Ignition Coil Failure Due to Excessive Spark Plug Gap on Ford Expedition

An illuminated Check Engine Light could indicate that one or more of the ignition coils has failed due to excessive spark plug gap. To fix this problem, the ignition coils that have failed, the spark plugs, and all coil boots should be replaced.

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Average mileage: 128,212 (11,002–240,000)
Engines affected: 4.6L V8, 5.4L V8
13 model years affected: 1997, 1998, 2000, 2001, more2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
67 people reported this problem
30 people shared problem details
when you get the sprrd up to 40 mph it feels like it starts skipping and you speed up it stops
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All of a sudden no power and my engine was backfiring. Had the computer checked and 3 ignition coils came up bad along with the oxygen sensor. No problems what so ever before this. Art Hill Ford quoted me $280.00/Ea to replace the sensors. WOW!! No Thanks. Checked on the part and they cost $40.00/ea plus you have to remove 1 screw to get the coil out. Takes about 5 min. per coil.
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Spark plugs have been changed and the coils have been changed too but the check light keeps coming on!!!!
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2003 Ford Expedition- 5.4L V8
The ignition coils are always going bad. Very frustrating.
2003 Ford Expedition- 5.4L V8141,000
Check engine light came on and read #4 cylinder misfire at start-up. Shop replaced #4 spark plug and ignition coil. $250. Said rest of the spark plugs could be put off for now to save money.
1997 Ford Expedition- 4.6L V8200,000
misfire on #1 cyl code 301...changed plug 2months again code 301 misfire... changed coil pack... all good 6mo
Shuddering hesitation when accelerating and very low power. Check engine light went on after a few weeks of this(flashing initially, then full on). when I let it idle for 30 minutes, the engine light went off completely, but still hesitates badly. Others have said just replace the spark plugs. They apparently break often on this vehicle and minimum cost is $450 before using the tool specially designed to remove broken plugs, which I'm told has meant a $1200 tune up for others. I should also mention that I bought the truck 5k miles ago from Suburban Ford in Sterling Heights, MI.
2005 Ford Expedition132,000
Hesitates when driving on the freeway reaching 40mph. Jerking motion.
hesitation when accelerating....all sparkplugs replced & coil...$850 at Ford!
1997 Ford Expedition- 5.4L V8139,000
Had to trade in because Ford stated that the motor was gone.
constant coil replacment
Coil pack was replaced all 8
2005 Ford Expedition- 5.4L V8123,000
All the plugs and coil packs were replaced now I have a knocking noise sound like it's coming from the intake
2000 Ford Expedition- 4.6L V8200,000
One engine coil 2nd from back on passenger side keeps blowing up. I have not replaced all the plugs coil which would be ideal. But l am getting ready to replace that coil boot for a third time.
2006 Ford Expedition- 4.6L V8
4,5 spark plug plus oxygen sensors need replaced.
2008 Ford Expedition113,000
Engine starting skipping or spuddering...check engine light came on and would blink periodically. When you speed up the problem seems to go away. Went to Firestone Auto Care and they replaced one spark plug (still under warranty) because I had all of them replaced less than a year ago. Spark plugs are an issue in this car, they have to have a special tool to remove them because they break easily - Ford aware of the problem and provides specific instructions for removing them. Misfiring of spark plug weakened one of the ignition coils so they replaced that. Less than $200 to fix. If you live in the central ohio area I recommend Firestone Auto Care on State Street in Westerville...I take all of our family vehicles there and they are great.
1997 Ford Expedition- 5.4L V8200,000
ran rough, miss-fire code replaced coil, spark plug and cap
Purchased the vehicle December 3 20014 has a 3 month power train warranty on vehicle check engine light came on and started missing very bad called place where I bought vehicle they said to bring it in but 159 miles to dealership they gave me number of the wrecker service they used called them they towed it to dealership looking over paperwork they replaced number 5 spark plug and coil for same problem now it is number 6 spark plug and coil but charging me 790 dollars 450 for the wrecker and 340 for parts and labor so ill right now should be under power train warranty but they saying no
Rainy day, hit a puddle near a corner (though not any deeper than about 6in) whilst turning at 10mph. CEL came on, flashing and alternately staying on at speed. Got worse over 2 days (dealer would not fix - Easy Credit Auto, OKC, OK), so I had to wait the weekend and drive across town to have repair done. O'Reilly Auto said code reader showed 2 plug packs back, but the mechanic who worked on it (the Credit Auto dealer warranty garage) 'repaired a leaking coolant line, removed, cleaned & regapped the plugs'. Engine is now running fine, but I'm most confused by all this!
Spark plugs were gapped to spec and I still get misfires. A new part only lasts for a short time, then the misfire comes back After having the same thing happen over and over, I decided to try a different coil, since there were a couple of cylinders that it happened on more often. I tried 2 Accel super coils in their spots, the first has been in for about 2 months, the other about 2 weeks. the problem went away and has not come back, and the engine runs a lor better.
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