Ford Expedition Recalls

The Ford Expedition has 78 recalls spanning the 1997 through 2027 model years, with the most serious recent issue being a 2024-2025 engine cup plug that can misalign and cause a rapid oil leak, potentially stalling the engine or igniting oil on hot engine components.

The 2025 model year also has a passenger-side airbag that can deploy with excessive force in a crash, raising the risk of injury to the front occupant. Also on 2025 vehicles, the electronic brake booster module can malfunction and strip away power brake assist, extending stopping distances. The 2022-2027 model years are subject to a trailer lighting software issue where a towed trailer's brakes and lights may not function, reducing trailer visibility and the driver's ability to slow it. On 2022-2024 vehicles, the front brake lines can contact the air cleaner outlet pipe and wear through, leaking brake fluid and reducing braking ability. The 2023 model year has a front axle pinion that can fracture, cutting 4-wheel drive and potentially locking the front wheels.

The 2021 model year has a separate engine compartment fire risk from a short circuit in the battery junction box that can ignite even with the ignition off. On 2021 vehicles, damaged front-door side impact pressure sensors can cause airbags to deploy incorrectly or not at all in a crash, and the moonroof wind deflector can detach and become a road hazard. The 2020 model year has a battery junction box fire risk as well, along with a front seat recliner mechanism that may not hold an occupant in a crash, a passenger seat belt tension sensor that can misclassify a child as an adult and allow the passenger airbag to fire when it should be suppressed, and a pre-collision assist system that may not function due to incorrect programming. Windshield wiper arms on 2020-2021 models can break and leave the driver without wiper coverage.

The 2018-2022 model years share a seatbelt pretensioner issue where the front seat pretensioners can lock the belt so it will not extend or retract, leaving an occupant poorly restrained in a crash. The 2018 model year alone has additional concerns: pretensioners that can deploy without a crash or fail to work when needed, a 10-speed transmission missing a roll pin that can prevent the Park function from holding the vehicle, a gear shift cable clip that can allow the lever to indicate Park while the transmission is in another gear, a fractured weld on the high-pressure fuel pump assembly that can leak fuel and raise the risk of fire, second-row outboard seat backs that may not be adequately secured to the seat base, second-row center seat track reinforcement brackets that may be missing and allow the seat to move in a crash, and second-row power windows that may not reverse when they contact an obstruction. The 2017-2018 brake master cylinder can leak fluid into the brake booster, reducing pedal effectiveness and extending stopping distances. The 2015-2017 front blower motor can fail and start a fire inside the cabin behind the glove box. The 2016-2017 brake master cylinder has a similar fluid leak concern affecting front braking performance.

Going back to the earlier generation, the 2012 model's automatic transmission can unexpectedly downshift to first gear at speed, causing sudden deceleration and possible rear tire lockup. The 1997 model year has rear axle track bar brackets that can separate from the frame, allowing the rear axle to shift