The Expedition SUV is a great value family hauler based on the best-selling Ford F-150. In production for 25 years, which years are best, and which are the worst?
Pickup trucks with closed bodies have been around since before Ford launched the Bronco in 1965. Cars like the first Range Rover and Jeep Wagoneer, took the concept upmarket and made it luxurious.
In 1990, Ford launched the Explorer, and it was a runaway sales success that opened up the market for SUVs. Due to the success of the Explorer, Ford decided to create a bigger brother: the Expedition.
Although available with four-wheel drive, Ford Expeditions are more likely to be two-wheel drive. The competition includes GMs Tahoe/Suburban/Yukon models and the Toyota Sequoia.
Which Year Ford Expedition Should You Avoid?
If you are thinking of buying an Expedition, it is important to look at the overall condition and level of care that particular vehicle has received more than particular model years. This is especially true with older, higher mileage, and lower-priced trucks.
A report by iSeeCars titled “Longest-Lasting Cars to Reach 200,000 Miles and Beyond” had the Expedition as number four in their list of the 10 longest-lasting vehicles, noting that nearly 5% of Expeditions had more than 200,000 miles.
Many model years of Expedition experienced no recalls (M.Y. 2010-11, 2013-17), something which is very unusual because modern cars are so complicated.
However, many Expeditions came with Ford’s 5.4-liter Triton V8, which has significant, well-known reliability issues discussed below. Expeditions made after 2015 use a new twin-turbo V6, so by looking at a more recent Expedition you avoid the issues of the 5.4.
If you are looking at an Expedition with a 5.4-liter V8, the best way to avoid problems is to buy one which has been well looked after. If it has had regular oil changes, 250,000 miles or more are possible.
Specifically, early 5.4-liter motors, with two valves per cylinder, have been known to spit their spark plugs out of the engine block as they are driving!
So, when Ford launched the new, three-valve version of the 5.4-liter in 2005, they used a new design of spark plug, with a much longer shank, to be sure of keeping it in the engine block.
Unfortunately, this often works too well: when you try to change the spark plug, they can break, with bits remaining stuck in the engine block. Removing these broken, stuck plugs then becomes a very frustrating, expensive job.
The best way to avoid this broken spark plug issue is to buy an Expedition that has had regular oil changes and new spark plugs recently fitted. However, if you do have to change the plugs, there are some things you can do to help get the plugs out.
First, run an internal engine cleaner to break down any corrosion inside the cylinder. Something like WD40 will do.
Making sure you have a proper spark plug wrench that snugly grips the plugs also makes a difference. The final thing you should do seems counterintuitive: You should change the plugs when the engine is warm.
An alternative to the 5.4 is the 4.6-liter Ford offered the Expedition between 1996 and 2005. This engine makes less power than the more common 5.4, however, it was found in Mustangs and Crown Victoria cop cars, and is generally a super-strong motor as proven by this 339,000-mile Expedition.
The Expedition shares many parts with the F-150 and other Ford models meaning spare parts are easy to find and affordable. A mechanic working on your Expedition is likely to have done that job many times before.
Ford Expedition First Generation (1997-2002)
Early Expeditions which have been well looked after represent outstandingly good value for money. They offer V8 power, a comfortable ride, and seating for eight, even nine in early models with bench front seats, yet they are only worth between $2000-5000. This space and luxury comes at the price of fuel economy, which is 13 mpg.
An owner with a strong running 20-year-old 339,000-mile example that still has good paint, reports a chipped or warped flywheel, and a radiator that needed replacement. His anti-lock brakes and airbag warning lights are on, too.
Other than that he has followed the maintenance schedule, replacing the timing chain, and ignition coils.
Built in Wayne, Michigan, the Ford Expedition was available with two V8 engines, the 4.6 making 215 hp and 290 lb.-ft. of torque, rising to 240 hp and 291 lb.-ft. of torque in 1999, and the 5.4, making 230 hp and 325 lb.-ft., rising to 260 hp and 350 lb.-ft. of torque with the 1999 refresh. Both were paired with four-speed automatic transmissions.
Higher specification Expeditions offered leather seats, a power moonroof, power-adjustable pedals, a sonar parking aid, self-leveling suspension, and Ford’s unique driver door keypad entry system.
The Sport truck production crew used the first-generation Expedition in the making of their vehicle reviews, putting 14,000 miles onto it. They liked what they found, although they did comment that they would prefer less vague steering.
Ford Expedition Second Generation (2003-2006)
The second-generation Expedition featured more boxy, modern styling developed by Tyler Blake and was launched at the 2002 Detroit Motor Show. The third generation looks very similar, and this means second-generation Expeditions have aged well, tending to look newer than they are.
Like the first generation Expedition, these are extremely good value vehicles, although care must be taken with the V8 engine.
The big change for 2003 was that the Expedition now had four-wheel independent suspension, a first for full-size SUVs. The new suspension was controversial, with many worrying that towing capability would be lost with the new design. Unsprung mass and ground clearance were improved, and in fact, towing capacity increased to 8,900 lbs with the tow package specified.
The transmission software was revised, and new, largest-in-class brakes were fitted. The transfer case and four-wheel-drive system, where fitted, was improved with new control software which could simulate locking axles. The 4.6-liter V8 now made 232 hp and 291 lb.-ft. of torque and the 5.4 made 260 hp and 350 lb.-ft. of torque.
Both engine blocks were redesigned, with the pistons receiving a new Teflon coating. New engine mounts were introduced to reduce noise and vibration.
New sound insulation was used to make the cabin of the Expedition quieter at speed. Ford spent engineering time and money to make the Expedition a more comfortable place to be.
Second-generation Expeditions were equipped with cutting-edge safety equipment, including ABS anti-lock brakes, electronic brake-force distribution, and emergency brake assist. Stability control, traction control, and roll stability control were available options.
Model year 2003-2006 Expeditions have a five-star NCAP crash safety rating.
In 2005 the new three-valve 5.4 was launched. It made 300 hp and 365 lb.-ft. of torque and featured variable valve timing technology. The 4.6 was discontinued, and the four-speed automatic transmission was revised.
Now designated the 4R75E, the transmission was now continually learning to better predict the correct shift points. Other changes through these years were limited to different trim levels – a King Ranch model was introduced – and new exterior colors.
Ford Expedition Third Generation (2007-2017)
The third generation was launched at the Houston Auto Show, a nod to the fact that one in five Expeditions were sold in Texas. The third generation of the Expedition was not significantly different from the second generation.
For many owners, this simplicity and familiarity make the Expedition appealing, even though by the end of its run the Expedition did not ride as well or offer the same equipment as the competition.
Changes for 2007 included a new “T1” ladder frame design, delivering more torsional rigidity, a refreshed exterior, and better quality materials inside, including a solar tinted windshield. To compete with the Chevy Suburban, a new long-wheelbase Expedition EL model was introduced.
All Expeditions came with a new six-speed transmission, the 6R75. Accommodation was now for only eight since the bench front seat option was discontinued.
The third-generation Expedition has an unusually low number of recalls. Model years 2014, 2013, 2011, and 2010 were not recalled at all. Model year 2012s seem to have suffered in reliability and build since they needed three recalls. Four were needed for 2008 Expeditions. This shows the reliability which can be expected from Expeditions of these years.
With that said, certain issues are known to crop up on third-generation Expeditions. By far the most serious are spark plugs which get stuck in the block, as discussed above. The mass airflow sensor can become dirty and malfunction. This results in a rough idle and poor gas mileage. Cleaning the sensor itself, and the wires connecting it can be enough to solve this problem.
If necessary, replacing the mass airflow sensor is not expensive or difficult. The EGR (Exhaust Gas Recirculation) system can get blocked, and again, cleaning or replacement solves the problem.
To save weight, aluminum trunks and hoods are used on third-generation Expeditions. These can corrode, leading to paint bubbling and falling off. Although ugly to look at, this does not affect the structural integrity of the SUV. Blower motors and resistors can also fail, and it is usually best to replace both at the same time.
In 2008, power running boards and a backup camera became available. For model year 2009, the 5.4-liter V8 was revised to produce 310 hp and 365 lb.-ft. of torque, remaining in this specification until the engine was discontinued in 2014. It now had FlexFuel E85 compatibility.
Also, the 6R75 automatic transmission was revised to the 6R80, with stronger internals and a tow/haul mode. The infotainment systems were also updated, with Ford Sync becoming available for the first time.
A facelifted Expedition was launched at the 2014 Dallas-Fort Worth Auto Show. Four trim levels were offered, XLT, Limited, King Ranch, and Platinum. Visually the new model featured a three-bar grille, thinner headlights, and a new bumper. Interior materials were upgraded.
Four-wheel drive models were offered with Hill Ascent Assist and Hill Descent Control. Importantly, the 5.4-liter V8 was replaced by Ford’s new Ecoboost twin-turbo V6.
This aluminum 3.5-liter 24 valve double overhead camshaft motor makes 365 hp and 420 lb.-ft. of torque and features direct injection and twin independent variable camshaft timing. Fuel economy improved to 18 mpg.
Model years 2015, 2016 and 2017 Expeditions have been subject to zero recalls. Modern cars and trucks are extremely complicated, and with so many systems, it is not unusual to see six or even ten recalls on a particular vehicle, even those with reputations for reliability.
To have zero recalls shows the reliability of Expeditions. New features for 2015 were a computer-controlled suspension system and blind-spot alert.
Ford Explorer Fourth Generation (2018-Present)
As has become tradition, the fourth generation Expedition launched in Texas, at the Dallas Cowboys training facility in early 2017. The Expedition retains a body-on-frame design, but now uses Ford’s new hydroformed T3 platform, constructed from boron steel.
The body is made of an aluminum alloy, enabling weight savings of 300 lbs over the third generation.
A hybrid version is offered, and a new ten-speed 10R80 transmission is introduced, controlled by a rotary dial on the console.
Visually, the new Expedition channels the F-150s “C- Clamp” headlight shape and wide, prominent grille design. Three trim levels were offered, XLT, Limited, and Platinum, although fleet market special XL trim and extended-length Max version were also available.
Many reviews of the fourth-generation Expedition demonstrate how it excels at passenger comfort; the third-row accommodation is comfortable for full-size adults, not just children. Second-row seats adjust, tip, and slide even with a child seat in place.
Third-row seats power fold almost flat to create a long, wide load space, and there are hidden underfloor storage compartments.
Connectivity is remarkable, with an in-vehicle wifi hotspot that has a fifty-foot range and can support ten devices. There are six USB outlets, a household plug socket, and a wireless charging pad. The optional dual-screen rear seats allow streaming of content from your phone and can play DVDs.
There have been several recalls around fourth-generation Expeditions. Model year 2019s have significantly fewer recalls than other years — only three.
Model year 2020s have seen seven recalls, for issues with the Automatic Emergency Braking system, which required dealers to refresh software across five different systems; weak welds in second-row head restraints; and issues with some seat supports, seat belt tensioners, and seat belt buckles.
Police Package vehicles also had a recall around the gear shift, because the transmission might not be in the gear selected by the driver.
Model year 2019 Expeditions have had three recalls. One was a software reprogram of the door chime, another was the same loose seat back issue as seen in 2020 models.
The third recall potential buyers should certainly confirm has been carried out is that the rear suspension toe link fasteners may not have been properly tightened to the frame. If the toe link suddenly separated from the frame while driving, there is a risk you could lose control of the truck and crash.
There are six recalls for model year 2018 Expeditions. One problem, similar to the one on 2020 Police Package vehicles is the transmission can be in a different gear than indicated by the gear shift lever position.
Another issue is the Park function can fail, and the vehicle roll after it has been put in Park. There is also a problem with fuel pumps on 2018 Expeditions with 3.5-liter V6 engines. The welds on the fuel pumps can fail, causing a fuel or oil leak, and hence a fire risk.
As with other gen-four Expeditions, 2018s had issues with seats not meeting legal safety requirements. In some cases, seat frame assemblies have been replaced. Other recalls include electric windows which could trap fingers under certain circumstances because the auto-reverse function did not work properly.
Is the Ford Expedition Worth the Money?
Overall Expeditions are extremely rugged, long-lived vehicles. With earlier Expeditions, especially those with the 5.4-liter motor, buying the right car is about looking at how this particular example has been taken care of and asking the previous owner about the maintenance which has been done, particularly how often the oil was changed, and when the spark plugs were last replaced.
First-generation Expeditions, with their nineties “jellybean” styling, may be old now, but if well cared for represent amazing value for money.
Second and third-generation Expeditions are similar in design and had an extremely long model lifecycle. This seems to have led to remarkable reliability. Model year 2010, 2011, 2013-17 Expeditions were not recalled at all.
These model years certainly seem seeking out. Model year 2015-17 Expeditions are particularly attractive since they have the new 3.5-liter V6 twin-turbo engine instead of the potentially troublesome 5.4.
Since model year 2012s needed three recalls, and 2008 Expeditions needed four, these might be years to consider avoiding.
Fourth-generation Expeditions have had significantly more recalls, however it should be remembered that this is a far more modern, up-to-date design, which does not feel dated next to Tahoe or Sequoia. Fourth-generation Expeditions are younger and will have done fewer miles too, helping their reliability.
Perhaps the best value Expeditions are model years 2015, 2016 and, 2017 which combine zero recalls with the new 3.5-liter twin-turbo V6 engine.
Photos: Ford