2003 Ford Expedition: fire, smoke or burning smell

Filed Jan 15, 2022 · Engine, Fuel system · TX

This is the 2nd time it happened to my 2003 ford expedition. While driving heard a loud popping noise, followed by continuous popping loud popping noise like a broken exhaust muffler, sounded like a motorcycle. After investigating, found out that the #3 spark plug popped out (ejected) of the head cylinder, broke the spark ignition coil. When this happened, I smelled fuel, and saw smoke coming from under the hood, so I did not drive the car and towed the car home. I had to replace the ignition coil and spark plug and reinstalled the spark plug but it seemed to be still loose, so I took it out and put thread lock and reinstalled it but did not tighten it to the max and did not start the car till after 24 hours so the thread lock will hold it in place. Yesterday the same thing happened to #8 spark plug, it also broke the coil, and when I tried to install the new spark plug, found out that the threads on the head cylinder will not grab the spark plug, and now I am stuck without a car. When I asked around, people said this is a common problem on the ford expedtion. This is dangerous and could kill someone if the engine caught on fire, because I smelled gas and smoke. If this is a common dangerous problem on the ford expedtion, how come there is no recall for it???? Are we waiting for someone to die due to engine / vehicle fire to do something about it? Please look into this issue asap and let ford fix this dangerous problem. Spark plugs ejecting out like this? I noticed that there are only 4 threads on the head cylinder holding the park plug, but the spark plug has 10 or 11 threads and ofcourse only 4 of those threads are being held by the head cylinder. This is a dangerous problem waiting to hurt or kill someone, please ask ford to fix this big problem, thank you....

Filed Sep 9, 2015 · Brakes · 180,000 miles · PA · fire

Tl* the contact owned a 2003 ford expedition. The contact stated that the brake pedal was depressed and smoke emitted into the vehicle from the air conditioning vents. The contact also noticed that there were flames under the hood. The fire was extinguished by the fire department. The vehicle was destroyed. The manufacturer was not notified of the failure. The approximate failure mileage was 180,000.

Filed Aug 29, 2014 · Electrical · 220,000 miles · MS · fire

Tl* the contact owned a 2003 ford expedition. While parked in a residential driveway, the vehicle caught fire and burned down to the frame. A fire report was filed. The vehicle was destroyed. The cause of the fire was unknown. The manufacturer was not notified. The VIN was unavailable. The failure mileage was 220,000.

Filed Sep 19, 2013 · Electrical, Engine · 120,000 miles · MN · fire

We moved it around in our shed at about 10pm on 6/16/12 and we awoke at 4 am to our shop, machine shed, and chicken coop engulfed in flames. We lost over $100,000 in property. The fire marshall determined that our ford expedition was to blame and that it started under the hood, somewhere in the electrical. We only had liability only on 2 of the 3 vehicles in the shop along with our motorcycle and trailer so they were not covered by insurance. I think ford should of compensated us for the items we did not get paid for. They should do a recall on this vehicle, and compensate the people that had fires with this vehicle.

Filed Apr 20, 2012 · Engine · 103,000 miles · TX · fire

Tl* the contact owns a 2003 ford expedition. The contact stated that the vehicle was parked and shut off when he noticed flames erupting from under the hood on the driver's side. The fire department extinguished the fire. The vehicle was not taken to have the failure diagnosed. The failure and current mileages were 103,000.

Filed Jun 14, 2011 · Electrical · 150,000 miles · NE · fire

At 4:40am, was woke up by the police and fire department who responded to a call in of our vehicle, a 2003 ford expedition being on fire. Based on the information received from the fire crew chief, the fire had started in the engine compartment, on the driver's side, and appeared to be electrical in nature. The car had last been used the prior night at 8pm, when we returned from eating dinner, and had remained idle since that time. Upon hearing our story, several friends mentioned that they had read stories about ford vehicles that had an issue with the cruise control switch causing fires, even in vehicles that had remained idle for several hours. I checked and it does not appear there were any recalls for my vehicle's year, but had been for the prior year's (2002). Here is a link to one article (although there are many): http://articles.cnn.com/2005-06-16/us/ford.vehicles_1_ford-vehicles-brake-fluid-cruise-control?_s=pm:us the car is a complete loss, the engine mostly gone and the tire and part of the body melted to my driveway. The damage inspector for our insurance company stated it was likely that they would not be able to cover our full lien amount and I believe at the very least ford should make whole for us. The insurance company is working with ford about possible subrogation, but it is unclear at this point in time if the insurance company will ask for dollars beyond what they would pay out in the loss. We were fortunate it did not spread to our home, my husband's ford parked next to it or to our boat which was directly in front of it. It was very, very close and could have easily happened. We feel very fortunate that we did not park the vehicle in our garage or any closer to the boat, whose cover had melted and could have easily set on fire given the heat and severity of the fire.

Filed Nov 9, 2010 · Engine · 58,000 miles · NY

On 11/7/10 traveling home with my family in my 2003 ford expedition I heard a loud bang thought I blew a tire. I started smelling a strong odor of gas. The car started to misfire. I pulled it over to make sure it wasn't on fire. Turns out a spark plug blew out of the engine. Found out threw some research on the internet that this is a on going problem with ford. Why are they not standing behind there product. I've heard it is a design flaw with the spark plugs not having enough thread on them. I am very disappointed. This is going to cost me somewhere around $3000.00 to get fixed. I bought this truck new from the dealer. I only have 58,000 miles on it to me this is still a new truck something has got to be done they do know that there was a design flaw because in 2004 they changed the design. Shame on ford. An american made vehicle .this should be recalled and ford should make good on there product.

Filed Aug 15, 2010 · Airbags · GA · crash · 3 injuries

A deer came onto the highway as I was switching lanes and I swerved to prevent hitting. Hit the deer and drag it approx 60 ft. Sparks and flames were coming from the vehicle as we flipped. Vehicle began to flip 6-8 times per passenger (daughter) and a tractor trailer driver. Air bags never deployed. This is the first time for the failure of the bags. The expedition was totaled because the front and rear window came out, the driver and passenger window in the front row were shattered, the ashtray disconnected and went out the window. The mirrors on the expo were damaged and the body of the vehicle was terribly damaged. A new vehicle was brought a couple of weeks later.

Filed Jul 27, 2010 · Engine · 105,002 miles · OK · fire

Tl* the contact owns a 2003 ford expedition, eddie bauer edition. The contact stated the vehicle unexpectedly exploded while parked in front of her place of residence. The contact stated the vehicle and the front yard of her home was engulfed in flames and smoke. The fire department advised that the fire originated from the engine. A fire report was available. The contact stated there was severe damages done to her garage and a large portion of the exterior of her home. The vehicle was destroyed. The failure and current mileages were 105,002.

Filed Dec 1, 2009 · Electrical · 99,600 miles · MI · fire

On june 19 2009, returning home from a short trip, thick smoke erupted with strong rubber smell from underneath the driver seat. I immediately turned off the ignition and exited the car. The following day I contacted ford motor co. And inform them of the safety issue, after going back and forth, ford general consul office made decision that the issue is not safety hazards and will not repair the vehicle. Pat milliken ford has the vehicle, and inspected the damage, which declared to be very extensive the repair cost may exceed $2000.00. Ford general consul was informed of the damage and still will not consider it as safety issue because the vehicle did not burst on fire. My smart and quick reaction to turn off the vehicle and cut the power off prevented a disaster to happen, and yet as a consumer I'm left with hefty repair bills for a possible manufacturing defect in the wiring.

Filed Dec 7, 2008 · Fuel system · 165,000 miles · MS · fire

I was driving on highway 12 west. As I turned onto a road, I noticed smoke coming from under my hood. My 8-year-old said, " what is that smell?" I told her that it is coming from under the hood of the vehicle. At this particular time, I turned the truck around and went to the nearest quick store. The man inside looked under my hood and used water to put on the "hood blanket". There was a hole in it above the brake fluid reservoir. The man kept putting water on it until it stopped smoking. At this particular time, he told me that me and little girl were lucky. I knew that it could have gotten worse. It was cold and if I were not close to the store I probably would have stayed in the vehicle to stay warm. I am so glad that I turned around and took a chance on getting to the nearest store. My insurance agent will be coming monday (today is saturday) to assess the damages and determine what could have caused the fire.

Filed Oct 2, 2008 · Electrical · 55,800 miles · IL · fire

My husband's 2003 ford expedition caught on fire. He had been out of the car for about 30 minutes. We heard a loud popping noise and thought nothing of it. We heard another loud popping noise, and went to see what it was. When we got outside there was smoke coming from under the hood. Then we saw flames coming from the dashboard. At that point we called 911. The fire department came and put the fire out, and said it was caused by something electrical. There was some sort of short in the wiring. He had taken the car in for repair because the door ajar light stayed on, although there were no doors open. This problem was supposedly fixed by car max. There have been no modifications to the vehicle.