My 1999 5.4L expy is a nightmare. Or maybe its Ford thats the nightmare since they can't fix it. I read these posts and we all seem to have alot of the same complaints. My engine sounds like a lawnmower and has a "spark knock". Have involved a Ford regional engineer that says this is normal. All engines knock. I can't seem to accept this. Everytime I drive the car ( unless I have the radio blasting) But this is difficult since my 6 disc changer is jammed.
Already had drive train replaced due to it being warped, mass air flow sensor replaced, and torque converter. Additional motor mounts since my vehicle did not have the correct amount on so my engine rocked causing severe vehicle vibration. All this and only 6000 miles. Plus they kept the car for 27 days while I drove a Ford Contour. Then they act (Ford Motor Co.,) The dealer agrees there is a problem.) like I am the only person who has had any problems. The parking lot at the service area is full of expy's. I love the way it looks. If I could sit in the driveway all day and not ever turn it on I couldn't complain. My beef is that Ford is doing extremly well financially and should just shut up and fix the problems so we can drive. Instead they have these moron customer no service personnel that inflame the situation to a point where all you want to do is get rid of the thing. My expy has a 6/22/99 mnfg. date which I heard is the last for the 1999's. To many lunch breaks? No, serious QC problems. Ask the service advisors at the dealership what they drive. Not expys..to many probs. Consumer reports no longer recommends expy since it has below average reliability. I have really lost faith in Ford and there really is no one to contact. I fax a letter and all related documents to the Executive offices in detroit everyday begging for help and receive no reply. e-mail me if you want this number) I know alot of you are happy with your expys and I'm glad but don't forget if you become unhappy they treat all of us the same. Shouldn't we demand more?

 

That's really a shame considering the F150's and Expy's have the same powertrain and many other items.

 

Well, of all the vehicles I've seen roll off the car carrier, the Rangers have had the least amound of pre delivery inspection problems. None to be exact, but the Edison, NJ plant is Fords best. I think the Michigan Expy plant must be the worst. The Expy must be the worst vehicle for p.d.i. Wrong seats are common. For example, Eddie Bauer, leather interior, the center fold down seat was cloth, but at least it was the right color! Twice in the last couple months we have gotten 2 in without heated seats like they were supposed to have. The one had no drivers heated seat, and the passenger side had a heated seat, but all the wiring in the seat for it was not there. The other one just didn't have heated seats. Got another one in, and the sunroof was open, went to close it, it didn't work. Had one Thursday, felt like it was "stuck" in 4wd, turned out it was the rear wheel sensor causing the awd to lock the front wheel in 4x. Remember, Quality is job none! Other than that, I like them and want to buy one for my wife soon. They are still a Ford, and probably the best vehicle of it's size.

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1997 F-150, 4.6, automatic, Dark Toreador Red, Supercab, Flareside, 4X4 Off-Road, Towing Package, Ford hvy dty rubber floor mats, Kenwood 10-disk cd changer, Ford bugshield, Chrome Grizzly Wrap Around Push Bar with 2 KC 100w Daylighters, Ventshades, Ford bedliner, cab and bed professionally undercoated, Code Alarm Sure Start RVS remote starter, Ford alarm, Realistic CB with Wilson Little Wil antenna and Astatic power mic, ported MAF sensor, and Lots of TLC!! (Besides being an F-150 nut, I am a Ford auto technician.)

 

Since you are a ford tech. could you tell me why would I have a spark knock on acceleration? its almost like a rolling. they have adjusted timing and reset the computer but told me they all sound like that. If they all sound like that I can't imagine that anyone would ever buy one after test driving. Now on acceleration when you hit gas pedal and release- its like a metallic winding down sound. It whirrs and then fades. Any comments. I will not quote you in any situations I just am so frustrated.

 

Sycoholic, how many plants produce expys, and where are they. How can I find out where mine was built. Lemonford stated his was built 6/99. Mine is marked 7/99, it must have been built real close to the end of the 99 run. I just got rid of a lemon 97 chevy pickup. I know what lemonford is going through, it is not fun. Just keeping my fingers crossed that I got a good one this time around. Man, I hope it was not built in the Michigan plant you commented on.

 

Sorry to hear about your problems lemonford.

My '97 is great! Only a few minor cosmetic issues to talk about. It was built just before Christmas in '96.


Kray...
All the X's are built at the same plant- Michigan. Most are built well.