Summary
The Ford Expedition has 45 recalls spanning 1997 through the 2025 model year, with the most serious recent issue being a passenger-side airbag on 2025 models that can deploy with excessive force in a crash, raising the risk of injury to the front-seat occupant.
On the 2024-2025 models equipped with the 3.5L turbocharged engine, a misaligned oil cup plug can cause a rapid oil leak that stalls the engine while driving. A related issue on 2024 models with the same engine adds a fire risk if leaking oil contacts hot components. The 2022-2024 models have front brake lines that can rub against the air intake pipe, wear through, and leak fluid, reducing braking ability. On 2021 models, an engine compartment fire can occur while the vehicle is being driven or while parked with the ignition off, and a moonroof wind deflector can detach and become a road hazard for other vehicles.
The 2020-2023 model years share a recurring wiper arm problem: the arms can break and leave the windshield uncleared in rain or snow, and on some 2020-2021 vehicles the issue was not fully resolved on a first repair attempt. The 2020 model also has several other concerns: the pre-collision assist system, including automatic emergency braking and forward collision warning, was not properly programmed and may not engage before a frontal impact, with multiple repair attempts required on some vehicles before the fix held; the front passenger seat belt tension sensor can misread a child occupant as an adult, enabling the airbag to deploy when it should be suppressed; and the gear selector can show the wrong gear position, potentially allowing unintended rollaway. The 2021-2022 model years have a software error that can disable trailer brakes on a towed trailer, extending stopping distance.
On 2018-2020 models, seat belt pretensioners in the front seats can spontaneously lock the belt, leaving it unable to retract or extend in a crash. The 2018 model has second-row seat issues on two fronts: center seat track reinforcement brackets may be missing, allowing the seat to shift in a crash, and outboard second-row seats may have insecure seatback bolts. The 2017-2018 brake master cylinder can leak fluid internally into the brake booster, reducing braking force. On 2019 models, the warning chime and message alerting the driver that the transmission is not in park plays for only a few seconds rather than the intended duration, a problem that also required a follow-up repair after an initial fix fell short.
Going further back, the 2015 model has a blower motor that can catch fire behind the glove box while the vehicle is running, and the rearview camera circuit board connection can fail, producing a blank or distorted backup image. The 2007 model has interior door handles that can stick and fail to return to the closed position. The 2006 model has assembly-line damage to left-side tires that may not have been caught before delivery.
Earlier production from 1999-2000 includes a fuel line that can leak and ignite near a heat source, a wiper motor switch that can overheat and smoke or catch fire, and a wheel hub contact area on certain chrome steel wheels that can deform and cause lug nuts to loosen. The 1997 model year has rear suspension track bar brackets and lower control arm brackets that can separate from the frame due to weld failures, allowing the rear axle to shift laterally and
