I have a 2004 Ford Expedition Eddie Bauer 4x4 model w/ 62,000 on it. I have had it in the shop for several things they can't seem to fix and am wondering if anybody else has had these problems

1. When the engine is cold (sat outside in fall/winter) and there is load applied (just normal acceleration - driving on a regular street), I hear what sounds like an exhaust leak from the front driver side area. It is a raspy sound that increases and decreases w/ engine RPM. This goes away after just a few minutes - thus the mechanics can't seem to track it down.
<O</O
2. My driver seat inner side support touches the center console lid and makes a rubbing noise. The dealer said the seat cushion had lost elasticity w/ normal use and needed to be replaced. My Ford Premium Warranty won't cover this. I am considering ordering the parts and doing this myself.
<O
3. Piston Slap - I do have this, and don't think anything can be done about it. The dealer said it is normal and produced a TSB stating so from Ford. My buddies 03 model doesn't do it as much as mine does, and the rental models I had didn't do it at all. I run Motorcraft 5W20 and the 820S filter

4. Key fobs stop working - Randomly. I can go for several weeks w/ no problems, then all of the sudden the key fob won't lock/unlock for several minutes to several hours. The batteries have been changed in the key fobs and the dealer can't replicated this.<O

Thanks in advance! I had hopes of this thing lasting till 200k, but if all the repairs keep coming, I won't be able to keep it that long. We do use it off road, towing, ranch driving, city driving - so it probably has "heavy" use than most do, but it is nothing outside of its ratings.....<O

 

Scott,

I haven't had any problems that you are having but I have been having an intermittent starting problem though. My 04 has 52k miles on and I have the premium care warranty as well. Well because my problem is intermittent and the dealer can't replicate when they want to they are refusing to fix it despite the fact that the service manager says he has experienced once but not again during the two weeks that they have had my truck.

Don't let them off the hook when they say that they can't duplicate your problem. You told what the issue is and they should be able to trouble shoot your problem. If that calls for them replacing parts then so be it because your truck is under warranty and never had that problem before. How else are they going to fix your problem if they have to wait for it to happen again. In the mean time you can't afford to sit at their service department until it happens again. Then they try it once, it doesn't happen, then you get it home it does. Because they can't hook it up to a machine or directly pin point your problem, it sounds to me like they are not willing to really trouble shoot and fix your problem.

I am going thru the same thing now with this starting problem on my truck and I have escalated it up to the Ford Motor Company for help. There are things that these services departments are supposed to be doing but they are not because either they are lazy or it's not direct cash coming straight into them that day so they don't want to be bothered. If your truck was not under the Premium Care Warranty and you had to pay them straight cash out of pocket, they'd have all of your problems fixed.... i have been in communication with two different Ford Techs and they ran down a list of things that the dealership should be doing but they are not. Also, they said that it appears that they are giving me the run-around because my truck is under warranty.

 

#1 sounds like you might have a exhaust manifold problem. It leaks when it's cold and closes up when it warms up.
#2 You could try switching to 5w30 and see if that helps any.

 

I've told the dealer that I think it is an exhaust manifold gasket leak. They still haven't done anything.

I have tried 5W30 in the past and it still does it...

To top it off, my backup sensors stopped working yesterday!

Thanks for the help.

 

The guys really seem to be trying to help, but say things like "We can't just replace a part on a hunch"... They have heard the noise, but can' find it by the time it stops.

I have also esclated it to Ford, but all they said is I might be able to talk to the zone rep about a really good deal on a trade.

I might try another dealer (this will be the third one)

I am SO fed up with this thing, and I would really like to get rid of it... The problems with that are, its paid for - and I won't have another payment - we need the seating space, and there is not another vehicle comparable (that the seats fold flat)...

Seems like I should just be happy because I have something that always has started, is paid for, is relatively nice, etc... However, I bought it new with the intent of driving it a few hundred thousand miles. It currently has about 62 on it, but should have about 70. I have put that many miles on rentals!

 

I know some of the tritons makes a bit of what sounds like a tick/tapping noise from the cat converters. And it's more noticeable when cold. Its a tsb that falls under f150s and some expys. Also try full synthetic oil like mobile, castrol, or penzoil.

 

As far as the driver's seat rubbing against the arm rest, mine does it as well, 2005 with 23k onit....I lubed the side of the seat with a vinyl protectant as well as the arm rest about a month ago, and it is still quiet. It drives me nuts as well. Maybe give this a try befor the replacement..??

 

I don't know what they did, but they did "fix" the armrest.

I've since been back in to get the backup system fixed. One of the sensors went out... Another $50 deductable.