2004 Ford Expedition

2004 Ford Expedition

Overview

The 2004 Ford Expedition, a full-size SUV, offered robust towing and passenger capacity, making it a popular choice for families and those needing utility. It was available with a choice of powerful V8 engines and a reliable transmission. While generally considered a solid vehicle for its era, like any vehicle, it has specific areas where owners have reported issues. This analysis focuses on common mechanical and electrical concerns beyond routine maintenance, providing insights into potential reliability challenges for prospective buyers or current owners.

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Engine

4.6L Triton V8

Intake Manifold Gasket Leaks

• Symptoms: Coolant leaks, engine misfires, rough idle, overheating.
• Solution: Replacement of the intake manifold gaskets.
• Cost: $400 - $700

Spark Plug Blowout

• Symptoms: Engine misfires, loss of power, ticking noise from engine.
• Solution: Requires specialized tools for extraction and replacement, often with thread inserts.
• Cost: $500 - $1000

5.4L Triton V8

Spark Plug Blowout

• Symptoms: Engine misfires, loss of power, ticking noise from engine.
• Solution: Requires specialized tools for extraction and replacement, often with thread inserts.
• Cost: $500 - $1000

Camshaft Synchronizer (Cam Sync) Failure

• Symptoms: Rattling noise from the front of the engine, especially on startup or at idle.
• Solution: Replacement of the camshaft synchronizer and potentially the camshaft phaser.
• Cost: $600 - $1200

Exhaust Manifold Stud Breakage

• Symptoms: Exhaust leak noise (ticking or puffing sound) from the engine bay, especially when cold.
• Solution: Drilling out broken studs and replacing with new ones, often using high-temperature hardware.
• Cost: $400 - $800

Transmission

4R70W (4-Speed Automatic)

Torque Converter Clutch (TCC) Issues

• Symptoms: Shuddering or slipping during acceleration, P0741 code.
• Solution: Replacement of the torque converter.
• Cost: $700 - $1500

Overheating and Fluid Leaks

• Symptoms: Transmission slipping, delayed shifting, burning smell, visible fluid leaks.
• Solution: Repair or replacement of transmission seals, cooler lines, or internal components.
• Cost: $1000 - $3000+

4R75E (4-Speed Automatic)

Overheating and Fluid Leaks

• Symptoms: Transmission slipping, delayed shifting, burning smell, visible fluid leaks.
• Solution: Repair or replacement of transmission seals, cooler lines, or internal components.
• Cost: $1000 - $3000+

Solenoid Pack Failure

• Symptoms: Harsh shifting, transmission not shifting into certain gears, P0750-P0760 codes.
• Solution: Replacement of the transmission solenoid pack.
• Cost: $500 - $900

Suspension

Standard Chassis

Ball Joint Wear

• Symptoms: Clunking noises over bumps, uneven tire wear, steering wander.
• Solution: Replacement of worn ball joints.
• Cost: $300 - $600

Sway Bar Link Bushing Deterioration

• Symptoms: Rattling or clunking noise when going over uneven surfaces or turning.
• Solution: Replacement of the sway bar link bushings.
• Cost: $150 - $300

Electrical

General Electrical System

Instrument Cluster Failures

• Symptoms: Gauges not working, flickering lights, dead pixels, intermittent power loss to cluster.
• Solution: Repair or replacement of the instrument cluster.
• Cost: $400 - $800

Window Motor Failures

• Symptoms: Power windows not operating, slow window operation.
• Solution: Replacement of individual window motors and regulators.
• Cost: $200 - $400 per window

Exterior

Body and Trim

Rear Hatch Latch Issues

• Symptoms: Difficulty opening or closing the rear hatch, latch not engaging properly.
• Solution: Lubrication or replacement of the rear hatch latch mechanism.
• Cost: $200 - $400

Interior

HVAC System

Blend Door Actuator Failure

• Symptoms: Inability to control temperature (stuck on hot or cold), clicking noises from dashboard.
• Solution: Replacement of the blend door actuator(s).
• Cost: $250 - $500

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Summary Verdict

The 2004 Ford Expedition, particularly with the Triton V8 engines, is known for potential issues like spark plug blowouts and intake manifold gasket leaks on the 4.6L, and cam sync/exhaust stud problems on the 5.4L. Transmission reliability is generally decent, but torque converter clutch issues and overheating can occur. Electrical components like the instrument cluster and window motors are also points of concern. Suspension components such as ball joints and sway bar links may require attention. While not plagued by widespread catastrophic failures, owners should be aware of these common repair areas. Regular maintenance and prompt attention to early symptoms can help mitigate more significant problems and costs.