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1999 Ford Expedition Problems: 1 Known Issue

1999 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026

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Issue summary

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1999 Ford Expedition has 1 documented issue, with 1 rated critical. The most serious is 5.4L 2-Valve Spark Plug Blow-Out From Cylinder Head ($150-$400 repair). Across all issues with published estimates, repair costs range from $150 to $400. DIY maintenance guides at au7o.io.

In This Article

  • Expedition Engine1
  • Recalls12
  • FAQ
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In This Article

  • Engine1
  • Recalls12
  • FAQ

All 1 Known Issue

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On the 1997-2008 Ford Expedition 5.4L Triton, the 5.4L Triton 2-valve V8 in 1997-2008 Expeditions is notorious for spark plugs ejecting from the aluminum cylinder heads. The 2-valve heads have only 4 threads holding each spark plug, which is insufficient for the clamping force needed. Over time, the threads strip and the spark plug launches out of the head under combustion pressure, taking the ignition coil with it. This typically happens when spark plugs are removed and reinstalled, or spontaneously at high mileage.

This issue also affects: Ford Aerostar, Ford Bronco, Ford Bronco Sport

Common Symptoms

  • Loud popping noise from engine
  • Spark plug and coil found on top of engine
  • Engine misfire on one cylinder
  • Hissing noise from plug hole
  • Loss of power and rough running

How to Fix

If a spark plug has blown out, a thread repair kit (Time-Sert or Heli-Coil) can permanently restore the threads without removing the cylinder head ($150-400 per plug at a shop). Prevention: Use anti-seize on spark plug threads, torque to exactly 22-25 ft-lbs (do not overtighten), and avoid changing plugs when the engine is hot. Time-Sert inserts are considered the superior repair ($30-50 per kit DIY). Some shops specialize in this repair and can do it in 30-60 minutes per plug.

Typical repair cost:$150 - $400

Research This Issue

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Community Reported
High Confidence
NHTSA Recalls12 recalls

LATCHES/LOCKS/LINKAGES:DOORS:LATCH

FORD IS RECALLING 123,632 MY 2007-2008 EXPEDITION AND LINCOLN NAVIGATOR VEHICLES. THE DOOR HANDLE HOUSING EMBOSSMENT RETAINING THE BOTTOM OF THE INTERIOR DOOR HANDLE SPRING ON ALL SIDE DOORS MAY FRACTURE DURING NORMAL CUSTOMER USAGE. THIS CAN RESULT IN INSUFFICIENT SPRING FORCE TO RETURN THE HANDLE TO THE FULLY CLOSED POSITION. THE HANDLE MAY BE LOOSE CAUSING A RATTLE OR NOISE AND THE HANDLE MAY NOT RETURN TO THE FULLY CLOSED POSITION. THIS CONDITION MAY ALSO PROVIDE A DELAYED RESISTANCE WHEN ACTUATING THE HANDLE PRIOR TO OPENING THE DOOR.

Campaign #08V05800005/02/2008

AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE

CERTAIN VEHICLES FAIL TO CONFORM TO THE REQUIREMENTS SPECIFIED IN FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 208, 'OCCUPANT CRASH PROTECTION.' THE DRIVER AIR BAG MODULE MAY NOT HAVE BEEN PROPERLY ASSEMBLED.

Campaign #07V54100021/11/2007

EXTERIOR LIGHTING

CERTAIN TRADESONIC COMBINATION LAMPS SOLD AS REPLACEMENT LAMPS FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. COMBINATION LAMPS NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.

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Other Ford Models

Ford F-15094Ford Explorer73Ford Escape48Ford Mustang46Ford Fiesta32Ford Bronco32

Frequently Asked Questions

What are the most common Ford Expedition problems?

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1999 Ford Expedition has 1 documented issue. The documented issue is: 5.4L 2-Valve Spark Plug Blow-Out From Cylinder Head. Of these, 1 is rated critical and should be addressed promptly.

Is the Ford Expedition reliable?

The 1999 Ford Expedition has 1 known issue compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 1 issue is rated critical: 5.4L 2-Valve Spark Plug Blow-Out From Cylinder Head. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Ford Expedition problems?

Repair costs for known Ford Expedition issues range from $150 to $400, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 5.4L 2-Valve Spark Plug Blow-Out From Cylinder Head, typically costs $150-$400 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 1997-2008 Ford Expedition 5.4L 2-Valve Spark Plug Blow-Out From Cylinder Head?

The 5.4L Triton 2-valve V8 in 1997-2008 Expeditions is notorious for spark plugs ejecting from the aluminum cylinder heads. The 2-valve heads have only 4 threads holding each spark plug, which is insufficient for the clamping force needed. Over time, the threads strip and the spa… Repairs typically run $150-$400. Severity: high.

Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.

Data compiled from NHTSA recalls, manufacturer TSBs, automotive forums, and AI-assisted research. No aggregated owner-report counts available for this vehicle yet.

Campaign #06E06400017/07/2006

EXTERIOR LIGHTING

SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.

Campaign #09E01200007/04/2009

FUEL SYSTEM, GASOLINE

CERTAIN AFTERMARKET FUEL FILTERS SOLD UNDER THE PUROLATOR BRAND NAME, P/N F65277, SHIPPED FROM JANUARY 16 THROUGH JUNE 2, 2006, FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. DUE TO INCORRECT DESIGN, THE QUICK CONNECTORS MAY NOT FULLY SEAT WITH THE TUBE INTERFACE, EVEN THOUGH THE PERSON MAKING THE CONNECTION MAY BELIEVE THAT THE QUICK CONNECTOR IS FULLY ATTACHED.

Campaign #06E05600013/06/2006

+ 7 more recalls. Check all on NHTSA.gov

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