2003 Ford Expedition: gas smell in the cabin

Filed May 4, 2017 · Engine · 90,000 miles · MA · fire

Tl* the contact owns a 2003 ford expedition. While driving approximately 35 MPH, the contact heard a loud blast followed by smoke from the hood. The contact also perceived a fuel odor and the service engine indicator illuminated. The contact opened the hood and noticed a wire hanging at the back of the engine. The contact also stated that there was a small amount of oil on the side of the engine. The vehicle was towed to an independent mechanic who diagnosed that the spark plugs popped out of the engine. The technician remedied the engine head and replaced the spark plugs, but the failure recurred a couple of times. The manufacturer was made aware of the failure and stated that there was no recall. The vehicle was not fully repaired. The failure mileage was approximately 90,000.

Filed May 10, 2015 · Engine · 190,000 miles · PA

We were driving with the kids headed home, going about 45mph and loud noise and smell of fuel, we pull over lifted the hood and saw my coil pack busted off, we drove the rest way home to ark it, and looked again. The spark plug arched inside the head and busted the coil pack bolt and all. Shame that we tried an insert to repair it and doesnt work. I have been stressing this considering im a single mom of two that have disabilities and we have these appointments left and right and its hard walking across town all the time. This problem needs fixed by ford. I researched and its a known problem cause the cheap aluminum heads. We really need our vehicle...

Filed May 24, 2010 · Engine · 63,000 miles · CA

I own a 2003 5.4l ford expedition ed bauer with 63,000 miles. My 2003 ford expedition very recently blew the #3 spark plug in may 2010. I purchased the expedition in 2006 with only 14,000 miles. The spark plugs on the vehicle are the original spark plugs from the factory and have not been replaced. The expedition started making a knocking sound. On may way home from work, as I tuned into the freeway entrance, the engine made a loud popping sound followed by a rattling soung. I continued to operate the vehicle for approximately 3 miles and then exit the freeway. There was also a smell of gasoline coming from the engine. Since I was not far from the ford service center (galpin ford in north hills, ca.), I continued to operate the vehicle to the service center for repair. A day later I received a call from the service technician indicating that the #3 spark plug blew out of the head. The technician mentioned that the enginene needed a new head since they could not repair the problem. Total parts and labor...$3834.00. After reading comments from this website, this is clearly a manufacturer defect that should not continue to be overlooked by ford.

Filed May 19, 2010 · Engine · 78,000 miles · NY

Spark plug ejected from the engine causing the coil to brake as well, and the whole car to smell of gas. This happened once in april, and again the other day (may 17th), on a different plug. It has caused me to lose work, and my mechanic installed a repair kit with a new spark plug. It was $200-$300 for each repair. Ford says its not a problem, but my mechanic has had other cases like this, and stated ford issued a service bulletin on how to fix the problem. I have contacted ford, asking them to at least check my other plugs to make sure they are tight, but they were unhelpful. There was no warning in either case. The truck drives fine, and then suddenly starts making a loud noise as its driven, and the whole truck smells of gas. These are the original plugs, and the truck has 78k miles on it. I believe the head needs to be replaced so it doesn't keep happening. I went on different car problem websites, and this seems to be a problem with this model truck.

Filed Jul 18, 2009 · Engine · 99,876 miles · AZ

Driving from las vegas to phx we were at wickenberg, az a loud pop occurred and knocking sound from the engine. The smell of gas was present and wouldn't run properly. The ford dealership in wickenberg was luckily open and instructed us that the spark plugs had blown out in the 1st and 2nd cylinders. They did also tell us that this occurs often in and there is a temp fix for it. They tapped out the head and inserted a steel sleeve for those 2 cylinders. Taking 2 hours it was fixed and we were on our way very happy to have it fixed but not happy at all at ford for having such a blatant design flaw. This needs to be fixed.

Filed Sep 23, 2008 · Engine · 71,221 miles · PA

Spark plug blew out of engine head on a 2003 ford expedition with a 5.4l engine the spark plug blew out of the engine head and gasoline were expelled on the engine and exhaust fumes into the passenger compartment. The engine head had to be repaired at a cost of $1,832.48.

Filed Jun 11, 2008 · Engine · 92,000 miles · MD

I was driving my 2003 ford expedition to work this morning and heard a loud "pop" noise, the vehicle began to vibrate and I smelled gas fumes. When I lifted the hood, I immediately noticed that the engine had blown a spark plug.