Not to cut in. I tried a private message but found no option.Do you recall what the $10 part was in the transfer case?
Mine is experiencing same problem. Can it be repaired in vehicle or do I need to pull it out of vehicle.

My 1999 Navigator has 136,758 . Replaced Elbow vacuum, balljoints. Trouble with 4wd at present.

 

2003 Expy EB 91000 miles Bought a little over 2 years ago. I had a spark plug blow out of the engine. $4500. Drivers side window broke. $400 Fuel pump loosing pressure. New fuel pump $500. Auto seat, mirror memory module bad. $500. I bought an exended warranty for 1600 and it covered all the above repairs. I just had to spend $500 for a front air bag sensor module that went bad. Ford didn't coat the sensor wiring with electric grease to prevent corrosion. After all the money spent, I still luv my EXPY.

Mike

 

Say what? First off, 2001 was the last year for spark plug blow outs. Starting in 2002, more threads were added to the plug holes to prevent this from happening. Second, no one would ever pay $4,500 to have a spark plug hole repaired...you can change the entire engine for that kind of money.

Count your blessing that you have a warranty to cover the costs, but once it runs out, you'll also want to run out...of that repair shop that is.

 

2000 5.4 2X4 EB Exp, 198,000 miles, replaced plugs and COP's once (about 50,000 miles ago), replaced alternator once, rear axle seals once (last week), going to replace the pinion seal this weekend (should have replaced it last weekend when I did the axle seals), upper and lower ball joints and tie rod ends at 110,000 miles (went with greasable Moogs and don't expect to have to do that job ever again). No motor or transmission work needed other than fluid and filter changes. I am very hard on vehicles and my Exp has held up better than I could have ever hoped for. I have loved this truck and it has been the best vehicle, bar none, that I have ever owned.

 

154,980 origanal everything, change oil every 3000k and service tranny at 30000k miles

 

2000 5.4 XLT with 85,000 miles, no major problems at all, just regual maintenance.

 

'98 expy xlt 4x4 5.4. with 62,xxx miles on her as of today. few minor issues i wanna fix otherwise mint.

 

2001 Expedition XLT 2wd. . 5.4L with 238,000 and still going strong. Recently had the rear axle rebuilt, front wheel bearings replaced. Original motor still knocks at cold start (same as day one). Odometer goes out sometimes, rear wiper works sometimes, rear washer leaks so i disconnected it and plugged it so i dont lose my windshield washer fluid and now it only operates the front windshield (which is ok). A vibration issue when i get past 70mph (cant find a tire store that can solve that problem yet).

 

1997 4x4 w/ 214,000 miles. Still going strong but probably needs front wheel bearings/hubs.

 

2004 5.4L 2WD XLT ... I have put 109,500 miles on it, never towed anything.
MSRP was 35,930, paid 29,600 driveout in March 2004.

had numerous problems at first but got most of them fixed/worked out by Ford:
- dealer replace all four crappy Continentals, out of round at 600 miles!
- replaced rear-end assembly/ring&pinion gear, had constant grinding noise/humm at 4k miles
- replaced stereo/6cd unit - CD's were HOT!! when ejected
- windshield washer low fluid light kept coming on, faulty sensor
- dark gray moulding along bottom sides, replace - fading from sun at 55k miles
- windshield washer sprayer not working
- replaced Alternator at 87k and A/C vacuum hose (cost $510)

now at 109k miles and my Service Engine soon light is coming on... have a slight hesitation issue at 50-60 mph, almost as if the transmission thinks about shifting but doesn't, a few times.

 

Sorry to hear about some of small irritating things that went bad on your vehicle, but this is exactly why I refuse to buy a new vehicle. You pay 30 grand for a truck and within 100k miles, all of this crap happened - and its all the small stupid crap too! It's like the electronics used just get cheaper and cheaper and so does the quality of materials used. Sorry to rant and use you as an example, but when I read of all the small stupid things that fail, I find the irritation not in Ford owning up and replacing items under warranty, but the fact that you have to schedule an appointment, drop the vehicle off, wait for the diagnosis and solutions, etc, deal with a crappy rental, the works. OK, I'm done!

Hmm...fuel injectors? I had a hesitation on acceleration at highway speeds and when I pulled the injectors, 3 of them had hairline cracks at the tips.

 

1997 Expedition Eddie Bauer 4x4 8cyl 5.4L - 92000 Kms

Bought it 2 weeks ago from someone selling it on behalf of the owner who left the country. Don't have much history on it, but it was a bargain, and I felt I could get whatever issues there were fixed up. Overall its in good condition and I love it!

Issues that I'm currently looking at getting fixed:

• 5 x 5 beeps. SRS air bag light does not come on at the start or at any point. I'm hoping this is just a case of looking at the circuit / wires to that light or replacing the light in the dashboard
• Overdrive light has started flashing and transmission slips / jerks when shifting from 1st to 2nd and back when its hottest outside in the day (40C +) Its there when its cooler but less noticeable. I've changed tranny oil but no luck. I'm hoping its a TTC solenoid or some thing other than needing to replace the whole transmission :/ Have a thread here asking for advice when I take it in: https://www.ford-trucks.com/forums/8...-slipping.html

 

1997 Expedition 2WD XLT 5.4L V8 (Full leather with towing package) - just went over 230K. With exception of heater core (which has had to be replaced twice), have had no real "major" issues ...

Purchased in 1999 with 32K ... replacements/upgrades since (in no particular order and many I did myself):
- upgraded radiator to heavy duty aluminum (from F350)
- replaced/upgraded rear air suspension with spring coils
- replaced alternator @150K miles
- replaced heater core (twice)
- replaced upper and lower ball joints and tie rod ends
- driver's side window regulator

May seem like alot of stuff but actually it's not ... she's been pretty good to me over the years ...

Items on the "soon-to-do-list" (before the end of the year):
- finally going to fix the dashboard ghosting issue this weekend (thanks to this forum)
- installing cold air intake
- considering installing an oil cooling system (heard those really help with engine life)
- sizeable exterior/interior mods (paint job, chrome replacements, replace carpet, upgrading Captain's chairs to "higher" back seats (Lariat style) with Katskinz covers, upgrading sound system and alarm system, etc.)

 

I only have two things to keep in mind ....preventive maintenance and synthetics....my signature doesn't lie.

 

I feel you on the synthetics (did that about 3 years ago and has worked beautifully) and I'm "learning as I go" about preventative maintenance ... just got her outta the shop for the suspension conversion and plan on being much more proactive with her in regards to that ...