1997 Ford Expedition Problems

What owners report

Owners of this model year most often describe spark plugs ejecting from the cylinder head of the 5.4L engine, brake lines rusting through until the pedal goes to the floor, and fires traced to the cruise control switch on vehicles parked with the engine off. Many reports arrive well past 100,000 miles on an aging vehicle, so corrosion-related failures and component wear are recurring themes rather than early-life defects.

1. 1
   Engine cooling

   Spark plug blows out of cylinder head

   Mentioned in 13 of 60 sampled complaints

   Owners describe a loud pop from the engine bay, often at start-up or while driving, followed by a misfire, rough running and loss of power; several report the plug, coil or boot came out and the threads in the head were stripped. Many had the truck towed, and some were told by the dealer the head needed replacement. A few report the same failure repeating across different cylinders, or shops declining to change plugs because of the risk of pulling threads. Reported from roughly 64,000 to over 250,000 miles, most commonly above 100,000 and often with the 5.4L V8.

   3 related service bulletins

   What to check: Ask whether the plugs have been serviced and whether any repair insert or head work was done; listen for a ticking or popping sound at start-up and check for a loose coil or oily residue around the plug wells.

   2 excerpts from owner complaints in NHTSA records

   “My 1997 Ford Expedition xlt beige in color since I have own this vehicle I have had to replace five (5) spark plugs and coil for they have blown out of the cylinder and I have had to have the vehicle towed into a repair facility which have been costly to me. The engine on this vehicle is a 5.4. The vehicle was in motion at the time of the problem on the highway”

   NHTSA complaint #11365980, filed 2020-10, 225,000 miles

   “I have a 1997 Ford Expedition, my 15 year daughter and I was driving on 10 freeway going eastbound towards san beradino, when my check engine light started flashing a then I heard a loud pop under my hood as my truck started to lose power and make loud popping sounds. I was terrified cause this happen as I was going between 65 and 70 miles per hour on free way. …”

   NHTSA complaint #10324454, filed 2010-04, 233,357 miles
2. 2
   Brakes

   Rusted brake lines, pedal to the floor

   • 81 complaints (10%)
   • median 102,000 mi at 8.8 yrs old (25 state mileage)
   • 10 mention a crash, fire or injury
   • owner-quoted repair $700 (median of 5 quotes)
   • filed 1997–2024

   Complaints describe the brake pedal sinking all the way down with little or no warning, usually traced to steel lines that rusted through along the frame. Owners report fluid loss, extended stopping distances and, in some cases, the vehicle being stopped by a curb or the parking brake. Dealers and shops typically replaced the corroded lines at the owner's expense, and some owners note additional lines were still badly rusted afterward. Mostly reported between about 96,000 and 160,000 miles on vehicles in rust-belt use.

   What to check: Have the steel brake lines from the master cylinder back inspected for surface rust and pitting, and ask whether any lines have already been replaced.

   2 excerpts from owner complaints in NHTSA records

   “The car is a 1997 Ford Expedition. The front to rear brake line corroded and failed. This happened coasting into my driveway. Even though it is a split system the braking left was minimal. The partition between the front chamber and the back didn't seem to leave enough fluid in the front chamber to allow effective remaining braking. Not to mention the brake line corroding through in less than 8 years. I had the brake line replaced but did not retain the old brake line. The cost was $623.04.”

   NHTSA complaint #10114427, filed 2005-03, 32,879 miles

   “While driving at 40 MPH, the driver applied the brakes and the brake pedal went to the floor. The vehicle was taken to a mechanic and the mechanic indicated that the steel line rusted and was allowing brake fluid to leak. The first incident,the brake line from the master cylinder rusted through and then on the third occasion the power steering line from pump to reservoir rusted through.”

   NHTSA complaint #10041960, filed 2003-10, 120,000 miles
3. 3
   Vehicle speed control

   Underhood fire traced to cruise control switch

   Mentioned in 7 of 60 sampled complaints

   Owners describe smoke or flames from under the hood, frequently while the vehicle was parked and switched off, sometimes shortly after driving. Several reports attribute the origin to the speed control deactivation switch on the brake master cylinder, and some say a fire inspector reached the same conclusion. Owners also mention recall 05V388000, with some stating their vehicle was not covered or that the added fuse link later blew. Reported across a wide mileage range, often around 100,000 to 200,000 miles, and typically with the engine off.

   Recall 05V388000

   What to check: Ask whether recall 05V388000 was performed and whether the switch or its jumper harness was replaced; visually check the switch area on the master cylinder for leak residue or scorching.

   2 excerpts from owner complaints in NHTSA records

   “On 13 july 2005, I parked my 1997 Ford Expedition at a co-workers home. We left for work in his vehicle. 45 minutes later, I received a telephone call from his spouse. She stated my vehicle was on fire and the schertz fire department had responded. The vehicle was a total loss. The deputy fire marshall, terry aikman, opined the ignition point of the fire was at the cruise control circuits. I contacted Ford motor company who responded with a letter. …”

   NHTSA complaint #10129691, filed 2005-07, 152,000 miles

   “My 1997 Ford Expedition caught fire in the middle of the night evidently to a faulty cruise control and I never got a notice on it from Ford. I lost my car and if I had parked it into the garage like I normally due my whole family would be dead!”

   NHTSA complaint #10231235, filed 2008-06, 185,000 miles
4. 4
   Electrical system

   Water leaks into dash causing electrical faults

   • 61 complaints (7%)
   • median 122,250 mi at 10.4 yrs old (28 state mileage)
   • 11 mention a crash, fire or injury
   • filed 1997–2020

   Owners report lights, blower motors, stereo and door locks operating on their own, sometimes with the key out, and intermittent no-start conditions. Several trace it to water entering through the windshield seal and dripping onto the module and fuse panel behind the dash, corroding connections over time. Repairs described include resealing the windshield and replacing the module and fuse box. Reported from around 60,000 to 190,000 miles, often noticed after rain or in intermittently wet conditions.

   What to check: Look for water stains, damp carpet or corrosion around the dash and fuse panel, and ask whether the windshield has been resealed or the module replaced.

   2 excerpts from owner complaints in NHTSA records

   “I am original owner of my 1997 Expedition, which just turned 60000. Driving at night, the dashboard lights flickered. Stopped the truck and it stalled. When trying to restart, battery did not have enough joice to turn engine. When hooking up jumper cables, the starter engaged by itself, without key in ignition, engine started, but starter remained engaged for a few minutes. Engine idled, but when headlights were turned on engine stalled. …”

   NHTSA complaint #10025870, filed 2003-07, 60,132 miles

   “Electrical devices in the car have turned on without keys even in the ignition. Concerned with fire hazard if such things as lights and blower motors turn on on their own, perhaps for extended periods. Also concerned as to what other electrical malfunctions will present themselves in unattended vehicle. Failure is apparently due to leaking windshield seals draining water onto gem (electronic module) and the fuse panel for the vehicle, shorting electrical connection and corroding the units over the long term. …”

   NHTSA complaint #10181384, filed 2007-02, 138,000 miles
5. 5
   Electrical system

   Rear door child locks engage on their own

   • 29 complaints (3%)
   • median 90,000 mi at 7.7 yrs old (11 state mileage)
   • 1 mention a crash, fire or injury
   • filed 1998–2014

   Complaints describe the rear door child safety locks moving from off to on by themselves as the vehicle is driven and the doors are used, so rear passengers cannot open the doors from inside. Owners report having the latch replaced, with the problem returning, and say passengers have to exit through a window or wait for someone outside to open the door. Reported from about 48,000 to 130,000 miles, developing gradually with use.

   What to check: Open and close each rear door several times and confirm the child lock lever stays in the off position and that interior handles release the door.

   2 excerpts from owner complaints in NHTSA records

   “While in the vehicle the consumer could not open the rear doors from the inside although the child safety locks were not engaged. The dealership had been notified. Both of the rear doors could be locked from the inside without the child lock being manually engaged. The rear doors were opened with normal use and was an intermittent problem.”

   NHTSA complaint #10042239, filed 2003-11, 50,000 miles

   “The child safety door locks on the rear doors of our 1997 Ford Expedition will gradually move themselves from the off to the on position, preventing the rear passengers from being able to exit without someone opening the door from the outside. Have attempted to tape the locks in the off position, but this has not worked.”

   NHTSA complaint #10231265, filed 2008-06, 130,000 miles

Buying note. A pre-purchase inspection focused on the brake lines, the cruise control switch and the spark plug threads covers most of what owners report. Service records showing recall 05V388000 completed and any head or brake line repairs are worth asking for.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.