The 2024 Expedition on the 3.5L EcoBoost is extremely fresh territory with limited real-world data, but early patterns mirror its F-150 cousin: cam phaser noise, oil consumption concerns, and the 10R80 transmission showing signs of premature wear under heavy towing loads.
Cam Phaser Rattle and Timing Chain Stretch (3.5L EcoBoost)
Occasional · high severity
Typical onset: 40,000-80,000 mi
Symptoms: Cold-start rattle lasting 5-15 seconds from front of engine, Check engine light for camshaft position correlation codes, Loss of power or rough idle once warm, Metallic ticking that worsens over time
Fix: Requires both cam phasers, timing chains, guides, and tensioners. Front engine disassembly, 12-16 hours labor. Ford has updated phaser design twice; insist on latest superseded parts.
Symptoms: Burns 1+ quart between oil changes, Blue smoke on hard acceleration or at startup, Fouled spark plugs on cylinders 1, 2, 5, 6 (most common), Low oil pressure warnings if neglected
Fix: Ford's eco-friendly low-tension rings don't seal well under boost and heat cycles. Fix requires engine-out rebuild with upgraded ring pack or short block replacement, 18-24 hours labor. Some get warranty coverage under 5yr/60k powertrain if documented consumption test performed.
Estimated cost: $6,500-9,000
10R80 Transmission Shudder and Premature Clutch Wear
Common · medium severity
Typical onset: 30,000-70,000 mi
Symptoms: Vibration at 25-35 mph during light acceleration, Harsh 2-3 or 3-4 upshifts, Slipping feel when towing or merging onto highway, Delayed engagement when shifting from Park to Drive
Fix: Early failures trace to inadequate fluid cooling when towing near max capacity. Transmission oil cooler upgrade plus fluid flush often buys time. Full rebuild with updated clutch packs runs 16-20 hours. Ford extended warranty to 10yr/150k on some units; check TSB 21-2347.
Estimated cost: $4,500-6,800
Turbocharger Wastegate Actuator Failure
Occasional · medium severity
Typical onset: 50,000-90,000 mi
Symptoms: Overboost or underboost codes (P0234, P0299), Limp mode with reduced power, Whistling or fluttering noise under acceleration, Poor fuel economy and sluggish throttle response
Fix: Wastegate actuator sticks or fails to modulate boost pressure. Turbo replacement usually required as actuators aren't sold separately for these Borg Warner units. 6-8 hours labor per side, but passenger-side turbo is worse for access.
Estimated cost: $2,200-3,500
Rear Differential Pinion Seal Leak
Occasional · low severity
Typical onset: 40,000-80,000 mi
Symptoms: Gear oil drips visible on rear diff cover or driveway, Low fluid causes whining noise during turns, Burnt gear oil smell after highway driving
Fix: Pinion seal fails from heat cycling and towing stress. Driveshaft removal, seal and crush sleeve replacement, gear oil refill. 2.5-3.5 hours labor. Not urgent if caught early and fluid topped off.
Symptoms: Trailer brake activation without input, Brake controller error message on dash, Inconsistent trailer brake response, SYNC screen freezing when trailer connected
Fix: NHTSA recall 24V-434 addresses this with software reflash. Dealer-only fix, 0.5-1 hour. No parts cost, recall repair is free.
Estimated cost: $0
Owner tips
Change oil every 5,000 miles maximum with full-synthetic 5W-30 if towing regularly; EcoBoost turbos cook oil fast under load
Install auxiliary transmission cooler if towing over 5,000 lbs — the factory cooler is marginal for max-rated loads
Run Top Tier fuel and add can of SeaFoam or similar every 10k miles to reduce carbon buildup on direct-injection valves
Check oil level every other fill-up; these engines show no warning until dangerously low
Keep documentation of any oil consumption complaints for potential warranty coverage on engine work
Too new to confidently recommend used — wait for 2020-2022 model years with sorted 3rd-gen EcoBoost issues to surface in the used market instead.
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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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.
ENGINE AND ENGINE COOLING:ENGINE:OIL/LUBRICATION · 25V198000
2025-03-28
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.
Consequence: A rapid oil leak can result in an engine stall, increasing the risk of a crash. In addition, an oil leak in the presence of an ignition source such as hot engine or exhaust components, can increase the risk of a fire.
Remedy: Dealers will inspect the engine cup plug alignment, and replace the plug if necessary, free of charge. Owner notification letters were mailed May 22, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S30.
ENGINE AND ENGINE COOLING:ENGINE:OIL/LUBRICATION · 24V851000
2024-12-20
Ford Motor Company (Ford) is recalling certain 2024-2025 F-150, 2024 Expedition and 2024 Lincoln Navigator vehicles equipped with a 3.5L GTDI engine. The engines may have a misaligned engine cup plug, which can result in a rapid oil leak.
Consequence: A rapid oil leak can result in an engine stall, increasing the risk of a crash. In addition, an oil leak in the presence of an ignition source such as hot engine or exhaust components, can increase the risk of a fire.
Remedy: Dealers will inspect the engine cup plug alignment, and replace the plug if necessary, free of charge. Owner notification letters were mailed on May 23, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S70.
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.
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