Was just looking into buying a 2004-2006 expedition. Anything specific I should know? Any years I should stay away from? Any feedback would be greatly appreciated. Thanks.

 

I don't have one in that year range so I'm no expert but 2 things I've heard about frequently are cam phasers and the spark plugs breaking when trying to remove them. I have a 97 so mine just blows the plugs out lol. I'm sure somebody else will chime in soon.

 

The 2 PC plug started in 2005 with the 3 valve engine. You might check that these plugs were replaced with the newer 1 pc before purchasing.
The advantage is a bit more power with the newer engine.

 

Here's the TSB on the spark plug issue.

http://www.aa1car.com/library/ford_tsb_08-7-6.pdf

 

Following.
I also heard the 04-06s go through transmissions like crazy. I wasnt a fan of the build quality on the 07.

 

Ok so as long as its had plugs recently I should be ok? Also how can I tell if it needs cam phasers? I've heard there may be some rattling at lower RPM? Thanks again for the help.

 

Since the 04's had a 4r70w and the 05's went to a 4r75e, which one?

I know they aren't the good old 4r100 that went into my rig or many F series.

 

I bought a new 2003 Expedition in 2003. I have 205,000 miles on the original 5.4L engine and it still runs good. However, there are some common problems with this generation of Expy's.

1-The factory Intake manifold tends to blowout, causing the numerous problems and the potential to burn up the engine. The 1st sign is usually a missing cylinder. The car stutters, very obvious. This is because the, what appears to be the laminated pressboard manifold, has blown at the back right. Coolant leaks into the coil packs causing the miss.
Here's the blowout on the factory manifold. If you look closely you can see the pressboard laminations.


The fix is repairing with a Dorman aftermarket plastic manifold. I had the original manifold replaced at around 140K miles. Unfortunately, the mechanics replaced it with a stock manifold. I installed a new Dorman myself at just under 205K. I expect this one to work where the factory piece failed.

2- Turn on the heater in the rear and heat a thumping sound. The blend door inside the plastic in the right rear compartment has stripped gears. There's an aftermarket piece you can find on amazon & ebay for around $30.00. Easy fix

3- Door open switches tend to stick over time resulting in not being able to start the car, or if it happens after you start driving, the Door open indicator lights up and you hear that annoying chiming. New switch runs $30.00 or so but be ready for frustration installing it yourself. I did it but it's awkward.

4- Battery life. There is some flaw in the factor wiring harness from the alternator to the battery. I've had to replace batteries at about twice as often as normal. I recently found a thread that identifies the issue and provides a part# for the fix. I have ordered the cable, it's about $40.00, but haven't received it yet. I will post results to the forum.

5- Leather Seats. The leather seat cushions tend to wear quickly and tear. I just replaced mine after living with it for years. I found the cushion at an online Ford dealership for right at $100.00 including shipping, and purchased a new leather cover from The Seat Shop for right at $200.00. The Seat Shop has videos for installing the new covers on their website so installations was fairly simple.