NHTSA Complaint #10216315 — 2003 FORD EXPEDITION

THERE WERE NO SYMPTOMS LEADING UP TO THE FAILURE. MY 2003 FORD EXPEDITION MADE A LOAD POP NOISE AND THEN CONTINUED TO MAKE A LOUD BUT MUFFLED POPPING SOUND UNDER THE HOOD. I IMMEDIATELY PULLED OVER AND SHUT OFF THE ENGINE. I HAD THE TRUCK TOWED TO MY LOCAL FORD DEALERSHIP WHERE THEY DIAGNOSED THE PROBLEM. THE PROBLEM WAS THE # 3 SPARK PLUG HAD "BACKED OUT" OR WAS "SPIT OUT" OF THE ENGINE HEAD. THE ESTIMATED REPAIR COST TO REPLACE THE HEAD WAS $3,500.00. A LESS EXPENSIVE FIX OF $700 - $800 TO RETHREAD THE HEAD FOR THE #3 SPARK PLUG, BUT WITH NO GUARANTEE HOW LONG IT WOULD LAST. THE REASON FOR THE COMPLAINT IS THAT AFTER HAVING MY VEHICLE REPAIRED I FOUND OUT THROUGH A FRIEND THAT THIS WAS NOT AN ISOLATED INCIDENT. AFTER RESEARCHING ONLINE I FOUND THAT HUNDREDS OF PEOPLE HAD THE SAME PROBLEM WITH THE #3 SPARK PLUG. EVEN THE SERVICE MANAGER AT THE FORD DEALERSHIP TOLD ME IT WAS AN ISSUE AND A POOR DESIGN ON FORDS PART. HOWEVER, FORD IS NOT TAKING RESPONSIBILITY FOR THE PROBLEM - LEAVING IT'S CUSTOMERS WITH A HEFTY REPAIR TO SAY THE LEAST. I ALSO FILED A COMPLIANT DIRECTLY TO FORD HEADQUARTERS. *TR