The 2000 Expedition's 4R100 transmission and 5.4L Triton spark plug issues dominate the repair landscape, with transmission cooler failures often killing the trans and the infamous two-piece spark plugs breaking off during removal.
4R100 Transmission Fluid Cross-Contamination via Failed Cooler
Common · high severity
Typical onset: 100,000-150,000 mi
Symptoms: Pink milkshake in coolant overflow tank (trans fluid mixing with coolant), Harsh shifting or slipping after coolant/trans fluid mixing detected, Transmission overheating warnings, Catastrophic transmission failure if driven after contamination
Fix: Replace internal radiator transmission cooler (often means new radiator), flush both cooling system and transmission thoroughly. If contamination went unnoticed and trans was driven, full rebuild or replacement required. Preventive external cooler install adds 2-3 hours labor but saves the trans. Transmission rebuild: 12-16 hours labor.
Symptoms: Misfires, rough idle, check engine light (P030x codes), Spark plug breaks off during removal attempt, leaving lower shell in cylinder head, Reduced power and fuel economy
Fix: Ford's early Triton plugs have a two-piece design that seizes and snaps. Removal requires specialized extractors, sometimes drilling/tapping. Budget 1.5-2 hours per broken plug beyond normal plug job. Worst case: 8-10 hours total if multiple plugs break. Prevention: change plugs early (60k) when they're easier to remove.
Symptoms: Sudden loud pop or hissing sound from engine bay, Immediate misfire and loss of power, Spark plug physically blown out of cylinder head, Compression loss in affected cylinder
Fix: 5.4L Triton heads have inadequate spark plug thread engagement (4 threads vs. industry standard 8+). Plug can blow out, stripping threads. Requires HeliCoil or TIME-SERT thread repair insert. Quality shops use TIME-SERT (stronger). Takes 3-5 hours per hole with proper kit. Do NOT just screw plug back in.
Estimated cost: $500-900 per cylinder
Intake Manifold Coolant Crossover Gasket Failure
Common · medium severity
Typical onset: 90,000-140,000 mi
Symptoms: Coolant loss with no visible external leaks, White smoke from exhaust on cold start, Rough idle, possible misfire from coolant in cylinder, Coolant in oil (milky dipstick) in severe cases
Fix: Plastic intake manifold coolant crossover passages crack or gaskets fail, leaking coolant into intake plenum or cylinders. Must remove intake manifold, replace all gaskets and coolant crossover if cracked. Common to replace thermostat housing while in there. 4-6 hours labor. Use Fel-Pro or Motorcraft gasket set.
Estimated cost: $600-1,100
Front Hub Bearing and Wheel Speed Sensor Failure
Common · medium severity
Typical onset: 80,000-130,000 mi
Symptoms: ABS light on with C1145 (wheel speed sensor) codes, Grinding or humming noise from front wheel area, changes with speed, Traction control and AdvanceTrac warnings, Vibration felt through steering wheel
Fix: Front hub assemblies wear out, often taking integrated wheel speed sensor with them. Replace entire hub/bearing assembly as a unit. Do both sides if one fails over 100k miles. 2-2.5 hours per side. 4WD models slightly more complex with locking hub components.
Estimated cost: $350-550 per side
Rear Differential Pinion Seal Leak
Occasional · low severity
Typical onset: 100,000-160,000 mi
Symptoms: Gear oil dripping from front of rear differential, Oil accumulation on differential nose and driveshaft, Low differential fluid if leak goes unnoticed long term
Fix: Pinion seal deteriorates, leaks gear oil. Requires removing driveshaft, pinion nut, pinion flange. Critical: mark pinion depth and preload before disassembly or you'll need full setup with new crush sleeve. Experienced tech: 2-3 hours. Rookie mistake: changing preload kills bearing life. Refill with 75W-140 synthetic.
Estimated cost: $300-500
Ball Joint Failure (Upper and Lower)
Common · high severity
Typical onset: 90,000-140,000 mi
Symptoms: Clunking noise over bumps from front suspension, Steering wander or looseness, Uneven tire wear (inside or outside edge), Visible play when prying on suspension with vehicle lifted
Fix: Independent front suspension ball joints wear out, especially with heavy loads or trailer towing. Lower ball joints typically fail first but inspect both. Some uppers are riveted to control arm (replace whole arm), lowers are serviceable. Safety critical—catastrophic if lower ball joint separates. 3-4 hours per side for both upper and lower. Always align after.
Estimated cost: $600-1,000 per side (both upper and lower)
Change spark plugs at 60,000 miles when they're easier to remove, use anti-seize and replace one at a time to avoid mixing up coils
Inspect ball joints and hub bearings every oil change after 80k miles—these fail gradually then catastrophically
Use Motorcraft or Mercon V fluid only in 4R100 transmission, change every 50k miles with filter
Keep close eye on coolant level—multiple leak points (intake gaskets, radiator, heater core) can cause overheating damage
Pass unless under 100k miles with documented transmission cooler upgrade and recent spark plugs—the catastrophic failure potential of trans cooler and spark plug issues outweighs the utility for most buyers.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
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CERTAIN MAXZONE HEADLIGHT ASSEMBLIES, DEPO BRAND, P/NOS. 331-1129L-ASN AND 331-1129R-ASN, SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR THE ABOVE LISTED PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE PHOTOMETRIC REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
Consequence: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Remedy: MAXZONE WILL NOTIFY OWNERS AND OFFER REIMBURSEMENT FOR ANY NONCOMPLIANT HEADLIGHTS. THE RECALL BEGAN ON JULY 28, 2006. OWNERS MAY CONTACT MAXZONE AT 909-822-3288.
EXTERIOR LIGHTING · 06E060000
2006-06-29
CERTAIN AAI MOTORSPORTS COMBINATION LAMPS SOLD AS REPLACEMENT LAMPS FOR USE ON THE ABOVE LIST 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."
Consequence: LACK OF AMBER SIDE REFLECTORS IN THE LAMPS WILL DECREASE LIGHTING VISIBILITY TO OTHER DRIVERS AND MAY POSSIBLY RESULT IN A VEHICLE CRASH
Remedy: AAI MOTORSPORTS WILL NOTIFY OWNERS AND REPLACE THE LAMPS FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 1, 2006. OWNERS MAY CONTACT AAI MOTORSPORTS AT 909-923-9188.
FUEL SYSTEM, GASOLINE · 06E056000
2006-06-13
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.
Consequence: FAILURE OF THIS CONNECTION COULD LEAD TO FUEL SPILLAGE AND, IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.
Remedy: UFI WILL NOTIFY OWNERS AND REPLACE THE FILTERS FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 4, 2006. OWNERS MAY CONTACT UFI FILTERS USA AT 800-230-5876.
VEHICLE SPEED CONTROL · 05V388000
2005-09-07 · EA05005
ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES EQUIPPED WITH SPEED CONTROL, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT, SMOKE, OR BURN.
Consequence: A FIRE AT THE SWITCH COULD OCCUR.
Remedy: BY LETTER DATED SEPTEMBER 12, 2005, OWNERS WERE INSTRUCTED TO RETURN THEIR VEHICLES TO THEIR DEALERS TO HAVE THE SPEED CONTROL DEACTIVATION SWITCH DISCONNECTED. OWNERS WHO HAVE HAD THEIR SPEED CONTROL DEACTIVATED ARE BEING NOTIFIED THAT PARTS WILL BE AVAILABLE AND ADVISED TO MAKE AN APPOINTMENT TO RECONNECT THE SPEED CONTROL BEGINNING IN FEBRUARY 2006. OWNERS WHO DID NOT HAVE THEIR SPEED CONTROL DEACTIVATED ARE BEING NOTIFIED TO HAVE THEIR SYSTEM REMEDIED BEGINNING IN FEBRUARY 2006. OWNERS ARE URGED TO AVAIL THEMSELVES OF THE FREE DISCONNECT SERVICE AS SOON AS POSSIBLE BECAUSE OF THE SIGNIFICANT RISK OF FIRE. OWNERS MAY CONTACT FORD AT 1-800-392-3673. (NOTE: ALSO SEE RECALLS 05V017 AND 06V286)
VEHICLE SPEED CONTROL:CRUISE CONTROL · 05V017000
2005-01-27 · PE04078
ON CERTAIN SPORT UTILITY VEHICLES AND PICKUP TRUCKS, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT, SMOKE, OR BURN.
Consequence: THIS CONDITION COULD LEAD TO A FIRE. FIRES HAVE OCCURRED WHILE THE VEHICLES WERE PARKED WITH THE IGNITION 'OFF.'
Remedy: AS AN INTERIM REPAIR, OWNERS WILL BE INSTRUCTED TO RETURN THEIR VEHICLES TO THEIR DEALERS TO HAVE THE SPEED CONTROL DEACTIVATION SWITCH DISCONNECTED. AS SOON AS REPLACEMENT PARTS ARE AVAILABLE (EARLY APRIL 2005), OWNERS WILL BE INSTRUCTED TO RETURN TO THE DEALERS FOR INSTALLATION OF A NEW SWITCH FREE OF CHARGE. OWNERS MAY CONTACT FORD AT 1-800-392-3673. (NOTE: ALSO SEE RECALLS 05V388 AND 06V286)
STRUCTURE · 03V094000
2003-03-07
CERTAIN PICKUP TRUCK, VAN, AND MINI VAN CONVERSIONS EQUIPPED WITH SOUTHERN COMFORT BUILT RUNNING BOARDS THAT CONTAIN CERTAIN COURTESY LIGHTS MANUFACTURED BY AMERICAN TECHNOLOGY COMPONENTS, INC. THESE UNITS CONTAIN A COURTESY LIGHT OR LIGHTS THAT MIGHT OVERHEAT WHEN THE WIRE HARNESS IS EXPOSED TO EXCESSIVE MOISTURE AND ROAD SALT.
Consequence: THIS OVERHEATING CONDITION CAN CAUSE THE RUNNING BOARD TO MELT OR CAUSE A FIRE.
Remedy: DEALERS WILL REPLACE THE WIRING HARNESS ON THESE RUNNING BOARDS. OWNER NOTIFICATION BEGAN MARCH 7, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT SOUTHERN COMFORT AT 1-800-745-6096.
EQUIPMENT:OTHER:LABELS · 02V239000
2002-09-09
CERTAIN 4X2 SPORT UTILITY VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 120, "TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS." THE REAR TIRE PRESSURE IS INCORRECTLY LISTED ON THE LABEL FOR 4.2 VEHICLES.
Consequence: CUSTOMERS MAY INFLATE THEIR REAR TIRES BASED ON THE INCORRECT TIRE PRESSURE INFORMATION ON THE CERTIFICATION LABEL.
Remedy: A SUPPLEMENTARY LABEL WILL BE SENT TO CUSTOMERS TO PLACE NEAR THE CERTIFICATION LABEL TO IDENTIFY THE APPROPRIATE REAR TIRE PRESSURE. THE CUSTOMER MAY ALSO HAVE THE DEALER INSTALL THE LABEL ON THE VEHICLE, IF THEY SO DESIRE. OWNER NOTIFICATION IS EXPECTED TO BEGIN DURING SEPTEMBER OR OCTOBER 2002. OWNERS WHO DO NOT RECEIVE THE FREE LABEL AND INSTALLATION INSTRUCTIONS WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-866-436-7332.
VEHICLE DESCRIPTION: PASSENGER CARS, SPORT UTILITY VEHICLES, AND LIGHT AND MEDIUM DUTY PICKUP TRUCKS. A SWITCH LOCATED IN THE PLASTIC COVER OF THE WIPER MOTOR GEAR CASE COULD MALFUNCTION AND OVERHEAT, POTENTIALLY RESULTING IN LOSS OF INTERMITTENT WIPER FUNCTION, LOSS OF WIPER PARK FUNCTION, COMPLETE LOSS OF WIPER FUNCTION, OR IGNITION OF THE PLASTIC COVER MATERIAL. SWITCH MALFUNCTION IS MOST LIKELY TO OCCUR WHEN THE INTERMITTENT SETTING OF THE WIPERS IS BEING USED, OR WHEN SNOW OR ICE OBSTRUCTS THE BLADES FROM RETURNING TO THE "PARKED" POSITION AT THE BOTTOM OF THE WINDSHIELD. THESE VEHICLES WERE BUILT AT THE FOLLOWING ASSEMBLY PLANTS: ATLANTA PLANT FROM 2/11/00 THROUGH 7/31/00; CHICAGO PLANT FROM 2/14/00 THROUGH 8/4/00; KANSAS CITY PLANT FROM 2/26/00 TO 9/4/00; KENTUCKY TRUCK PLANT FROM 2/18/00 TO 8/31/00; MICHIGAN TRUCK PLANT FROM 2/23/00 THROUGH 8/3/00; NORFOLK PLANT FROM 2/21/00 THROUGH 7/27/00; WAYNE STAMPING AND ASSEMBLY PLANT FROM 2/25/00 THROUGH 8/15/00; AND WIXOM PLANT FROM 2/15/00 THROUGH 8/8/00.
Consequence: LOSS OF VISIBILITY WHILE DRIVING INCREASES THE RISK OF A CRASH.
Remedy: DEALERS WILL INSPECT THE DATE CODE ON THE WIPER MOTOR. MOTORS BUILT WITH THE SUSPECT TIME FRAME WILL HAVE THE WIPER MOTOR GEAR CASE COVER REPLACED. OWNER NOTIFICATION BEGAN AUGUST 20, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-866-436-7332.
TIRES:TREAD/BELT · 01X001000
2001-05-22
THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY.
EQUIPMENT DESCRIPTION: FORD IS REPLACING ALL FIRESTONE WILDERNESS AT 15, 16, AND 17 INCH TIRES MOUNTED ON FORD TRUCKS AND SUVS. FORD REPORTS TREAD SEPARATION CAN OCCUR DUE TO A COMBINATION OF THE SENSITIVITY OF THE TIRE DESIGN TO STRESS, AGING, AND MANUFACTURING DIFFERENCES BETWEEN PLANTS. FORD IS REPLACING THESE TIRES TO PREVENT POSSIBLE PREMATURE TIRE FAILURE.
VEHICLE DESCRIPTION: THE VEHICLES LISTED BELOW MAY HAVE BEEN ORIGINALLY EQUIPPED WITH FIRESTONE WILDERNESS AT TIRES OR MAY HAVE HAD WILDERNESS AT TIRES INSTALLED DURING THE FIRESTONE RECALL LAUNCHED IN AUGUST 2000.
CERTAIN 1991 THROUGHT 2002 FORD EXPLORER
CERTAIN 2001 THROUGHT 2002 EXPLORER SPORT, AND SPORT TRAC
CERTAIN 1997 THROUGH 2002 MERCURY MOUNTAINEER
CERTAIN 1991 THROUGH 2001 RANGER
CERTAIN 1999 THROUGH 2001 EXPEDITION
CERTAIN 1991 THROUGH 1994, AND 1997 MODEL YEAR F-SERIES
CERTAIN 1991 THROUGH 1994 BRONCO
NOTE: BOTH ORIGINAL EQUIPMENT AND REPLACEMENT TIRES ARE AFFECTED.
Consequence: SHOULD THE TREAD SEPARATE AT HIGHWAY SPEEDS, A VEHICLE CRASH COULD OCCUR, POSSIBLY RESULTING IN PERSONAL INJURY OR DEATH.
Remedy: THE REPLACEMENT/REIMBURSEMENT PROGRAM FOR THIS CAMPAIGN EXPIRED ON MARCH 31, 2002. HOWEVER, CUSTOMERS CAN CONTACT FORD AT 1-877-917-3673 OR GO ON-LINE TO WWW.FORD.COM FOR POSSIBLE ASSISTANCE.
VEHICLE DESCRIPTION: CERTAIN SPORT UTILITY VEHICLES, PICKUP TRUCKS, AND PASSENGER VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FMVSS 225, "CHILD RESTRAINT ANCHORAGE SYSTEMS." THE AFFECTED EXPEDITION/NAVIGATOR OWNER GUIDES DO NOT IDENTIFY THE LOCATIONS OF SEATING POSITIONS EQUIPPED WITH TETHER ANCHORAGES, AND DO NOT PROVIDE INSTRUCTIONS FOR SECURING CHILD SEATS TO THESE TETHER ANCHORAGES. THE F150 SC OWNER GUIDES DO NOT PROVIDE THE PROCEDURE FOR SECURING CHILD SEATS TO THE TETHER ANCHORAGES. THE TAURUS/SABLE OWNER GUIDES DO NOT IDENTIFY THE CENTER REAR SEATING POSITION AS HAVING LATCH COMPATIBLE LOWER ANCHORAGES.
Consequence: IN THE EVENT OF A CRASH, THE CHILD SEAT MAY NOT BE PROPERLY ATTACHED INCREASING THE RISK OF INJURY TO THE CHILD.
Remedy: OWNERS WILL BE PROVIDED WITH OWNER GUIDE INSERTS REVISED TO PROVIDE THE REQUIRED INFORMATION, AND INSTRUCTIONS FOR AFFIXING THESE INSERTS TO THEIR OWNER GUIDES. CUSTOMERS WILL ALSO BE ADVISED THAT IF THEY PREFER, THEIR DEALER WILL AFFIX THE INSERTS TO THEIR OWNER GUIDES.
TRAILER HITCHES · 00V073000
2000-03-07 · PE99060
VEHICLE DESCRIPTION: MULTI-PURPOSE VEHICLES. THE TRAILER HITCH ASSEMBLY TO THE FRAME ATTACHING BOLTS COULD LOSE THE CLAMP LOAD.
Consequence: THE TRAILER HITCH COULD THEN SEPARATE FROM THE VEHICLE.
Remedy: DEALERS WILL REPLACE THE TRAILER HITCH MOUNTING BOLTS AND NUT PLATES.
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