Various vehicles equipped with a 4.6L, 5.4L, 6.8L modular 3 valve engine built on or before 8-Jan-2016 may exhibit symptoms that may include upper end engine noise, rough running, misfire and/or engine damage. If diagnosis leads to only camshaft/camshaft roller follower(s) requiring replacement, replace all of the camshaft roller followers on both banks/cylinder heads with part number 3L3Z-6564-A, not just the faulty roller follower(s). When replacing the camshaft roller followers, refer to Workshop Manual (WSM), Section 303-01.
full bulletin at NHTSA ↗2007 Ford Expedition engine problems
severe 23 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
23
Recalls
0
Avg fix
$3,100
1crash
1fire
When does it fail?
Of the 23 engine complaints filed for the 2007 Ford Expedition, here's the actual mileage breakdown — failures cluster heaviest at 50,000-75,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
No new NHTSA engine complaint has been filed on this vehicle in over 8 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering engine on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate when reading these PIDs and cannot display quickly enough to validate a concern. The PCM automatically monitors these inputs more accurately and will set diagnostic trouble codes (DTCs) when appropriate. Using these PIDs for diagnostics will lead to inaccurate results and improper ETB replacements. If a concern is intermittent and no DTCs are present, refer to historical DTCs and the PC/ED, Section 3 No DTCs Present Index chart for further information.
full bulletin at NHTSA ↗LINCOLN/FORD: WHEN DRIVING FROM IDLE UP TO 1200 RPM, THERE MAY BE AN INTERMITTENT RATTLE NOISE COMING FROM ENGINE. 2004-2013 F-150, F-250, F-350, EXPEDITION, MARK LT, NAVIGATOR.
full bulletin at NHTSA ↗FORD: IF THERE IS AN INTERMITTENT LACK OF POWER, SURGE, OR HESITATION WHILE DRIVING THE BRAKES WILL OVERRIDE ACCELERATION.
full bulletin at NHTSA ↗FORD: SOME EXPEDITION, F-150, AND NAVIGATOR MODELS MAY EXPERIENCE A DELAYED FORWARD OR REVERSE TRANSMISSION ENGAGEMENT. USUALLY HAPPENS ON COLD START IN COLD CLIMATES.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 5.4L Triton engine in these 2007 Expeditions shows a pattern of problems that emerge across the fleet. Spark plugs break off inside the cylinder head when removed—a design flaw owners say Ford was aware of—requiring extraction and often costing $800–$1,100 per repair. Owners replace plugs as often as weekly because they foul or burn out, leading to rough idle, misfiring, and extended cranking.
Cam phasers fail prematurely, creating a tapping or ticking noise from the top of the engine, especially at idle. Related diagnostic codes (P0022, CAM position timing) appear when the variable valve timing system loses control. Timing chains wear and require replacement, sometimes with all rockers and lifters. Oil distribution issues—allegedly from manufacturing defects—starve cylinders of lubrication, leading to metal debris contamination.
Fuel system failures include melted fuel pump wiring ($790 repair), fuel rail leaks, and rapid fuel consumption. Stalling occurs under load or during acceleration, sometimes without warning. One vehicle caught fire at 40 mph; Ford denied responsibility. Catalytic converter failures trigger check-engine lights around 90,000 miles. One owner reported the engine revving uncontrollably during braking, causing a rear-end collision at 1,000 miles. Owners cite internet complaints and class-action lawsuits; Ford Technical Service Bulletins acknowledge the problems but dealers often refuse repairs on intermittent issues without a confirmed code.
Same Ford Expedition engine reports on nearby years: 2005 · 2006
Failure modes owners describe
Spark plug stiction and breakage
Spark plugs seize in the cylinder head due to dissimilar metal design flaw; plugs break off when removed, requiring specialized extraction tools and creating metal debris inside the engine.
When: Occurs during routine plug replacement; failure mileage ranges from early ownership to 130,000 miles
Symptoms owners cite: Misfire and rough idle; Engine light illumination; Spitting and sputtering at cruising speeds; Fouled plugs requiring weekly replacement in severe cases
Codes mentioned: Check Engine Light (specific codes not always documented)
Repairs/costs cited: $800–$1,100 to replace all 8 spark plugs; special extraction tool required when plugs break in head. Owners report Ford knew of the flaw and multiple class-action lawsuits exist.
Recalls/TSBs owners mention: Ford aware of design flaw; no recall issued despite internet complaints and lawsuits dating to early 2000s.
Cam phaser failure and variable valve timing malfunction
Intake cam phasers fail prematurely; variable valve timing system loses control, causing loss of power, rough running, and abnormal engine noise.
When: 115,000–123,000 miles reported; some owners experience symptoms earlier
Symptoms owners cite: Tapping or ticking noise from top of engine (passenger side); Rough idle with uncontrolled bouncing; Loss of power on highway; speed drops from 70 mph to below 30 mph; Hesitation during acceleration; Two-cylinder misfire
Codes mentioned: P0022 (Intake Cam Position Timing Over-Retarded, Bank 2), Cam position sensor codes
Repairs/costs cited: VVT solenoids replaced but problem persists in some cases. Owners report Ford issued Technical Service Bulletin identifying the problem. Dealers refuse warranty coverage on intermittent tapping without confirmed code.
Recalls/TSBs owners mention: Technical Service Bulletin sent to dealers; warranty denial reported for intermittent issues.
Timing chain wear and internal engine damage
Timing chains wear prematurely and fail, sometimes accompanied by roller cam damage and tapet failure; alleged manufacturing defect causes uneven oil distribution, starving cylinders of lubrication.
When: 5 years old; mileage varies but occurs within first 70,000–100,000 miles in some cases
Symptoms owners cite: Loud ticking or tapping noise from engine; Rough startup at 1,800 rpm; Knocking noise increasing with engine speed; Loss of power; Metal shreds and contamination inside engine
Codes mentioned: No specific codes documented; diagnosis typically requires internal inspection
Repairs/costs cited: Timing chains replaced; rockers and lifters inspected. One owner reports cam lobes eaten up, roller frozen, tapet damaged. Engine replacement required in at least one case.
Recalls/TSBs owners mention: Ford Technical Advisory Bulletin issued to service departments.
Fuel pump failure with melted wiring
Fuel pump wires melt, creating fire hazard and causing stalling. One repair shop noted the owner was lucky the vehicle did not explode.
When: Mileage not consistently documented; one failure around 12,000 miles; another with melted wires at unknown mileage
Symptoms owners cite: Vehicle stalls without warning; Rough running before failure; Fuel smell outside vehicle; Flames from hood (one vehicle fire)
Codes mentioned: No diagnostic codes in some cases; fuel pump detected via mechanical testing
Repairs/costs cited: $790 fuel pump replacement; wires melted indicating electrical fault or short. One owner notes this appears to be a common problem online.
Recalls/TSBs owners mention: Owner reports doubt that Ford would pay for fuel pump failure; no manufacturer response documented.
Fuel rail leak
Fuel leaks from the fuel rail on the engine, creating strong fuel odor inside and outside vehicle; degraded fuel economy.
When: 97,500 miles
Symptoms owners cite: Strong fuel odor when parked and while driving; Reduced fuel economy (miles per gallon dropped); Fuel visible leaking from rail
Repairs/costs cited: Repair not completed at time of complaint; cause attributed to fuel rail defect.
Recalls/TSBs owners mention: Manufacturer notified but no action documented.
Cam sensor failure and fuel mixture richness
Cam position sensors fail or malfunction, triggering check-engine light and causing stalling and rough running. Fuel system reads too rich, suggesting sensor or ECU calibration issue.
When: 70,000 miles reported; 2–3 weeks after extended highway driving in one case
Symptoms owners cite: Vehicle loses rpm and stalls during deceleration or light throttle; Rough running while slowing down; Check Engine Light illuminates (after initial delay); Stumbling on acceleration
Codes mentioned: Cam position sensor codes, System running too rich code
Repairs/costs cited: Dealership estimated ~$2,000 for repair; unable to finalize estimate without computer diagnosis. Owner notes uncertainty whether repair or full engine replacement needed.
Catalytic converter failure
Catalytic converter requires replacement, triggered by check-engine light; failure mileage indicates premature wear.
When: 90,000 miles reported
Symptoms owners cite: Check Engine Light illuminates
Codes mentioned: Catalytic converter code (specific code not documented)
Repairs/costs cited: Catalytic converter replacement needed; repair not completed at time of complaint.
Engine fire with denied responsibility
Vehicle caught fire while driving at 40 mph; flames visible from hood. Ford denied responsibility by claiming fire originated in rear, despite fire department report indicating hood origin.
When: 12,000 miles
Symptoms owners cite: Flames visible from hood; Vehicle stalled and lost complete power; Driver-side engulfed in flames within 5 minutes
Repairs/costs cited: Vehicle towed to collision center; fire department extinguished fire. Ford's liability position contradicts fire department findings.
Recalls/TSBs owners mention: Ford stated no responsibility due to claimed fire origin in vehicle rear; fire department report contradicts this.
Uncontrolled engine rpm and brake pedal interaction
Engine revs uncontrollably when brake pedal is depressed during deceleration, creating unsafe condition and causing collision.
When: 1,000 miles
Symptoms owners cite: Engine revving when brake applied at 5 mph deceleration; Loss of braking authority; rear-ended another vehicle
Repairs/costs cited: Dealer unable to determine cause; vehicle not repaired. Police report filed.
Throttle body malfunction and stumbling acceleration
Throttle body problems combined with cam and fuel system issues cause hesitation, spurting, and loss of power during acceleration from stop or speed increase.
When: Variable; one case at 70,000 miles
Symptoms owners cite: Spurting, hesitation, and loss of power when accelerating; Engine never fully cuts off but fails to respond to throttle input; Inability to merge safely into traffic; Problem occurs repeatedly on highway at 55–60 mph acceleration
Codes mentioned: Check Engine Light may or may not illuminate
Repairs/costs cited: Dealer inspected multiple times; unable to diagnose without illuminated check-engine light. Owner suggested fuel filter or O2 sensor; dealer stated neither is applicable to model.
Recalls/TSBs owners mention: Dealer refuses service until check-engine light appears.
Transmission issue—loss of reverse and acceleration failure
Vehicle unable to move in reverse on grades and unable to accelerate smoothly from stop; one owner reports vehicle moves forward while shift selector is in reverse.
When: Early in ownership
Symptoms owners cite: No reverse motion on any grade; Jerky acceleration from stops and into traffic; Vehicle moves forward while in reverse (owner's report); Near-miss collisions due to inability to merge safely
Repairs/costs cited: Lemon-law arbitration pursued; dealership records disputed by manufacturer. Vehicle now sits unused; owner purchased replacement vehicle and remains on loan for original.
Recalls/TSBs owners mention: Ford stated no issues exist; arbitration found complaint records to be false and denied lemon-law claim.
Exhaust manifold bolt failure
Exhaust manifold bolts break, causing loud exhaust leak at rear of manifold.
When: Mileage not specified
Symptoms owners cite: Loud exhaust noise at rear of manifold
Repairs/costs cited: Dealer repair quote: $850.
Missing heat shield on catalytic converter
Catalytic converter not covered with heat shield; floor board becomes dangerously hot.
When: 122,700 miles
Symptoms owners cite: Passenger-side floor board extremely hot to touch (106 degrees ambient); No thermal protection between converter and floor
Repairs/costs cited: Not repaired at time of complaint; independent mechanic diagnosis only.
Recalls/TSBs owners mention: Neither dealer nor manufacturer contacted.
Synthesized from 23 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
I have the 5.4 engine in my 2007 Ford expedition with only 70,000 miles which I purchased in 2007. I am now experiencing cam sensor problems, throttle body problems and need major repairs. I have visited many sites and understand that Ford has been sued because of complaints with this particular engine and nothing came from this suit. This started around 2-3 weeks ago, I had been traveling…
Had engine trouble with your 2007 Ford Expedition?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the engine problem on the 2007 Ford Expedition?
It's a meaningful issue. 23 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $3,100.
At what mileage does the engine typically fail?
Across the 22 complaints that reported odometer mileage, most engine failures cluster between 72,000 and 123,800 miles, with the median around 93,000. A quarter of owners report trouble before 72,000; a quarter make it past 123,800. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $3,100 for engine repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to engine?
No active recalls currently cover engine issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2007/Ford/Expedition.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.