1999 Ford Expedition Problems

What owners report

Owners of this model year most often describe spark plugs ejecting from the cylinder heads of the 4.6L and 5.4L engines, often preceded by a ticking or knocking sound, and oil seepage from the rear of the cylinder head gaskets. Electrical complaints are also common and many are traced to water entering through the windshield and reaching the GEM module and fuse box, which can make lights, wipers and the starter act on their own. Reports span a wide mileage range, with many appearing between roughly 60,000 and 130,000 miles.

1. 1
   Engine cooling

   Spark plug blows out of cylinder head

   • 132 complaints (14%)
   • median 113,000 mi at 8.9 yrs old (122 state mileage)
   • 8 mention a crash, fire or injury
   • owner-quoted repair $2,500 (median of 30 quotes)
   • filed 2003–2018

   Owners describe a loud pop or bang followed by a miss, rough running or loss of power, and later find a spark plug has come out of the head with its threads stripped. Some report the coil-on-plug unit damaged and a replacement head needed; others say a thread repair insert was fitted but did not last. Complaints note the truck often had to be towed, and that dealers and independent mechanics described the pattern as familiar on these engines. Reported from about 30,000 to 185,000 miles, with many between roughly 60,000 and 130,000 miles, often without warning during normal driving.

   1 related service bulletin

   What to check: Listen for a ticking or knocking sound that changes with engine speed and ask whether any plug has ever ejected or been thread-repaired. A 10023943-type spark plug thread repair procedure exists for these engines, so ask for repair records.

   2 excerpts from owner complaints in NHTSA records

   “I have had 2 different spark plugs ejected from the engine on 2 separate occasions. The first time I took it in and had a heli coil installed. I have not repaired the second instance yet. There was a 2 year time span between the events. The first time it happened I was at low speed going through town. The second time I was on the freeway.”

   NHTSA complaint #10855526, filed 2016-04, 138,000 miles

   “I own a 1999 eddie bauer Expedition. Was at a light and turned right going about 20 miles and hour when I heard an exaggerated pop and it seemed like it rattled very loudly. This is the third time spark #3 has popped out. This is ridiculous. Worst part is that it happened at 2:00 am on a dark road. Had to get it towed to a local mechanic.”

   NHTSA complaint #10382499, filed 2011-02, 185,689 miles
2. 2
   Vehicle speed control

   Engine-compartment fires while parked

   • 103 complaints (11%)
   • median 108,000 mi at 7.8 yrs old (58 state mileage)
   • 60 mention a crash, fire or injury
   • owner-quoted repair $1,398 (median of 10 quotes)
   • filed 1999–2016

   Several complaints describe smoke and flames under the hood shortly after the vehicle was parked, in some cases after being driven for a while and in others after sitting for days. Owners report damage around the driver's side of the engine bay, the master cylinder or wiring harness; a few mention the cruise control deactivation switch, which is covered by a recall, and one notes the recall work had been done. Reported at mileages from roughly 65,000 to 250,000, typically minutes to hours after parking with the engine off.

   Recall 05V388000

   What to check: Ask whether recall 05V388000 for the speed control deactivation switch has been completed, and have the area around the master cylinder and under-hood wiring inspected for heat damage or fluid leaks.

   2 excerpts from owner complaints in NHTSA records

   “Truck parked, not drove for three days, alarm went off and truck burst into flames in motor area, truck total loss, found out after fire they had recall on cruise control switch, would've been nice to know, so I'm sure several people unaware.car company need to realize cars is how they make there money and our cars are the way we pay them.”

   NHTSA complaint #10465375, filed 2012-07, 126,000 miles

   “I own a 1999 Ford Expedition truck, this truck caught on fire and blew up tuesday october 2, 2007 at approximately 7:02 pm. I had just finished parking the truck 7 minutes prior to it catching on fire and blowing up. The vehicle is now of no use. The consumer stated wrote Ford twice about the defect but Ford informed him there was nothing they could do due to the extensive damage on the vehicle. New jersey incident report. Updated 11/06/07”

   NHTSA complaint #10205041, filed 2007-10, 100,437 miles
3. 3
   Engine cooling

   Oil leak at rear of cylinder head gasket

   • 63 complaints (7%)
   • median 68,700 mi at 5.4 yrs old (41 state mileage)
   • 2 mention a crash, fire or injury
   • owner-quoted repair $1,925 (median of 12 quotes)
   • filed 2000–2010

   Owners report a hot oil smell, smoke rising near the hood after parking, and oil drips under the truck, traced to the rear of the passenger-side head gasket. Some describe oil running onto the starter or exhaust manifold, and several mention the leak returning after a gasket replacement. Complaints also describe having to add oil regularly between changes. Commonly reported between roughly 60,000 and 140,000 miles, noticed after driving and parking.

   What to check: Look for oil residue and a burnt smell at the back of the engine near the exhaust manifold and starter, check the oil level and look for drips after a test drive.

   2 excerpts from owner complaints in NHTSA records

   “On my 1999 Ford Expedition I noticed the smell of hot oil. When I would stop and park the vehicle the smell became stronger and smoke would come up around the hood of the vehicle. I also noticed some oil drops on the ground. Upon taking the vehicle to the local Ford dealer I was informed the the head gasket was leaking oil on the rear of the right head. Cost to repair was $1,295.04. I then found on the internet that this was a know problem and was widespread. …”

   NHTSA complaint #10220049, filed 2008-03, 86,830 miles

   “We bought a 1999 Ford Expedition eddie bauer almost a year ago. The day we bought it we noticed a burnt oil smell. The dealer replaced the head gasket. Now almost a year later, we blew a spark plug and need a new head. Dealer says that the head gasket and head are not related???? I was told that this car has these problems because of aluminum heads..I want the dealer to replace it, I am willing to pay more for a new one, but I am not willing to repair it and take a loss! Help!!”

   NHTSA complaint #10058411, filed 2004-02, 69,000 miles
4. 4
   Electrical system

   Water leaks shorting electrical module and fuse box

   Mentioned in 7 of 60 sampled complaints

   Owners describe wipers, interior lights, headlights, radio and heater turning on and off by themselves, often after rain, snow or a car wash, and sometimes the engine cranking or starting on its own. Several complaints say a leaking windshield let water reach the GEM module and fuse box, which corroded; dealers replaced the module and fuse box, and in some cases resealed or replaced the windshield, without always finding where the water entered. Mostly reported from about 60,000 to 145,000 miles, tied to wet weather or washing the vehicle.

   What to check: Check for water stains, damp carpet or corrosion around the windshield edges and the fuse box, and test wipers, lights and radio in wet conditions; ask whether the GEM module or windshield has been replaced.

   2 excerpts from owner complaints in NHTSA records

   “It started a year and a half ago. The windshield wipers would come on for no reason. It didn't happen very often at the time I took it in to evaluate the problem. The dealer told me they could not fix a problem they didn't see. Slowly the problem got worst, especially in wet weather. About eight months ago, the headlights would go out if the steering column was lowered. I can no longer raise or lower the column anymore for fear the wipers, locks and headlamps will not work. …”

   NHTSA complaint #10144943, filed 2005-12, 63,000 miles

   “(1) 1999 Ford Expedition would not start, dead battery. Replaced battery, determined all electonic components shorting out and inoperable: headlights, brake lights, and interior lights goes on and off, wipers work only intermittently. (2) vehicle taken to local Ford repair facility. Dealership was immedietly familliar with problem. …”

   NHTSA complaint #10114551, filed 2005-03, 70,900 miles

Buying note. Have a pre-purchase inspection focus on the cylinder heads and plug threads, the rear head gasket area, water intrusion around the windshield and fuse box, and the spare tire cable. Confirm open recalls by campaign number are completed before purchase.

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.