The 2023 Ford Expedition with the 3.5L EcoBoost is still fresh on the road, but early patterns mirror late-gen models: carbon buildup on direct-injection intakes, cam phaser rattle, and transmission cooler leaks are the real concerns, plus some catastrophic engine failures tied to low-speed pre-ignition knocking.
Cam Phaser Rattle and Timing Chain Stretch
Occasional · high severity
Typical onset: 40,000-80,000 mi
Symptoms: Cold-start rattle from front of engine lasting 3-10 seconds, Check engine light with P0016/P0017 cam/crank correlation codes, Loss of power or rough idle as stretch progresses
Fix: Replace cam phasers, timing chains, guides, and tensioners. Requires front-engine teardown, 12-16 hours labor. Often both banks need service even if only one side codes.
Estimated cost: $3,500-5,500
Transmission Oil Cooler Line Leaks
Common · medium severity
Typical onset: 30,000-70,000 mi
Symptoms: Transmission fluid puddle under front of vehicle, passenger side, Burnt smell or low fluid warning on dash, Harsh shifting or slipping if fluid level drops significantly
Fix: Replace cooler lines or entire oil cooler assembly at radiator. Quick-connect fittings corrode or crack. 2-4 hours labor plus fluid flush.
Estimated cost: $600-1,200
Carbon Buildup on Intake Valves (Direct Injection)
Common · medium severity
Typical onset: 60,000-100,000 mi
Symptoms: Rough idle, hesitation on acceleration, Misfires on cold start (P030X codes), Reduced fuel economy and loss of top-end power
Fix: Walnut blasting intake valves, both banks. Remove intake manifolds, 6-8 hours labor. No true fix exists—direct injection engines accumulate carbon without port injection to wash valves.
Estimated cost: $800-1,400
Low-Speed Pre-Ignition (LSPI) Engine Knock and Catastrophic Failure
Rare · high severity
Symptoms: Heavy knocking under light throttle at low RPM (1,200-2,500 RPM) during acceleration, Sudden loss of power, check engine light, and engine dies, Metal debris in oil, scored cylinder walls, broken pistons or rods
Fix: No warning—engine grenades from super-knock event. Requires complete engine rebuild or replacement: pistons, rings, crankshaft, bearings, head gaskets. 40-60 hours labor if rebuilding in-house, or long-block swap at 20-25 hours.
Estimated cost: $12,000-18,000
Integrated Trailer Brake Controller Faults
Occasional · low severity
Symptoms: Trailer brake error message on dash even without trailer connected, Loss of trailer brake function while towing, Intermittent ABS or stability control warnings
Fix: Software update via dealer (NHTSA recall 23V-397). If hardware issue, replace brake controller module behind center console, 1.5-2 hours labor.
Estimated cost: $0 (recall) or $400-700
Rear Axle Bearing Noise and Seal Leaks
Occasional · medium severity
Typical onset: 50,000-90,000 mi
Symptoms: Growling or humming from rear that increases with speed, Gear oil leak at differential cover or axle tubes, Vibration in rear end under acceleration
Fix: Replace axle bearings and seals. May require axle shaft replacement if splines are damaged. 4-6 hours per side, plus differential service.
Estimated cost: $800-1,600
Windshield Wiper Linkage Binding and Motor Failure
Occasional · low severity
Typical onset: 20,000-60,000 mi
Symptoms: Wipers stop mid-cycle or park at wrong position, Grinding or clicking noise from cowl area during wiper operation, One wiper works, the other doesn't move
Fix: Replace wiper linkage arms and bushings, sometimes motor assembly. Plastic bushings wear out prematurely. 2-3 hours labor, cowl cover removal required.
Estimated cost: $350-700
Owner tips
Use Top Tier fuel and avoid lugging the engine below 2,000 RPM under heavy throttle—LSPI risk is real with turbo EcoBoosts.
Service transmission fluid every 40,000 miles even though Ford calls it 'lifetime'—cooler line leaks contaminate fluid.
Run a can of CRC Intake Valve Cleaner through vacuum lines every 15,000 miles to slow carbon buildup.
Check cam phaser sound at every cold start—catch timing issues early before chain stretches and jumps a tooth.
Inspect trailer brake wiring and connectors if you tow; corrosion triggers false faults even on non-towing trucks.
Buy if you need the towing capacity and space, but budget $2,000/year for the EcoBoost tax—these engines demand maintenance and occasionally explode without warning.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
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Ford Motor Company (Ford) is recalling certain 2021-2023 Lincoln Navigator, Expedition, and 2022-2023 F-250 SD, F-350 SD, F-450 SD, F-550 SD, and F-600 SD vehicles. The windshield wiper arms may break, causing the wipers to fail.
Consequence: Windshield wiper failure can reduce visibility, increasing the risk of a crash.
Remedy: Dealers will inspect and replace the wiper arms, as necessary, free of charge. Interim letters, notifying owners of the safety risk, were mailed April 16, 2026. Additional letters will be sent once the remedy is available. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26S24.Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on April 1, 2026.
ELECTRICAL SYSTEM: INTEGRATED TRAILER BRAKE CONTROL · 26V104000
2026-02-20
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."
Consequence: Trailer lights or brakes that do not function can reduce the driver’s ability to control the trailer and decrease the trailers visibility to other road users, increasing the risk of a crash.
Remedy: The integrated trailer module software will be updated by a dealer, or through an over-the-air (OTA) update, free of charge. Owner notification letters were mailed March 25, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26C10. Vehicle Identification Numbers (VINs) involved in this recall will be searchable on NHTSA.gov beginning March 17, 2026.
BACK OVER PREVENTION:SOFTWARE · 25V315000
2025-05-14
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.
Consequence: A frozen or missing rearview camera image can reduce the driver's view behind the vehicle, increasing the risk of a crash.
Remedy: The accessory protocol interface module (APIM) software will be updated by a dealer or through an over-the-air update, free of charge. This will be a phased campaign, with the remedy becoming available in different phases based on model and model years. Interim letters notifying owners of the safety risk were mailed on June 26, 2025. Additional letters will be mailed once the final remedy is available on each phase. Owner notification letters were sent on October 8, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S49.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS · 25V314000
2025-05-09
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.
Consequence: A loss of brake function increases the risk of a crash.
Remedy: Dealers will inspect the front brake line and replace the brake line or air cleaner outlet pipe, as necessary, free of charge. Owner notification letters were mailed May 29, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S47.
EQUIPMENT:OTHER:LABELS · 24V852000
2024-11-08
Ford Motor Company (Ford) is recalling certain 2020-2025 Explorer, Lincoln Aviator, 2020-2024 Escape, Lincoln Corsair, 2018-2024 F-150, Expedition and Lincoln Navigator vehicles. The air bag warning label may be missing from the dashboard. As such, these vehicles fail to comply with the requirement Federal Motor Vehicle Safety Standard number 208, "Occupant Crash Protection."
Consequence: Without a label that shows the proper restraint usage guidelines, the occupants may have an increased risk of injury in the event of a crash.
Remedy: Ford will mail owners the warning labels, free of charge. Owner notification letters were mailed December 19, 2024. Owners may call Ford customer service at 1-866-436-7332. Ford's number for this recall is 24C39.
Ford Motor Company (Ford) is recalling certain 2018-2023 Expedition and Lincoln Navigator vehicles equipped with third-row seating; and 2019-2023 F-Super Duty F-250, F-350, F-450, and F-550 SuperCab vehicles. The owner's manual does not include instructions for adjusting or removing certain head restraints. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 202, "Head Restraints."
Consequence: Without instructions, the head restraints may be improperly adjusted, increasing the risk of injury in the event of a crash.
Remedy: Ford will mail the Owner's Manual addendums that describe how to adjust and remove the head restraints for the center seating positions, free of charge. Owner notification letters were mailed July 21, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23C20.
POWER TRAIN:AXLE ASSEMBLY · 23V128000
2023-02-24
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.
Consequence: A fractured pinion can result in a loss of 4-wheel drive and may cause the front wheels to lock up, increasng the risk of a crash.
Remedy: Dealers will replace the front axle pinion gear set. If there is a broken front axle pinion, the entire axle assembly will be replaced. Repairs will be performed free of charge. Owner notification letters were mailed April 21, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S07.
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