2025 Ford Expedition Problems: 4 Known Issues
2025 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated October 2026
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2025 Ford Expedition has 4 documented known issues, with 2 rated critical. The most serious are 3.5L EcoBoost Engine Cup Plug Misalignment and Rapid Oil Leak (Recalls 24V851 / 25V198) ($0-$0 repair) and Electronic Brake Booster Module Malfunction and Loss of Power Brake Assist (Recall 25V823) ($0-$0 repair). Across all issues with published estimates, repair costs range from $20 to $500. DIY maintenance guides at au7o.io.
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All 4 Known Issues
NHTSA Recalls25 recalls
POWER TRAIN:AXLE ASSEMBLY
Ford Motor Company (Ford) is recalling certain 2023 F-150, Expedition, and Lincoln Navigator vehicles. The front axle pinion may not have been heat-treated, which can cause it to fracture.
STRUCTURE:INTERIOR PANELS:CENTER CONSOLE
Ford Motor Company (Ford) is recalling certain 2018-2024 Expedition vehicles. The chrome plating on the center console may bubble and peel, resulting in sharp edges.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS
Ford Motor Company (Ford) is recalling certain 2022-2024 Navigator and Expedition vehicles. The front brake lines may contact the engine air cleaner outlet pipe and become damaged, possibly resulting in a brake fluid leak and reduced brake function.
BACK OVER PREVENTION:SOFTWARE
Ford Motor Company (Ford) is recalling certain 2021-2024 Bronco, F-150, 2021-2024 Edge, 2022-2025 Escape, F-250, F-350, F-450, F-550, F-600, 2022-2024 Expedition, 2022-2025 Transit, 2021-2023 Mach-E, 2024 Ranger, Mustang, 2021-2023 Lincoln Nautilus, 2022-2024 Navigator, and 2023-2024 Corsair vehicles. A software error may cause the rearview camera image to delay, freeze, or not display when the vehicle is in reverse.
FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP
Ford Motor Company (Ford) is recalling certain 2021-2023 Bronco, Explorer, Lincoln Aviator, F-250 SD, F-350 SD, F-450 SD, F-550 SD, 2021-2022 Lincoln Navigator, Mustang, F-150, and 2022 Expedition vehicles. The low-pressure fuel pump may fail, which can result in an engine stall while driving.
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Frequently Asked Questions
What are the most common Ford Expedition problems?
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2025 Ford Expedition has 4 documented issues. The most frequently reported are: 3.5L EcoBoost Engine Cup Plug Misalignment and Rapid Oil Leak (Recalls 24V851 / 25V198), Electronic Brake Booster Module Malfunction and Loss of Power Brake Assist (Recall 25V823), Rear Liftgate and Panel Water Leak. Of these, 2 are rated critical and should be addressed promptly.
Is the Ford Expedition reliable?
The 2025 Ford Expedition has 4 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 2 issues are rated critical: 3.5L EcoBoost Engine Cup Plug Misalignment and Rapid Oil Leak (Recalls 24V851 / 25V198) and Electronic Brake Booster Module Malfunction and Loss of Power Brake Assist (Recall 25V823). 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.
How much does it cost to fix common Ford Expedition problems?
Repair costs for known Ford Expedition issues range from $0 to $500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 3.5L EcoBoost Engine Cup Plug Misalignment and Rapid Oil Leak (Recalls 24V851 / 25V198), typically costs $0-$0 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What is the 2024-2025 Ford Expedition 3.5L EcoBoost Engine Cup Plug Misalignment and Rapid Oil Leak (Recalls 24V851 / 25V198)?
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.
What is the 2025 Ford Expedition Electronic Brake Booster Module Malfunction and Loss of Power Brake Assist (Recall 25V823)?
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.
What is the 2018-2025 Ford Expedition Rear Liftgate and Panel Water Leak?
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.
What is the 2025 Ford Expedition Third-Row PowerFold Seats Inoperative - Seat Module Software (SSM 53824)?
Ford SSM 53824 states that some 2025 Expedition vehicles with third-row power seats may have an inoperative power-fold function when the 3L, 3R or Both switch is pressed, which may be due to software in seat control module J (SCMJ). Ford gives a relearn procedure, notes the condi… 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.