2004 Ford Expedition Repair and Maintenance

A guide to problems, costs, maintenance and repair for your 2004 Ford Expedition

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2004 Ford Expedition Problems

Rough Idle Caused By EGR Sensor Sticking

Intermittent rough idle may be caused by the EGR sensor sticking, causing the EGR valve to stay slightly open. Our technicians tell us the valve and sensor must be replaced together to correct this concern.

Check Engine Light due to worn spark plugs

An illuminated Check Engine Light may indicate that the spark plugs are worn; this will cause intermittent misfire and damage to the coil packs.

One or More Spark Plugs May be Ejectioned From the Cylinder Head

There is a technical service bulletin for the V8 engines regarding a possible problem with the spark plug being ejected from the cylinder head, damaging the threads in the spark plug hole. If the vehicle is under warranty, cylinder head replacement is recommended. If the vehicle is out of warranty, Ford authorized the use of a specific thread insert to repair the head.

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2004 Ford Expedition Reviews

This is another one for the good reviews column. I have a 2004 Expedition that currently has 357,000 miles on it. Other than normal wear it has been a phenomenal truck. It is out of service now because it has blown the same spark plug out for the third time, resulting in it needing to have the head replaced (or another engine). Overall, an excellent truck - however, I admit I replaced t...
I've owned my 04 Eddie since 2006. Had the hood and rear door repainted because of bubbling paint on the front edge of hood and around the inside of rear door and outside handle. I called Ford in 08 about the problem and they stated they only warranty their paint for 3 years. Wow! Not impressed. Had 1 bubble spot come back on hood due to obvious aluminum contamination. No warranty on that! I ...
I have a 2004 Expedition that I purchased in October of 2005 with only 1600 miles on it. It's now 10/17/2012 and I have over 121,000 miles on it, and KNOCK ON WOOD, it is running perfectly! Aside from the normal wear and tear that a car goes through and a hole on the roof of the truck that I am going to get fixed. I ABSOLUTELY LOVE my Expedition!

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