2000 Ford Expedition Problems

What owners report

Owners of this model year most often describe electrical trouble that appears after rain or snow, when water reaches the fuse box and GEM module and windows, wipers, radio and door locks behave unpredictably. A second large group of complaints covers engine fires while parked with the ignition off, and many owners tie these to the speed control switch on the driver's side of the engine bay. Separately, the 5.4L V8 is frequently described as ejecting spark plugs from the cylinder head, often above 90,000 miles.

1. 1
   Electrical system

   Water leak into fuse box and GEM module (electrical)

   • 110 complaints (12%)
   • median 98,000 mi at 7.6 yrs old (87 state mileage)
   • 8 mention a crash, fire or injury
   • owner-quoted repair $1,000 (median of 24 quotes)
   • filed 1999–2015

   Complaints describe the windshield seal letting water in behind the dash, where it reaches the fuse box and GEM module. Owners report wipers stopping mid-drive, radio cutting out, windows going up or down on their own, doors locking and unlocking by themselves, the blower running with the key out, starter engaging on a running engine, and no-start or stalling conditions, mostly during or after rain and snow. Several say a dealer replaced the GEM module and fuse box, or found rusted connectors, while others report shops being unable to reproduce the leak. Reported from roughly 30,000 to over 200,000 miles, with most accounts clustered between 55,000 and 160,000 miles and triggered by wet weather.

   3 related service bulletins

   What to check: Check for water stains, damp carpet or corrosion around the passenger-side fuse box and behind the dash, and test wipers, windows, locks and radio after washing the windshield or in rain. Ask whether the windshield seal and GEM module have been replaced.

   2 excerpts from owner complaints in NHTSA records

   “I went out to my truck to start it and the radio was on. No keys in ignition. Starter engages while running in park and neutral. Wipers come on and off no keys in ignition. Locks and unlocks by itself no keys in ignition. While driving have to put in neutral to roll window down and up. All this happens when it rains or snows.”

   NHTSA complaint #10266340, filed 2009-04, 101,000 miles

   “I noticed when ever I drove my car in the rain water would leak on my right leg and foot, my wipers, radio and clock would stop working and I heard a sizzling noise in the left dash area. I also was unable to use my keyless remote, the alarm would go off every time. I brought my 2000 Expedition to hayward Ford to have them check and repair the problem in march of this year. …”

   NHTSA complaint #10126309, filed 2005-06, 32,288 miles
2. 2
   Engine cooling

   Engine compartment fire while parked

   • 189 complaints (21%)
   • median 100,000 mi at 7.0 yrs old (122 state mileage)
   • 157 mention a crash, fire or injury
   • owner-quoted repair $3,250 (median of 6 quotes)
   • filed 2000–2026

   Owners describe fires starting under the hood with the vehicle parked and the key removed, sometimes an hour or more after the last drive, often on the driver's side near the master cylinder or firewall. Some report smoke or flames at the cowl, total losses, and fire departments unable to establish a cause; a few mention that the dealer could not identify a cause. Several complaints note the speed control system as the suspected area. Usually described between about 50,000 and 180,000 miles, in vehicles parked for varying periods after a drive.

   Recall 05V388000Recall 05V017000

   What to check: Ask whether the speed control deactivation switch recall work (campaigns 05V388000 and 05V017000) has been completed, and inspect the switch and connector on the driver's side of the engine bay for signs of heat, melting or fluid residue.

   2 excerpts from owner complaints in NHTSA records

   “My truck has been running fine with new parts on it. I went to my friend's house went in to switch my laundry, looked out her window and my was on fire!! Truck off and keys were not in ignition and it was parked in a driveway under a carport. It posed no problems on the way over there, no smells, no sounds, no nothing. And then bam! Hood shooting out flames.”

   NHTSA complaint #11306520, filed 2020-02, 195,000 miles

   “My Expedition caught on fire parked in my driveway at least 30 minutes after driving it. I was able to put the fire out with a fire extinguisher and a water hose, but the plastic parts were were melted on the driver side. The battery was disconnected and I was told by a mechanic that it was the cruise control relay.”

   NHTSA complaint #11196458, filed 2019-04, 258,000 miles
3. 3
   Engine cooling

   Spark plug blown out of cylinder head

   Mentioned in 13 of 60 sampled complaints

   Complaints describe a loud pop followed by rough running, a strong fuel smell and loss of power, with a spark plug found ejected from the head and sometimes the coil dislodged. Owners report the same cylinder or a different one failing again after repair, and dealers quoting temporary thread repairs or head repair, with some owners choosing the cheaper option due to cost. Misfires and coil failures are also described, including coils affected by moisture under the hood. Mostly reported between roughly 90,000 and 180,000 miles, including while driving at highway speeds.

   3 related service bulletins

   What to check: Ask whether any spark plug threads have been repaired and by what method, listen for misfire or ticking at idle, and check plug torque and coil condition; a service bulletin describes a thread repair procedure for this engine family.

   2 excerpts from owner complaints in NHTSA records

   “2000 Ford Expedition 5.4l my spark plug ejected from the motor causing the coil to eject as well. It has happened twice now. I took it to the shop and because I do not have the funds to have the head rethreaded they would only due a temporary repair.”

   NHTSA complaint #10315895, filed 2010-03, 132,000 miles

   “I have a 2000 Ford Expedition with the triton 5.4 litre v8 engine. This vehicle has a little over 100,000 miles and is used for personal transportation only. Today we had a spark plug blow out on the vehicle and had to have it towed to the local Ford dealership. The mechanic at the dealership quoted me a price of over $700 to have a temporary fix of a heli coil placed into the spark plug hole to replace the stripped threads caused by the blowout and to have the coil replaced. …”

   NHTSA complaint #10254203, filed 2009-01, 110,000 miles
4. 4
   Suspension

   Steering and front-end component separation

   • 153 complaints (17%)
   • median 87,700 mi at 6.9 yrs old (80 state mileage)
   • 21 mention a crash, fire or injury
   • owner-quoted repair $900 (median of 6 quotes)
   • filed 1999–2024

   A small group of complaints describes front tie rod separation or a broken tie rod while driving, with loss of steering control and front-end bounce, followed by roadside repair. Others describe the steering binding or locking briefly on long grades at higher rpm, which dealers could not reproduce, and one report of a rear lower control arm failure. Complaints also mention the rear air suspension dropping and the compressor running without an obvious leak. Reported from very low mileage up to about 130,000 miles, with tie rod accounts around 50,000 to 65,000 miles.

   What to check: Have a shop inspect tie rod ends, ball joints and control arms for play or corrosion before purchase, and check that the rear air suspension holds height overnight without the compressor cycling repeatedly.

   2 excerpts from owner complaints in NHTSA records

   “At high speed, on long sustained, steep grades 5-7%, at high RPM, the steering locks up for 2-10 seconds. The steering makes a noise and then breaks free. I have brought this to the dealership 4 times and they say they can not find a problem and can not reproduce this event. Every time I drive into the colorado mountains this problems recurs. This problem never shows up on flat terrain. This problem is extremely dangerous. …”

   NHTSA complaint #10008531, filed 2002-11, 17,000 miles

   “While driving 30 MPH, the front tie rod separated and the consumer lost control of the vehicle. The seat belt did not restrain the consumer properly and the air bag did not deploy. 4 days later the consumer received a letter in the from Ford warning him about possible tie rod failure, the consumer stated the VIN and other information was wrong which may have delayed receiving the mail.”

   NHTSA complaint #10092642, filed 2004-10, 50,029 miles
5. 5
   Vehicle speed control

   Speed control switch overheating or failing

   • 95 complaints (11%)
   • median 107,000 mi at 7.0 yrs old (69 state mileage)
   • 83 mention a crash, fire or injury
   • filed 2000–2026

   Owners report the cruise control setting or dropping out on its own and the dealer tracing it to the speed control switch, sometimes noting that recall work had already been done on the vehicle. Others describe the switch area as the suspected source of underhood smoke or fire while the vehicle was parked, and several complaints were filed specifically referencing the speed control campaigns. Often reported between about 60,000 and 130,000 miles, on vehicles of varying use.

   Recall 05V388000Recall 05V017000

   What to check: Confirm the deactivation switch recall was performed and check the switch for scorching or brake fluid residue; test that cruise control engages and cancels normally, including with the brake pedal.

   2 excerpts from owner complaints in NHTSA records

   “Consumer parked vehicle at 9:00 am, and at around 4:00 pm fire started in the engine compartment on driver's side. Fire spread to house. Air conditioner compressor was replaced nearly six months before fire. Fuse went out on a blinker. Never had problems with cruise control. Rarely used cruise control. Made a long trip within 3 weeks before fire and cruise were working.”

   NHTSA complaint #10106667, filed 2005-01, 50,000 miles

   “The vehicle was in park when the consumer heard a loud boom noise, and then another. The vehicle was engulfed in flames. It started on the drivers side where the black box was. There was no warning it just exploded. The consumer stated the cruise control had been acting up. At times when the consumer set the cruise control at 90 miles it would take off and then some times it would not work. Please provide any further information.”

   NHTSA complaint #10103427, filed 2004-12, 60,000 miles

Buying note. Have a pre-purchase inspection focus on the windshield seal, fuse box and GEM module, confirm the speed control switch recall was completed, and check spark plug condition and steering linkages; service records for these items are more useful than mileage alone on this model year.

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.