Common Ford Expedition Problems: 3rd Generation (2007 to 2017)

Ford Expedition Problems

Every vehicle has its typical issues owners can expect to run into. Here are the 5 most common Ford Expedition problems of the 3rd generation, years 2007 to 2017.

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Top 5 Issues on the 3rd Gen Ford Expedition (2007 to 2017)

1. MAF Sensor Failure

Symptoms of MAF Sensor Failure

  • Poor fuel economy
  • Rough engine idle
  • Hesitation after pressing the accelerator pedal

Causes of MAF Sensor Failure

The MAF sensor measures how much air the engine is drawing so the computer knows how much fuel to mix with it for combustion. If the MAF sensor is dirty or has internal damage, it can cause the symptoms above. Sometimes the MAF sensor fails from use, and other times it fails from moisture sneaking in and damaging the internal components or from a problem with the electrical connection.

A dirty engine air filter may also cause these symptoms.

A loose or unlatched air filter housing cover or air intake hose clamp can also cause these symptoms.

How to Fix MAF Sensor Failure

Check the wires for damage like tearing. Disconnect the electrical connector and check it for corrosion or discoloration on the terminals.

Check the sensor unit on the MAF sensor for dark markings or accumulation. This is a sign the MAF sensor is dirty. You can try cleaning the MAF sensor with MAF sensor cleaner, and if that doesn’t clear the symptoms, replace the MAF sensor.

Check the air filter in the air filter housing for debris and dirt. If the engine air filter is dirty, replace it.

Make sure the air filter housing is secure and that all of the hoses and hose clamps are securely connected.

2. EGR Valve and Sensor Failure

Note: Not all 3rd gen Expeditions will have an EGR, also known as exhaust gas recirculation.

Symptoms of EGR Valve and Sensor Problems on the 2007 to 2017 Ford Expedition

  • Slower acceleration
  • Rough idling
  • Engine ticking
  • Engine knocking

Causes of a Bad EGR Valve and Sensor

If the EGR sensor isn’t working, it can’t control the EGR valve. If the EGR valve can’t open and close on time, the engine won’t perform as well. Carbon build-up can also keep the EGR valve from opening and closing as it needs to.

A closed EGR valve will cause build-up of nitrous oxide gas in the engine cylinder, which can cause engine ticking and knocking.

A stuck open EGR valve can cause rough idling and slower acceleration.

How to Fix a Bad EGR Valve and Sensor

General steps for testing an EGR valve

  1. Read any Engine Codes

    Connect a scanner to the OBD-II port and pull the codes for the check engine light

  2. Remove the EGR Valve

    Disconnect and remove the EGR valve

  3. Clean the EGR Valve

    Clean the EGR valve and its hoses of any carbon build-up

  4. Replace the EGR Sensor

    If there is still an issue, replace the sensor

3. Spark Plugs Sticking

Symptoms of Spark Plug Problems

  • Spark plugs difficult to remove from the engine

Causes of Spark Plug Problems on the 3rd Gen Ford Expedition

The spark plugs on the 2-valve engines had an issue remaining fastened inside. On the 5.4L 3-valve engines the spark plugs fall a little further down into the engine head because of a sleeve to fix the fastening issue, but the spark plugs’ sleeve is prone to sticking inside of the engine from rust and carbon build-up when it’s time to replace them.

How to Fix Spark Plug Problems

Run an internal engine cleaner that can break down the carbon in the spark plug area.

While it’s not good practice to work on a warm engine, we recommend changing the spark plugs with the engine warm to help loosen them from the build-up.

After the ignition coils have been removed, spray compressed air into the engine cylinder to loosen the spark plug sleeves. Then spray a little rust penetrant to loosen the spark plugs further. Remove the spark plugs with a specialized spark plug socket, which can help remove the spark plugs from the 3rd gen Expedition easier.

If one of the spark plugs breaks, the tool set below from can help remove it.

4. Aluminum Body Panel Corrosion

Flaking paint revealing corrosion, a common problem on the 2007 to 2017 Ford Expedition
Flaking paint revealing corrosion

Symptoms of Body Panel Corrosion

  • Gray corrosion underneath the paint can bubble and flake it

Causes of Aluminum Body Panel Corrosion

The corrosion stems from iron contamination during manufacture that occurred before the vehicle was coated and painted. The 3rd gen Expedition can also corrode from the body being exposed to the elements.

How to Fix Body Panel Corrosion

The corrosion is not a safety issue or a structural problem but an aesthetic issue. Sanding the area down, cleaning it, and resurfacing the area with new paint should fix this problem. A body shop can also fix this problem.

5. Blower Motor Resistor

Symptoms of Blower Motor Resistor

  • Heat and fan settings only work at certain speeds

Causes of Blower Motor Resistor

The blower motor resistor tends to fail on the lower settings, which means it should be replaced. Sometimes a failed blower motor can melt down the wiring. Corrosion on the wires can also cause failure.

How to Fix a Blower Motor Resistor

Replace the blower motor resistor. We recommend replacing the blower motor at the same time in case it is causing the failure. If the resistor has corrosion, check the electrical connector, which may need to be cleaned and also replaced.

Fix Your 3rd Gen Ford Expedition Yourself

Check out 1A Auto’s how-to videos that cover tons of repairs for the 2007 to 2017 Ford Expedition and more models.

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Ford Expedition Problems - 3rd Generation (2007 to 2017) - 1A Auto
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Ford Expedition Problems - 3rd Generation (2007 to 2017) - 1A Auto
This article covers the top Ford Expedition problems of the 3rd generation, years 2007 to 2017, and their symptoms, causes, and fixes.
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1A Auto
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