1997-2025 model years · 13,920+ owner reports · Updated October 2026
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According to Au7o's analysis of 13,920+ owner reports, the 1997-2025 Ford Expedition has 23 documented known issues, with 11 rated critical. The most serious are 5.4L 3V Triton Cam Phaser and Timing Chain Failure ($1,800-$4,500 repair), 10R80 Park-By-Wire Parking Pawl Engagement and Rollaway (Recall 26V402) ($0-$0 repair), 3.5L EcoBoost Engine Cup Plug Misalignment and Rapid Oil Leak (Recalls 24V851 / 25V198) ($0-$0 repair), Battery Junction Box Printed Circuit Board Short and Underhood Fire (Recalls 22V346 / 25V628) ($0-$0 repair), Brake Master Cylinder Cup Seal Leak Into the Booster (Recall 25V236) ($0-$0 repair), Front Brake Line Chafing Against the Air Cleaner Outlet Pipe (Recall 25V314) ($0-$0 repair), Front Seat Belt Retractor Pretensioner Inadvertent Deployment (Recalls 24V099 / 25V197 / 26V344) ($0-$0 repair), Low-Pressure Fuel Pump Failure Causing Engine Stall (Recall 25V455) ($0-$0 repair), Front HVAC Blower Motor Overheating and Interior Fire (Recall 22V648) ($0-$0 repair), Electronic Brake Booster Module Malfunction and Loss of Power Brake Assist (Recall 25V823) ($0-$0 repair) and 5.4L 2-Valve Spark Plug Blow-Out From Cylinder Head ($150-$400 repair). The most commonly reported issue is HVAC Blend Door Actuator Failure - Clicking and Incorrect Temperature with 4,100 owner reports. Across all issues with published estimates, repair costs range from $20 to $4,500. DIY maintenance guides at au7o.io.
ENGINE AND ENGINE COOLING:ENGINE:OIL/LUBRICATION
Ford Motor Company (Ford) is recalling certain 2024-2025 F-150, Expedition, and 2024 Lincoln Navigator vehicles equipped with 3.5L GTDI engines. The engine may have a misaligned engine cup plug, which can result in a rapid oil leak.
AIR BAGS:FRONTAL
Ford Motor Company (Ford) is recalling certain 2025 Navigator and Expedition vehicles. The passenger side air bag may have been manufactured incorrectly, which can cause the air bag to deploy with excessive force during a crash.
SERVICE BRAKES, HYDRAULIC:POWER ASSIST:ELECTRIC:CONTROL MODULE:SOFTWARE
Ford Motor Company (Ford) is recalling certain 2025 Lincoln Navigator, F-150, Expedition, Bronco, and Ranger vehicles. The Electronic Brake Booster (EBB) module may malfunction while driving or when the driver is utilizing an Advanced Driver Assistance System (ADAS) feature, resulting in a loss of power brake assist.
SERVICE BRAKES, HYDRAULIC:POWER ASSIST:ELECTRIC:CONTROL MODULE
Ford Motor Company (Ford) is recalling certain 2025 Lincoln Navigator, F-150, Expedition, Bronco, and Ranger vehicles. The Electronic Brake Booster (EBB) module may malfunction while driving or when the driver is utilizing an Advanced Driver Assistance System (ADAS) feature, resulting in a loss of power brake assist.
ELECTRICAL SYSTEM: INTEGRATED TRAILER BRAKE CONTROL
Ford Motor Company (Ford) is recalling certain 2021-2026 F-150, 2022-2026 F-250 SD, F-350 SD, F-450 SD, F-550 SD, Maverick, 2024-2026 Ranger, 2023-2026 F-600 SD, 2022-2027 Lincoln Navigator, Expedition, and 2026 E-Transit vehicles. When towing a trailer, the integrated trailer module (ITRM) may lose communication with the vehicle, possibly causing a loss of brake and turn signal lights, or a loss of brake function. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 108, " Lamps, Reflective Devices, and Associated Equipment."
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According to Au7o's analysis of 13,920+ owner reports, the 1997-2025 Ford Expedition has 23 documented issues. The most frequently reported are: 5.4L 3V Triton Cam Phaser and Timing Chain Failure, 10R80 Park-By-Wire Parking Pawl Engagement and Rollaway (Recall 26V402), 3.5L EcoBoost Engine Cup Plug Misalignment and Rapid Oil Leak (Recalls 24V851 / 25V198). Of these, 11 are rated critical and should be addressed promptly.
The 1997-2025 Ford Expedition has 23 known issues documented across 13,920+ owner reports. 11 issues are rated critical: 5.4L 3V Triton Cam Phaser and Timing Chain Failure and 10R80 Park-By-Wire Parking Pawl Engagement and Rollaway (Recall 26V402) and 3.5L EcoBoost Engine Cup Plug Misalignment and Rapid Oil Leak (Recalls 24V851 / 25V198) and Battery Junction Box Printed Circuit Board Short and Underhood Fire (Recalls 22V346 / 25V628) and Brake Master Cylinder Cup Seal Leak Into the Booster (Recall 25V236) and Front Brake Line Chafing Against the Air Cleaner Outlet Pipe (Recall 25V314) and Front Seat Belt Retractor Pretensioner Inadvertent Deployment (Recalls 24V099 / 25V197 / 26V344) and Low-Pressure Fuel Pump Failure Causing Engine Stall (Recall 25V455) and Front HVAC Blower Motor Overheating and Interior Fire (Recall 22V648) and Electronic Brake Booster Module Malfunction and Loss of Power Brake Assist (Recall 25V823) and 5.4L 2-Valve Spark Plug Blow-Out From Cylinder Head. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
Repair costs for known Ford Expedition issues range from $0 to $4,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 5.4L 3V Triton Cam Phaser and Timing Chain Failure, typically costs $1,800-$4,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
Reliability varies across model years of the Ford Expedition. Based on documented issues, problems are most commonly reported in earlier model years. Au7o recommends checking the specific known issues for your target year before purchasing, and having a pre-purchase inspection performed by a qualified mechanic. Our known issues database covers the 1997-2025 Ford Expedition with 23 documented issues documented across 13,920+ owner reports.
The 5.4L 3-valve (3V) Triton V8 in 2004-2014 Ford Expedition is notorious for cam phaser failures and timing chain stretch, representing one of the most common and expensive repairs on these trucks. The VCT (Variable Camshaft Timing) system uses oil pressure to actuate the cam ph… Repairs typically run $1,800-$4,500. Severity: high.
On 2018-2021 Expeditions built with the 10R80 ten-speed and park-by-wire shifter, the transmission parking pawl can temporarily engage while the vehicle is still moving when certain shifts are commanded. The momentary engagement damages the park system components, and once the pa… Repairs typically run $0-$0. Severity: high.
On 2024-2025 Expeditions with the 3.5L GTDI EcoBoost, a cup plug in the engine cylinder head may have been installed misaligned at the engine plant. The misaligned plug can unseat and release engine oil rapidly, dropping oil pressure and stalling the engine with little warning. B… Repairs typically run $0-$0. Severity: high.
The battery junction box on 2020-2021 Expedition and Navigator models contains a printed circuit board that is susceptible to a high-current internal short. When the short occurs, the current load overheats the circuit board and can ignite an underhood fire. As of May 12, 2022, 1… Repairs typically run $0-$0. Severity: high.
Master cylinders on 2017-2018 Expeditions with the 3.5L EcoBoost built between February 1 and June 30, 2017 can leak brake fluid from the front wheel circuit into the brake booster. Ford's investigation attributed the leak to brake fluid contamination interfering with the rear cu… Repairs typically run $0-$0. Severity: high.
Certain 2022–2024 Expedition front brake lines may have been bent during engine installation, allowing contact with the air-cleaner outlet pipe and a brake-fluid leak. Ford identified a radiator-hose handling process as the cause. A leak may increase pedal travel and stopping dis… Repairs typically run $0-$0. Severity: high.
Certain 2018–2022 Expeditions have front seat-belt retractor pretensioners with a legacy propellant/stabilizer mixture that can degrade in high heat. Corrosive by-products can damage internal components and cause unintended deployment. A deployment locks the belt against extensio… Repairs typically run $0-$0. Severity: high.
Selected 2022 Expeditions can lose fuel pressure and flow because of low-pressure pump failure. The recall identifies jet-pump contamination and reduced pump clearances, which increase friction and sensitivity to vapor lock. Low fuel and warm/hot-fuel conditions increase risk. Wa… Repairs typically run $0-$0. Severity: high.
Selected 2015–2017 Expeditions have a front climate-control blower motor that can overheat and cause an interior fire while the vehicle is on. The recall covers 163,253 Expeditions and 35,229 Navigators. Reported warnings include an inoperative fan, burning odor and smoke from th… Repairs typically run $0-$0. Severity: high.
Certain 2025 Expeditions have an electronic brake booster whose integrated-circuit manufacturing variation can trigger a fault state and remove brake boost, including during driver-assistance braking. Stopping distance may increase. The December 1, 2025 filing lists 17 Expedition… Repairs typically run $0-$0. Severity: high.
The 5.4L Triton 2-valve V8 in 1997-2008 Expeditions is notorious for spark plugs ejecting from the aluminum cylinder heads. The 2-valve heads have only 4 threads holding each spark plug, which is insufficient for the clamping force needed. Over time, the threads strip and the spa… Repairs typically run $150-$400. Severity: high.
The 2003-2017 Ford Expedition with optional air suspension (standard on Eddie Bauer, King Ranch, Platinum, and EL/MAX trims) suffers from air suspension compressor failure, air spring leaks, and ride height sensor malfunctions. The compressor, located under the vehicle, is expose… Repairs typically run $300-$1,500. Severity: medium.
The 5.4L 3-valve Triton V8 in 2004-2010 Expeditions uses a unique two-piece spark plug design where the plug can seize in the aluminum cylinder head and break during removal. The lower portion of the plug (the hex section and electrode) frequently separates and remains stuck deep… Repairs typically run $200-$2,800. Severity: medium.
The 2nd-generation 3.5L EcoBoost V6 in 2018-2022 Ford Expedition (Gen 4) addressed the timing chain stretch issue of early-generation 3.5L EcoBoost engines (2011-2016) but introduced a new problem: VCT (Variable Camshaft Timing) unit wear that causes a distinctive ticking/tapping… Repairs typically run $900-$2,800. Severity: medium.
Expeditions equipped with the rear air suspension system experience compressor failure, causing the rear of the vehicle to sag. The compressor wears out from overwork — it cycles frequently due to slow air leaks in the air springs (bags) and supply lines. When the compressor fail… Repairs typically run $200-$1,200. Severity: medium.
Selected 2021–2022 Expeditions with a moonroof have wind-deflector clips that may not be fully seated, potentially because of excess molding material. The deflector can separate while driving and become a road hazard. Ford reported two driver-strike incidents across the campaign,… Repairs typically run $0-$0. Severity: medium.
Different rear-camera recalls cover distinct Expedition populations. Amended 25V315 covers certain 2022–2024 vehicles with affected SYNC 4 software: a display freeze, blackout or reboot can interrupt the reverse image. Its July 2025 filing lists 18,140 Expeditions within 1,076,13… Repairs typically run $0-$0. Severity: medium.
Wiper arms on 2021-2023 Expeditions built October 25, 2021 - December 31, 2022 were assembled with a latch retention plate that the supplier staked incorrectly, so the arm may not stay secured to the wiper pivot. The wiper can then operate erratically, stop working entirely, or d… Repairs typically run $0-$0. Severity: medium.
The fourth generation (2018+) Expedition develops water leaks at the rear liftgate and D-pillar area. Water enters through deteriorated weatherstripping seals around the liftgate opening and through the rear tail light gaskets. The leak causes water to pool in the cargo area, beh… Repairs typically run $20-$500. Severity: medium.
The 2003-2017 Ford Expedition suffers from frequent HVAC blend door actuator failures. The Expedition has up to 5 individual blend door actuators (front driver temp blend, front passenger temp blend, front mode, rear temp blend, and rear mode) that control airflow direction and t… Repairs typically run $50-$700. Severity: low.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.
