2001 Ford Expedition Problems

What owners report

Owners of the 2001 Expedition most often describe spark plugs ejecting from the cylinder head — a loud pop, a rough-running engine, and in many cases damaged threads requiring a head repair. Electrical problems are the second recurring theme, frequently tied to water leaking through the windshield into the fuse box, and some owners report the speed control deactivation switch overheating or catching fire. Reports cluster well past 80,000 miles for most of these, while tire complaints arrive much earlier.

1. 1
   Engine cooling

   Spark plug blows out of the cylinder head

   • 85 complaints (15%)
   • median 105,569 mi at 8.5 yrs old (77 state mileage)
   • 3 mention a crash, fire or injury
   • owner-quoted repair $2,600 (median of 17 quotes)
   • filed 2004–2020

   Owners describe a loud pop or bang from the engine bay, followed by rough running, a tractor-like exhaust noise, and fuel or exhaust smells in the cabin. Many report the plug stripped the threads in the aluminum head, sometimes taking the coil with it, so a simple plug replacement is not possible and a thread repair or head work is needed. Several owners mention the same cylinder failing more than once. Most reports appear between roughly 60,000 and 160,000 miles, and some trucks repeat the failure within weeks of a repair.

   1 related service bulletin

   What to check: Ask whether any cylinder has been repaired for a blown plug and whether inserts were installed; listen for a ticking or exhaust-like noise at idle and check for signs of thread repair around the spark plug holes.

   2 excerpts from owner complaints in NHTSA records

   “I have a 2001 Ford Expedition 4.6 v8, and my spark plug blew out on me damaging my head and snapping my coil. I understand that this is becoming a common problem with Ford and they no about it but refuse to take care of the problem. I had to replace my coil and take my head to a machinist so I can put a spark plug back in it.”

   NHTSA complaint #10298011, filed 2010-01, 140,000 miles

   “Going to michigan from tennessee, driving on the expressway what's my Ford Expedition trident motor v8 heard a popping sound and almost got in an accident and found out once again the sparkplug blew out of the motor again with my family in the vehiclee it's a 2001 and I think your company should pay for the repairs.”

   NHTSA complaint #11337782, filed 2020-07, 202,758 miles
2. 2
   Vehicle speed control

   Speed control switch overheats or catches fire

   • 191 complaints (33%)
   • median 105,375 mi at 8.4 yrs old (132 state mileage)
   • 100 mention a crash, fire or injury
   • owner-quoted repair $1,500 (median of 15 quotes)
   • filed 2001–2026

   Complaints describe the speed control deactivation switch on the brake master cylinder smoking, burning, or igniting, sometimes while the vehicle is parked for hours. Some owners link underhood fires to that area; others report fires they attribute to the cruise control circuit. Several mention the recall repair, including waiting for parts or continued symptoms afterward, and some describe unintended acceleration or surging with and without cruise engaged. Reported across a wide mileage range, from about 15,000 to over 200,000 miles, often while parked or shortly after driving.

   Recall 05V388000

   What to check: Ask whether recall 05V388000 was completed and whether the switch on the master cylinder was replaced; look for scorching or fluid residue around the switch and connector.

   2 excerpts from owner complaints in NHTSA records

   “I have had my truck suddenly jump forward about 5ft after already being stopped for a little bit at a stop light. It has happened to me more then once and my foot is planted firmly on the brake pedal. It feels almost like you are being hit in the rear but there is no one there so what gives?”

   NHTSA complaint #10403788, filed 2011-05, 189,370 miles

   “On 02/13/10 at approximately 10:30 a.m., I was driving my 2001 Ford Expedition with the 5.4 liter v-8 down us highway 151 north of fond du lac, wisconsin. The throttle/accelerator stuck and the Expedition accelerated to over 60 miles per hour. I applied the brakes to slow down to avoid an accident. The engine continued to race and the back tires spun on the ice and the front tires stopped as I came to a stop upon the ice. I turned the ignition off. After a few minutes, I started the 5.4 liter engine again. …”

   NHTSA complaint #10310829, filed 2010-02, 110,000 miles
3. 3
   Electrical system

   Water leak into fuse box leads to electrical faults

   • 143 complaints (25%)
   • median 85,000 mi at 6.4 yrs old (111 state mileage)
   • 19 mention a crash, fire or injury
   • owner-quoted repair $1,000 (median of 21 quotes)
   • filed 2001–2017

   Owners report the wipers, radio, clock, blower, and other dash functions cutting out or running with the key removed after water gets into the central junction box and GEM module. Several trace the water to a leaking windshield seal at the top of the glass, and describe the dealer resealing the windshield and replacing the GEM and junction box. Some owners also report battery drain, intermittent no-starts, and instruments or lights behaving unpredictably. Reported from around 30,000 to 190,000 miles, often after heavy rain or when the truck has sat outside.

   1 related service bulletin

   What to check: Check the passenger-side kick panel and fuse box area for water stains, rust, or a damp smell, inspect the upper windshield seal, and confirm the wipers, blower, and radio all behave normally with the key off and in drive.

   2 excerpts from owner complaints in NHTSA records

   “I have a 2001 Ford Expedition (eddie bauer). The truck is experiencing erratic electronic problems such as dying driving down the road, electric functions turning on and off while vehicle is unattended, security light flashing, mileage indicator has lines through it, radio turing on and off, blower turning on and off, lights acting on their own, etc. The failure to run and dying unexpectedly has caused near death accidents as I pull onto the roadway from a cross street. …”

   NHTSA complaint #10189312, filed 2007-04, 109,000 miles

   “On the morning of 12/1/08 my 2001 Ford Expedition would not start, battery was dead. I jumped it off and drove it to the dealer. The AC fan and radio remained on even with the key out of the ignition. I have also learned the ABS system could be affected. Also; due to the electrical system shorting out there is the potential for fire. It has been determined that the windshield leaked water onto the fuse box/gem. Ford issues a special service message #15773, in april of 2002. …”

   NHTSA complaint #10250465, filed 2008-12, 91,000 miles
4. 4
   Tires

   Tire tread separation and blowouts

   • 50 complaints (9%)
   • median 56,325 mi at 4.8 yrs old (23 state mileage)
   • 7 mention a crash, fire or injury
   • filed 2001–2013

   Owners describe original-equipment tires developing bubbles, wobbling, or losing tread at highway speed, sometimes within the first few years of ownership. Several report repeated failures across a set and replacement at their own expense, and a few mention the spare tire cable breaking and dropping the spare onto the road. Mostly reported between about 26,000 and 57,000 miles, often at highway speeds.

   What to check: Check the tire brand, DOT date codes, and sidewalls for bulges or cracking, and inspect the spare tire hoist cable for rust or fraying.

   2 excerpts from owner complaints in NHTSA records

   “Purchased a 2001 Ford Expedition from maroone Ford in margate on 11/05/2004. The tires that came with this vehicle were the contitrac aw id # 02t012000. On 04/02/05 while traveling on I-95 at the speed of 55 MPH my left rear tire blew out. I was able to get the truck under control without hitting any other cars and I was not injured. I had that tired replaced the same day and thought it must have been something on I-95 that caused the tire to blow out. …”

   NHTSA complaint #10124639, filed 2005-06, 56,325 miles

   “Spare tire cable broke underneath the truck while driving 20 MPH or less, causing the spare tire to roll into another vehicle on the highway. The dealer was contacted.”

   NHTSA complaint #10094688, filed 2004-09, 60,000 miles

Buying note. A 2001 Expedition with service records showing spark plug thread repairs, a resealed windshield, and completion of the speed control recall is the safer bet. Expect to inspect the fuse box area for water intrusion and budget for tires and transmission service on a high-mileage example.

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.