3 Most Common Ford Expedition Problems Reported by Hundreds of Real Owners

Since 1997 we’ve relied on the Ford Expedition as a big family hauler. This SUV hit the market as a step above the Ford Explorer, giving us a full-size Ford SUV that can do it all. Many Expeditions have carried the load for more than two decades. Still, this SUV has faced its share of troubles. Here are the most common Ford Expedition problems to look for in this full-size SUV.

Most common Ford Expedition Problems

Although the Ford Expedition brings more than 25 years of data to the market, the most common issues reported didn’t impact owners in large numbers. RepairPal tells us the three most common Ford Expedition problems are:

  • TSB for possible ejection of the spark plug from cylinder head – reported by 180 owners
  • Ignition coil failure due to excessive spark plug gap – reported by 152 owners
  • Check engine light after hesitation or stalling – reported by 107 owners

Spark plug ejection is a common theme for full-size Ford vehicles?

If you saw our article covering the most common Ford F-150 problems, you’ll notice the spark plug ejection issue listed as one of the issues for the most popular truck. Considering the Ford Expedition and F-150 use the same engines, these problems are consistent.

The fix for an engine that’s ejecting the spark plugs is the replacement of the cylinder head and head gasket. This fix also requires replacing the spark plugs. This repair can range from $288-$343 to replace the spark plugs.

An excessive spark plug gap could cause the ignition coil to fail

One of the most common Ford Expedition problems results from excessive spark plug gaps, which can cause the ignition coils to fail. Typically, the Check Engine Light will come on, indicating an issue.

If this problem occurs, a mechanic must complete a diagnostic review. This problem is closely related to the first problem, and only a proper engine diagnosis will identify the actual issue. If the problem is the spark plug gap, your mechanic should replace the plugs and coil boots.

What causes this Ford SUV to stall or hesitate?

Ford Expedition models with the Triton V8 engine are prone to rough idling, hesitation, or stalling. This is caused by the Mass Flow Sensor (MAF) failing, which causes the Check Engine Light to illuminate.

When this issue occurs, you must replace the MAF. The typical replacement cost is $237-$417. To prevent this problem in the future, ensure the air filter is properly installed and sealed to the air filter housing.

Is the Ford Expedition a reliable full-size SUV?

2023 Ford Expedition Timberline is worth the price because it's off-road ready.
2023 Ford Expedition Timberline | Ford

The Ford Expedition receives a reliability score of 3.0 out of 5.0 from RepairPal. This places the Expedition in the seventh spot out of 14 models for the full-size SUV class. This ranking is based on three factors which are:

  • Cost – The Ford Expedition’s average annual repair and maintenance costs are $861 compared to $784 for full-size SUVs
  • Frequency – Expedition owners bring their vehicles to the repair shop for unscheduled repairs 0.25 times per year compared to 0.4 for the class.
  • Severity – The probability of severe repairs for the Ford Expedition is 15% compared to 15% for full-size SUVs

What do other experts have to say about the Ford Expedition’s reliability?

Consumer Reports lists the 2023 Ford Expedition as the highest in the full-size SUV segment for reliability. Turning to U.S. News, this Ford SUV is ranked second out of seven in its class overall. The Expedition is backed by a standard three-year/36,000-mile basic warranty and a five-year/60,000-mile powertrain warranty.

Is the Ford Expedition a good full-size SUV?

2023 Ford Expedition Towing a trailer on a dirt trail
2023 Ford Expedition Towing | Ford

The 2023 Ford Expedition offers roomy seating for up to eight people, plenty of cargo room, and a long list of features. The interior quality is in-line with what’s expected from Ford, and the new twin-turbocharged V6 makes this full-size SUV relatively efficient.

Next, check out five long-lasting full-size SUVs, or learn more about the 2023 Ford Expedition in this video below:


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