2010 FORD EXPEDITION

Typical onset: 80,000-150,000 mi

Symptoms: Cold-start rattle that lasts 5-30 seconds, sounds like marbles in a can, Check engine light with cam timing codes (P0022, P0012), Metal shavings in oil if phasers have grenaded, Complete loss of power or no-start if timing chain jumps

Fix: Requires timing chain, both cam phasers, tensioners, and guides replacement — 12-16 labor hours if caught early. If metal contaminated the engine, you're looking at full engine rebuild or replacement because debris circulates through bearings and oil passages. This is why you see so many engine rebuilds, short blocks, and bearing jobs on these.

Estimated cost: $2,800-5,500 for phaser job alone, $8,000-12,000+ for full engine rebuild

Typical onset: 60,000-120,000 mi

Symptoms: Sudden misfire with loud hissing or popping sound from engine bay, Plug breaks off during removal leaving electrode in cylinder, Loss of compression on affected cylinder, Rough idle and check engine light with misfire codes

Fix: The 3V Triton heads have inadequate spark plug thread engagement and plugs can blow out or break. Removal requires special tools and technique. Blowout requires HeliCoil or TimeSert repair (2-4 hours per plug). Broken plugs need extractor tools (1-3 hours per plug if lucky, head removal if not). Never let these go beyond 100k without plug service.

Estimated cost: $400-800 for careful plug change with extractors, $1,200-2,000 per cylinder for blowout thread repair, $3,000-5,000 if head removal needed

Typical onset: 90,000-140,000 mi

Symptoms: Transmission fluid in coolant (strawberry milkshake in overflow tank), Coolant in transmission (check trans fluid for foamy appearance), Transmission slipping or delayed engagement after cooler failure, Overheating transmission temperature

Fix: The 6R80 transmission uses an internal oil cooler in the radiator that fails and cross-contaminates. Once mixing occurs, transmission is usually destroyed within miles. Proper fix requires radiator replacement, external transmission cooler installation, complete transmission fluid system flush or trans rebuild (8-12 hours for cooler/flush, 18-24 hours if trans rebuild needed).

Estimated cost: $800-1,500 for radiator and external cooler if caught immediately, $3,500-5,500 if transmission rebuild required

Typical onset: 70,000-120,000 mi

Symptoms: Clunk when shifting from Park to Drive or Reverse, Vibration during acceleration, Excessive drivetrain movement visible from engine bay, Transmission shifting harshly

Fix: The rear transmission mount collapses from engine torque and weight. Replacement is straightforward but requires supporting the transmission (2-3 hours). Often done alongside other trans work.

Estimated cost: $300-500

Typical onset: 80,000-130,000 mi

Symptoms: No-start condition with no fuel pump prime sound, Intermittent stalling, especially when hot, Long crank before starting, Dies while driving and won't restart until cool

Fix: The fuel pump driver module (mounted on frame rail near tank) fails due to heat and corrosion. Module replacement takes 1-2 hours. Often misdiagnosed as fuel pump itself.

Estimated cost: $250-450

Typical onset: 60,000-100,000 mi

Symptoms: Rear HVAC only works on high speed, No rear heat or air conditioning, Intermittent rear blower operation, Burning smell from rear vents

Fix: Resistor block behind rear quarter panel fails. Requires interior panel removal but straightforward replacement (1.5-2 hours).

Estimated cost: $200-350