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Ford Expedition Engine Replacement Cost – How Much Will I Have To Spend?

The Ford Expedition is a full-size, three-row SUV produced and manufactured by Ford Motor Company. First introduced in the 1997 model year, this model was the first full-size Ford SUV with a four-door body. Despite the modern styling and performance, the high Ford Expedition engine repair cost deters some users from buying this car – owners might have to pay over $4,000!

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The Expedition has been produced for over two decades and spans four generations, with the model available in either a rear-wheel-drive or front-wheel-drive option.

Ford Expedition Engine Types

First Generation

The engine type used in the first generation Ford Expedition is a 4.6-liter Triton 16V V8 or a 5.4-liter Triton 16 V8, with the Triton 16V being an overhead camshaft small block engine. Part of the Modular engine overhead camshaft V8 and V10 gas-powered lineup, this engine is used in various Ford vehicle platforms, showing the popularity on the market.

The Triton can produce 215 horsepower and provide 290 pounds-per-foot of torque, making this a powerful and high-performance engine. Unfortunately, the horsepower output does not make up for the high Ford Expedition engine replacement cost.

Second Generation

The second-generation Expedition uses the same engine types, with the second 5.4-liter Triton engine available in a 24V V8 engine. The 24V engine is more powerful and performance-oriented than the previous model option, offering major changes and improvements from the first generation.

Both engines, the 4.6-liter, and the 5.4-liter, were changed in terms of design and overall efficiency. The Expedition, due to the engine changes, now qualified as an Ultra Low Emission Vehicle. This means that the car produces very low emissions levels compared to other vehicles on the road.

Furthermore, the second generation Expedition was certified under the EPA, showing environmental proficiency and its benefits. However, despite the fuel and environmental changes, the high Ford Expedition engine replacement cost was still a concern for potential buyers.

Other changes in the second generation included the 4.6-liter engine gaining an all-new cast aluminum engine block, improving the weight distribution and performance. Furthermore, the 5.4-liter engine earned new ribbing and bracing, helping reduce unwanted vibrations and noise while driving. The improved construction helped for a smoother, safer, and quieter ride.

Third Generation

The third generation of the Ford Expedition was procured from 2007 until 2017 and used the 5.4-liter Triton engine and a new 3.5-liter EcoBoost V6. The EcoBoost was used in the 2014-2017 models and was a turbocharged, direct-injection gasoline engine produced by Ford. The EcoBoost engine could produce upwards of 365 horsepower and 420-pound-per-foot of torque.

Even with these performance and power benefits, the high Ford Expedition engine replacement cost was concerning to some users who did not want to risk paying a hefty sum on an unreliable or underperforming engine.

Fourth Generation

The fourth generation of the Expedition only used the 3.5-liter EcoBoost V6 engine introduced in the previous generation. The 2018 Expedition’s engine uses a variable camshaft timing valve train and a 10-speed automatic transmission, providing seamless shifting and ample power transfer.

Furthermore, the engine provides 375 horsepower and 470-pound-per-foot of torque at around 5,000 RPM. with a compression ratio of 10:1, this engine is focused on performance – but sometimes forgets the hefty Ford Expedition engine replacement cost associated with high power outputs.

Ford Expedition Repair Cost Distribution

There are specific areas of the Ford Expedition that have a higher incidence rate of problem, regardless of the model year. This helps you figure out what area in the Ford Expedition is most susceptible to durability issues and concerns, helping you diagnose and analyze any problems you find in your vehicle.

The engine is the highest area of concern, having 31% of the vehicle’s most reported issues, while the air conditioning and electrical system comes in second at 28%. Furthermore, the suspension and transmission both equate to 12% of total car problems, while the brakes, trim, and body account for 6% of the problems in the Expedition.

As you can see, the engine concerns are the most prevalent and can cause the high Ford Expedition engine replacement cost compared to other vehicle areas. Repairs in the Expedition typically range between $100 and $499 on average, but certain areas, like the engine, have a higher replacement cost.

28% of repairs are less than $100, while 38% of repairs range between $100 and $499. Furthermore, the more expensive repairs and replacements are between $500 and $999 and account for 21%, while repairs over $2500 are only 3% of the reported repairs in the Expedition.

Lastly, the repairs necessary in the Ford Expedition vary depending on the model year. Expedition cars that were produced after the 2018 model year account for 0% of the repairs, showing how the Ford Expedition engine replacement cost severely diminished after engine problems were fixed. The majority of issues occurred between the model years of 2003 and 2006, accounting for over 50% of user concerns, while the model years 2007-2014 accounted for 30% of issues.

Worst Model Years of the Ford Expedition

When looking at the total Ford Expedition engine replacement cost, you must consider the worst model production years. This way, you can avoid purchasing unreliable and underperforming vehicles instead of focusing on safety and efficiency.

The worst model years of the Expedition are the 1999, 2000, 2003, 2004, and 2006 years, with the company seemingly doing most of the pressing issues after the 2008 model year. The most-reported problem is the spark plugs failing in the 2004 Expedition. This model year is also considered the worst production year due to the lack of reliability, high repair cost, and excess problems at low mileage.

Regarding the top three concerns in every single model year, the number one issue focuses on the transmission failure in the 2004 Expedition at around 76,000 miles. This problem costs owners around $2,700 to replace or repair the transmission. In addition, the second most severe problem is the engine shutting off while driving in the 2006 Expedition, costing owners around $700 for the Ford Expedition engine replacement cost.

Lastly, the third most common issue is the paint bubbling in the 2005 Expedition, costing owners around $400 to repair the exterior damage.

1999 Ford Expedition Engine Problems

The engine category was by far the most pressing in the 1999 Expedition. The NHS also cited various issues with the engine, cooling system, gasoline, vehicle speed control, cruise control, accelerator pedal, and linkages. Owners cited issues with the spark plugs blowing out of the socket, the head gasket breaking, the coils failing, the engine having a high rev at idle, and the engine stumbling upon acceleration.

Fixing the spark plugs will typically cost owners around $830 for the Ford Expedition engine replacement cost to replace the spark plugs, replace the coils, replace the timing chain, or repair the broken coils. Owners will have to carry out this repair at below 160,000 miles, with drivers complaining about the spark plugs blowing, the cylinder head cracking, and the car making loud noises while accelerating.

2000 Ford Expedition Engine Problems

In the 2000 Expedition, owners complained about the spark plug failure, the engine making loud knocking sounds, engine misfiring, the car stumbling upon acceleration, the car running roughly, a blown head gasket, and the engine catching fire.

To fix the spark plugs blowing out, owners will have to install the spark plugs, clean and replace the spark plugs, or replace the coils for around $250. The typical repair time is around 150,000 miles, showing the unreliability and high Ford Expedition engine replacement cost in this production year.

Furthermore, an even more expensive repair required in this model year is fixing the engine’s knocking sound for around $1,400. Owners will have to replace or repair the engine heads at below 100,000 miles.

2003 Ford Expedition Engine Problems

The worst issues in the 2003 Ford Expedition in regards to the high Ford Expedition engine replacement cost focus on the spark plug damage, engine shutting down and stalling, engine sputtering, faulty ignition coils, and the engine seizing while driving. Fixing the spark plugs is an expensive repair, with owners having to re-thread the spark plugs or replace the engine head for around $1,160.

Regarding the engine stalling and shutting down while driving, owners need to replace the fuse box for around $610 and nearly 152,000 miles.

2004 Ford Expedition Engine Problems

The 2004 Ford Expedition is sometimes considered the worst model year due to the severity and prevalence. However, some of the engine concerns have been remedied since the previous model years, with the majority of complaints in this production year focusing on the paint and transmission concerns.

However, the top owner issues with the engine deal with the spark plug failing, the car randomly cutting off, the engine running rough, and the car turning over but not starting. Repairing the spark plugs costs owners around $1,750 to install a new Helicoil, spark plug, coil, and cable in their vehicle.

2006 Ford Expedition Engine Problems

Unfortunately for Expedition owners, the engine concerns have still not been fixed in the 2006 production year. The top issues are the engine shutting off during use, difficulties in changing spark plugs, the engine running very roughly, the engine stalling and shutting off while driving, and the ignition coil failing.

The average Ford Expedition engine replacement cost for the engine shutting off while driving is around $720 to replace the throttle body or replace the throttle body sensor at nearly 83,000 miles.

2008 Ford Expedition Engine Recall

In early 2008, Ford Motor Company recalled certain 2006-2007 E-150, E-250, E-350, and 2007 Expedition and Lincoln Navigator vehicles. All of the affected model years contained the same 5.4-liter engine that could potentially leak depending on the durability and construction of the cross-over hose. As a result, the hose could crack and cause a fuel leak, leading to a high Ford Expedition engine replacement cost.

If the fuel leaks in the presence of a hot area, ignition source, or area of excess friction, it could cause a potential fire and unsafe driving situation.