns a 2004 Ford Expedition. The contact stated that while driving approximately 30 mph, the vehicle stalled without warning. The vehicle was able to restart, but the failure occurred on numerous occasions. The vehicle was taken to a dealer where it was diagnosed that the wiring harness and the ECU needed to be replaced. The vehicle was repaired however, the failure persisted. The manufacturer was not made aware of the failure. The approximate failure mileage was 105,000.

- St Petersburg, FL, USA

Battery drains, took fuse to radio out and fixed the problem for a while but then the locks started to act on there own no way to fix dealers keep saying they never heard of the problem or they want to try things but all they end up dong is costing me more money. But I have found hundreds of people on the internet with the same problems.

- Council Bluffs, IA, USA

We have had a down pour not long ago on Saturday. The next day after using the Expedition once when it was turned off the power locks repeatedly lock and unlock (we had to take the fuse out to get it to stop). There is a clicking noise in the fuse box/on the passenger side where the fuse box is located. When the locks function on their own with every click the dash lights faintly flicker. With the power locks fuse removed the dash lights still flicker making the gauges jump with every flicker. It eventually stops. I've read on many forums of these similar problems. But Ford seems to turn the other way with these reported problems. I've called Ford already and there is no recalls. On the forums with these similar and same issues it says it was diagnosed as a leak into the fuse box by bad manufacturing windshield sealant. Some vehicles seem to function on their own even at night and there had been some that burst into flames and the loss of the vehicle was the result. This is the manufacturer's responsibility due to faulty put together and product causing electrical problems when water drips down into the fuse box. Please help us! we cannot afford the $1000's of dollars for this particular repair that is an ongoing issue for many other Ford Expedition and Ford F-150 and Ford Taurus vehicles!!!

- Fort Stewart, GA, USA

After owning the vehicle for about 3 months the battery went dead, I put a new battery in it and it worked fine for about 2 weeks then it was dead again. I hooked it to a diagnostic machine and no codes. I then replaced the alternator and now there is a code but since the 1st incident I had to disconnect the battery every time I turn the engine off or after 4 to 8 hours the battery is dead again. I haven't had the codes check yet but I will soon.

- Council Bluffs, IA, USA

The contact owns a 2004 Ford Expedition. The contact stated that while the air conditioning system was activated, an abnormal noise was heard from the rear passenger's side. The vehicle was taken to the dealer, who replaced the air conditioning compressor however, the failure was not corrected. The manufacturer was made aware of the failure. The approximate failure mileage was 25,000 and the current mileage was 89,000.

- Anaheim, CA, USA

The contact owns a 2004 Ford Expedition. The contact stated that after turning the vehicle on and shifting into drive, numerous electrical systems failed. The radio powered off and on independently, the windshield wipers seized, the air conditioning system would not power off, and the windshield wiper and 4X4 lights on the instrument panel illuminated. The vehicle was taken to the dealer for diagnosis but they were unable to duplicate the problem. The manufacturer was not notified. The approximate failure mileage was 149,000.

- Pennsauken, NJ, USA

Was driving down the road and my Expedition just shut down. All power off and steering wheel locked up. Was stuck in middle of the road. Had it towed to Ford dealership who replaced the main fuse. It happened again 6 months later. Once again had to have it towed. Once again main fuse blew and my SUV lost all power. Ford dealership gave us extra fuses. Since then it has happened twice, once about a month ago and we replaced the main fuse. The last time which was Thursday, January 17th, my teenage son was driving and he ran off the road into a ditch. Wheel rim bent but he thankfully was just shook up and not injured.this time it was not the fuse but the SUV just lost power and steering locked and he went off the road. Missed a tree by a few feet. When this first began to happen I called Ford and wrote them multiple letters. They were polite, but stated is was not their problem since car had 120,000 miles on it.

- Seneca, SC, USA