My 2006 Expedition is a lemon. On a cold start I get a very loud grunting/rattling noise that you can hear a block down the street. Ford said this has something to do with the a/c unit, Ford also chalks this up as normal operating characteristics. How can this be classified as NORMAL? Not only that, I managed to get a copy of the TSB report and I am shocked to know they have cars, trucks, suv’s listed all the way back to 1998 with this problem. Oh, and also, this so called normal noise is also NON FIXABLE according to Ford. WHAT A JOKE!

My expedition has the same grunting/rattling noise..The dealer replaced the starter, and it is still making the noise; however, not every time I start it. It has even stalled out when starting. I have also had problems with the power windows, back side of rear seats disconnecting, a tapping noise in the engine, and a heavy vibration when in drive at stand still…My expedition was manufactured in Detroit in December 2005. I bought it December 30,2005… It is very frustarting to have a brand new vehicle>7800 miles have so many problems…I have had to drive a rental twice already. YOu say that Ford told you the noise is NON FIXABLE–That is ridiculous!!! If I continue to have problems they do not fix, I am hiring an attorney and I am going to lemon law mine! Good luck to you.

I too have an ‘06 expedition with the same engine noise.It only occurrs on “COLD START UP.” It’s very similar to the sound of “DRY ROD BEARINGS” rattling on initial start up of a worn out engine. I also was told it is A/C compressor related and nothing to worry about. I like my new SUV, but as a CAR GUY who really knows engines, it’s embarrassing when people look at me as if to say “What the heck was that noise?” Can anybody relate to this? Please R.S.V.P. if so. - Ron

My 2006 expedition won’t start. I drove my kids to school, dropped them off, and ten minutes later it wouldn’t start. We tried jump starting the battery, but it seems to be fine, and there is not any clikcing like you get with a bad alternator. Any suggestions?

My 2006 Expedition has the same grunting noise also. It seems to only happen when it sits awhile in the heat, once it has started it doesn’t do it again till the next long sit. I keep it in the Garage and in the morning it does not do it. It seems to be when it is hot outside. Im thinking it has something to do with the fuel lines. Not sure? Has anyone found a cure? Please let me know.

I have a 2006 ford Expedition E.baure it has 1400miles and has a vibration that can be felt throughout the car they have changed tiers and the drive shaft and it still has the same vibration.I have been to the shop 5times.

My 06 Expedition EB has 14500 miles. It also has the startup noise issue and I was told it’s an a/c issue. I agree the explanation by Ford is not reassuring. Last night while driving, the engine speed decreased to 300 rpm and it would not respond to the accelerator pedal. It had to be towed. This morning at the dealer it ran fine and they could find no problem. Has anyone experienced similar problems or do you know what may cause this?

I have a 2000 Ford Expadition and just noticed some paint bubble on the hood on the driver side front in a “curved” area. Hard to explain the exact spot but I noticed a neighbor had the same “spot” on the front of his hood at the exact same location. Is this a defect in the design of the hood? Poor rust protection on the hood? Anyone else have the same trouble?

The new EXPEDITION Is awesome! I test drove and will buy it! SWEET INTERIOR!

My 2006 Expedition Ltd. also has that noise upon start-up. I never had it checked. I chalk it off to the system doing an A/C compressor test. There is also a bit of a rough idle at times: I think that’s just the way the engine is designed, albeit it shouldn’t be like that for a new motor. In regards to the tires, don’t expect much from original tires that the manufacturer uses. Once they wear in a little , it’s all downhill from there. The other thing I’ve noticed is a clunk in the driveline when starting off from zero. It’s like something in the transfer case is winding up.Other than that, it’s been great. I installed a cold air box, cat-back exhaust, and re-programmed the computer so I am now at about 400 HP. Awesome torque when pulling a trailer up a hill and generally passing sedans.

I am also considering on getting a 2006 expedition. my only concern would be the gas consumption. How much a week do you guys spend on a full tank??

I have a 2000 Expedition with the same paint problems on the hood and the dealership and Ford will not pay for any portion of the repair. It was already repaired once with just 20,000 miles on it at the dealership, but is now out of the warranty period. I have made three calls to Ford and 2 trips to the dealer with no chance that they will help with any repair or replacement of their defective hood… I wonder why the Ford stock is down to around $7.00 now ?

I will buy more foreign cars in the future that have much less problems….there tires do not even blow out!

Below is an article and links on the problem.
Thanks

Ford Service Bulletin Shows Paint Defect on Many 2000-05 Models

Ford has issued a Technical Service Bulletin that shows a major paint defect in many large 2000-05 Ford, Lincoln and Mercury cars, trucks and SUVs that used aluminum body parts (hoods and fenders) to reduce vehicle weight. Affected models are the 2000-04 Crown Victoria, Taurus, Expedition, F-150, Ranger; Mercury Grand Marquis, Sable; Lincoln LS, Town Car Navigator and the 2000-05 Explorer, Mercury Mountaineer.

According to the TSB, “Some vehicles may exhibit a bubbling or blistering under the paint on aluminum body parts. This is due to iron contamination of the aluminum panel. . . . Ford’s Scientific Research Laboratory has performed a number of tests on vehicle body parts returned for corrosion related concerns. Testing has revealed that the aluminum corrosion was caused by iron particles working their way into the aluminum body part, prior to it being painted.”

CAS Executive Director Clarence Ditlow said:
“This is a very expensive defect to remedy. The TSB requires “extreme care to be taken” including special tools and segregated work areas to remove the corrosion by blasting, repriming and repainting. This repair is so difficult that CAS recommends the best fix is to replace the corroded part with a primed steel part and paint it. Ford cannot guarantee this repair will eliminate all the iron corrosion or prevent other areas from bubbling or blistering in the future.”
Consumers who have experienced this problem are encouraged to file a complaint via our website.
Related DocumentsClick here for Technical Service Bulletin
Related linksFord urged to pay cost of fixing paint faults

My brother bought a 2004 Expedition new. It now has 20k miles on it and is rusting completely out. Ford is trying to run down the clock on the warranty only offering to “bondo” it up. It has never been to the beach or kept outside. This is so wrong. Has anyone had the same problem?

I have a 2006 King Ranch with the same terrible vibration that Claudine described in the September 20th post.

I have been to the dealer countless times. The new tires didn’t fix the problem. The regional rep got involved and said the vibration was normal!?!

Claudine - I am not sure if you are still monitoring this thread, but if you are can you please post your resolution to the problem. If you are still experiencing the problem, let me know. I have a meeting with Ford shortly and it would be nice to present your experience as well. Maybe we can get to the bottom of this.

Actually my previous post was referring to L. Creighton’s post not Claudine’s.

L Creighton - how was the vibration resolved?

Y’all may want to post over at the Automotive.com forums:

http://forums.automotive.com/

I think there are tech or something from what I’ve read on the replies.

Any help?? My ongoing problems with the 06 King Ranch vibration problem. It has been road forced balanced 3-times with new Michelin tires. The drive shaft angle and run out have been checked and per Ford are in spec. Will have the drive shaft checked off the car for balance this week. Over 10 times to the shop. Still have vibration in the floor, seat, gas peddel. Both seats in front and even in the second row. Also have it in the steering wheel. Where else can I direct Ford to look?? Prior to the lemon law. Thanks to anyone who respones.

I have a 2006 Expedition. I now have 25000 miles on it. No problems so far. Same start-up noise though. I commute in it 22 miles to work. I average about 19 mpg. more if i drive slower and more if i do more highway driving.

My 2002 Expedition caught fire and then blew up! Thank God my 5 children were not in it at the time! I had the recall repaired that was supposed to stop it from catching fire, it did it anyway. Beware.

I have an ‘03 Expedition with 52K on it. Just noticed corrosion on the center hub caps on the 17″ wheels. All four have the same bubbling. The truck is washed regularly with special attention to the wheels, as the nasty looking brake dust drives me nuts. Any others with the same issue?

have a 2006 -30000 miles love it -poor mileage -drivers side seat bottom cover ,cloth -close to 300 dollars –unbelievable -good brakes but cant keep brake dust off wheels -need wheels blowing in toward rotors-what kind of computer hop up works?

the noise at start up might be the 5 w 20 oil-what a crock -20 weight oil is break in oil-lol

OH WOW! Let me Tell you all something. My 06 Expedition that I bought NEW in October 06 is a complete piece of $h**!!!!! The rattling noise at start up that everone is talking about… ME TOO!!! I thought it was my imagination a few times, maybe an echo in my garage…but thanks to you all I know I’m not going mental and hearing things! Thanks!! Now to the good part… it was in the shop ALL WEEK! Last Friday I took it in for routine oil change then was told I was leaking “some kind of fluid, either oil or power steering fluid”. I brought it back Monday the 12th…put me in a friggen rent a car for a whole week. Just picked my vehicle up today at 5pm and was headed about 6 miles away from the dealer when the piece of $h** took a huge crap on me. The leak issue in the beginning was news to me, my truck stays in my garage every night, I WOULD NOTICE A LEAK….however, they said it was my head gasket. Not only that, the vehicle never showed “any symptoms” of power steering or major engine problems. whatever. Then on my way home from the dealer after a week at the “Ford Spa” I was cruising at about 55mph, had to brake to about 45mph then when I went to accelerate again the whole truck shook like the motor and tranny fell out from underneath and wouldn’t accelerate. I HATE FORD. Just when you thought the expression “Found On Road Dead” for FORD was funny, then it really happens and I am literally Found On Road Dead. Had to call a tow truck and need to go back to the dealer in the morning (a Saturday none the less, like I havent been inconvenienced enough) to get ANOTHER rental. I’ve been a Chevy girl my whole life, had every SUV made by Chevy, several Camaros and a Vette….never ONE PROBLEM! NEVER! This FORD crap is UNBELIEVEABLE! Oh, and dont let me forget about the tire pressure light coming on constantly, they finally determined the sensor wasn’t even in place. Nice. New vehicle with a bunk engine and sensors that should be there but were never installed. Hope they didnt forget to install our airbags! Look out Lemon Law, I’m a’comin!

Always wanted to have an Expedition, and always like them. Now the chance to have one has come but now,reading all your comments, not sure. The one that planning to buy it`s a 2002. Don`t know what to do. Please can anyone give an advice, Thank YOu

I just purchased a 2007 expedition.It has the 6 speed trans.and shifts are butter smooth.Has any one noticed the sound of wind noise by the window in the drivers seat.It sounds like the window is open a crack ,but it isnt.I drove another new expedition and found the same thing.On inspection the seals look good and seem to line up.The noise starts at around 50 mph.It doesnt seem to get worse at higher speeds .I have a convertable that keeps more noise out.Anyone have any suggestions?

Re: 2006-Expy 5.4l. Is anyone else experiencing oil consumption using Mobil- 1, 5-20 synthetic? I noticed it using oil when I tried Mobil -1 before they came out with the 5-20, which I figured they composed to alleviate the problem, but I don’t think they have. Also,after Ford replaced front pinion seal, I’m getting a vibration starting at around 94 mph/ 150km/hr. I ‘m pretty sure it wasn’t there before. Hope you’re not all thinking about why I’m going that fast to begin with.

fords common problem is normally electrical my expidition steering col. harness connector is hard plastic and inter wire connecter is far from a reliable way to connect iam a ibew member and now work in industry .this steering wheel harness connection is hard plastic and cannot holt connection .break plastic off and keep metal connector and put shrink tue on solder on shrink and 33 or stuff good rubber into connector not tape but rubber from both directions but may not work

Well let me tell you about my 2006 Ford Expedition. It has already had the brakes replaced last year due to some kind of bulletin out on it. Basically when I applied the breaks the whole car shook. Well now it is back in the shop again. I too had the loud noise on start-up but it was only when it sat outside and it was hot outside all day. When I went to start it it made a loud noise. Well I guess that was due to some kind of bad sensor. When I turn the steering wheel I was hearing a bad noise too. They tell me the four wheel drive was trying to engage and their must be a vacuum leak somewhere. Now they tell me they have to replace the hubs. Today we got a call that the bell housing may be cracked. It is still making a noise and they are trying to track it down!!! The car has been in the shop for a week now. All of this makes me VERY nervous when my warranty runs out!!

I got one of these fine 2006 Expeditions, coming from a Ford guy, this think is a piece of sh*t
I too have the noise on start up, it has already had the front axle seals replaced, the passenger side motor mount was replaced, the belt was replaced, this was all done at less then 10K miles, the first time it went in for the noise on start up was at 720 miles on it
and of coarse they couldn’t find the noise, I am a ASE Certified Tech, and had it diagnosed as a A/C Compressor noise from the first time I heard it
well after about the 5th or 6th return to Ford for this noise, they found the noise, and surprise it was the compressor
boy was I surprised when the service advisor told me this was normal,
I let him run his mouth for a minute before I told him that I was a Certified Tech and that he was full of sh*t and this is not normal, his tone and story started to change real quick
bottom line here is everyone with these problems needs to file a report with the Better Business Bureau, and somehow a class action lawsuit needs to be filed against Ford for all these problems

if anyone has had any success with the compressor noise please send me a E-mail (Preferredauto@windstream.net) and let me know what was done to correct it

Thanks