Engine And Engine Cooling Problems of Ford Expedition - part 1

My 2018 Ford Expedition with the 3. 5l ecoboost engine has developed a pronounced rattling/knocking noise at startup. This appears consistent with the well documented cam phaser/vct problem affecting this engine family. At approximately 118,212 miles, an independent firestone complete auto care inspected the vehicle and recommended major timing system repairs. Their estimate calls for replacement of the timing chain components and variable timing sprockets/cam phasers, with a total recommended repair cost of $5,232. 13. 220782orderrevisions. Pdf the concern is not simply the noise. The cam phasers and timing system control critical valve timing. If these components continue to deteriorate, there is a risk of improper engine timing, severe drivability problems, loss of power, stalling, or significant internal engine damage. A failure while traveling at highway speeds or in traffic could create a serious safety hazard for the occupants and surrounding motorists. There have not yet been warning lights or dashboard messages associated with the condition. The primary symptom has been the recurring startup rattle/knock, which has now been confirmed by an independent repair facility as requiring substantial timing system repair. The vehicle remains available for inspection. This has been an ongoing issue for the last few months but was first diagnosed on September 12, 2026 during a repair for another unrelated issue. I am especially concerned because this is not an isolated or unusual type of failure on the 3. 5l ecoboost. Ford has previously recognized cam phaser/vct startup noise on these engines through service guidance. A known timing-related defect requiring more than $5,000 in repairs, with the potential to progress into engine damage or loss of engine performance, represents a significant reliability and potential safety concern.

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VIN):[xxx]/make/model: 2021 Ford Expedition xltcurrent mileage: approx. 150,000 mileslocation: [xxx] of the safety defect:el vehículo presenta un defecto DE seguridad crítico y extremo en el tren motriz que pone en riesgo inminente la vida DE los ocupantes y DE terceros en la vía pública. En dos ocasiones distintas durante los últimos 15 días, el vehículo ha sufrido una pérdida total DE comunicación electrónica y un bloqueo mecánico absoluto mientras se encontraba en plena marcha en avenidas DE [xxx]. Al ocurrir la falla, el tablero activa DE inmediato la luz DE la llave inglesa (wrench light), descontrola la marcha, bloquea la transmisión DE 10 velocidades y activa DE manera imprevista y automática el freno DE emergencia electrónico, deteniendo el vehículo por completo en medio del tráfico. En el primer incidente (ocurrido en sábado), la gravedad del bloqueo mecánico obligó la intervención DE los servicios DE emergencia en la vía pública, requiriendo la asistencia DE la policía y el cuerpo DE bomberos para mover el vehículo a una zona segura. El sistema electrónico sufre un colapso total (cortocircuito térmico o fallo DE la red can bus) provocado por las temperaturas DE la zona; el vehículo se vuelve inoperante y la computadora no responde ni permite el encendido hasta que se deja enfriar por un lapso forzoso DE 2 horas. Esta falla mortal se agudizó y se volvió recurrente inmediatamente después DE que un concesionario oficial DE Ford aplicara la reprogramación DE software correspondiente al recall DE emisiones xxx pcm. El concesionario original (team Ford Lincoln) se niega a diagnosticar la gravedad DE este fallo DE seguridad sin un cobro DE tarifa DE diagnóstico DE más DE $500 dólares, deslindándose del peligro vial provocado tras la ejecución DE su propia campaña oficial DE servicio. Solicito la intervención DE las autoridades federales para que el fabricante asuma la responsabilidad. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

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The vehicle disengages and loses power, feels like it shifts to park and won’t go.

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Car is stalling out while driving it.

The engine stalled out while trying to pass someone. The car wouldn't go faster when hitting the gas and felt like I couldnt safely slow down to get back over. It felt like something slipped and lost traction, but roads were dry and not rocky or sandy. Tapping breaks and letting off gas did nothing. It has happened before but usually in winter, and gettin up to speed. Its like the gear shift got stuck.

Incident happened 06/26/2026. My wife was driving with our 4 kids down the highway to family event. My wife smelled a funny odor coming from the vents and was going to drive to the next exit and then noticed smoke. At that moment she wasn’t sure where the smoke was coming from. She put the hazards on and started pulling off to the shoulder thinking possibly it was the radiator. She came to a stop and called me (husband) that something was wrong with the vehicle. She was going to leave the kids in the car, get out and check the radiator. That’s when smoke started coming in through the air vents. She didn’t want the kids to breath in the smoke so they exited the vehicle, that’s when she noticed a fire under the engine. At that point a state trooper arrived on scene. He checked on my wife and kids and brought them back to his patrol car. The trooper went back to the vehicle to grab the baby’s diaper bag and wife’s purse. The trooper tried to extinguish the flames but the front of the vehicle was well involved already. Within 10-15 minute from my wife stopping the whole car was burnt to the ground and nothing left of the car. Looking back my wife only had a couple minutes to get to safety, had they lingered before getting out of the vehicle this could have been a tragic fatality incident. Our children do not feel safe riding in a vehicle since the incident happened. The safety of the trooper on scene was at risk helping get everyone to safety. It seems that something on the engine failed with how quickly the fire started. Vehicle can and should be inspected to find out what happened so this does not happen to another family. The vehicle has not been inspected yet. No warning lights ever came on. There was never any symptoms prior to this incident and the vehicle has been serviced by the dealer prior to and since we purchased the vehicle.

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I noticed a loud rattle when starting my 2018 Ford Expedition, at first occasionally and then on every cold start. The Ford dealer's service department diagnosed a cam phaser issue. There were no warning lights or messages available to me, but the service department's diagnosis showed several timing faults. I was told the cam phaser repair is $4000 - $5000 and continued use puts the engine and transmission at risk. I contacted Ford customer service and was told that my vehicle was not eligible for assistance with these repairs and that my level of loyalty also did not make me eligible for assistance. I have maintained this vehicle with oil changes, fluid changes, tire and brake maintenance for the life of the vehicle. I would like the NHTSA to investigate Ford for a recall of the cam phasers and effected parts since this is a known and prominent issue that also impacts road safey.

While driving vehicle on state highway exit at approximately 55 mph a knocking noise started coming from engine then engine just died and would not restart. Engine was replaced under recall.

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- the cam phasers are failing. The dealer on my last visit said that the engine makes a rattle, and the cam phasers are the issue. It's apparently a wide spread issue with this year of vehicle. I wasn't aware previously. - the dealer said that the issue persisting will introduce debris into the engine resulting in failure. - the Ford dealer service brought this to my attention. - the component issue is known by Ford, but they have never issued a recall. - no warning lamps, no messages. I as a car owner wouldn't know an issue was existing. The dealer service department brought it to my attention when I had my car in for another service.

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Multiple times we have received powertrain failure warnings. These warnings typically happen when driving in cruise control but also happens in normal driving. The car has trouble shifting gears, gets stuck in gears, and has trouble downshifting. This creates unsafe and unstable driving especially at high speeds. Repeated visits to the dealer have yielded no results and the dealer has not mentioned transmission work one time despite a clear issue and widespread issues with this transmission model. This issue has been persistent since the car was bought.

Vehicle suddenly shifts to 1st gear while travelling at 45mph or more causing immediate jerking and slowing of vehicle, placing driver, occupants and other drivers at risk of crash. In this condition, the speedometer reads 0mph while still travelling and other warnings on dash are: airbag failure, blindspot system fault, cross traffic system fault, and see manual. Vehicle then appears stuck in 3rd gear until pulling over, stopping the engine and restarting. All warnings clear after restarting. This has occurred many times without proper diagnosis from Ford service. Now vehicle is doing this two to three times weekly and is currently in Ford service. Now diagnosed as lead frame failure. Estimated cost is $1,523. 38 and Ford refuses to pay for repair due to no active recalls on this specific vehicle, however the same transmission issue is in recall on same year model f-150's with the same transmission.

While driving on the highway, my 2022 Ford Expedition suddenly lost acceleration. The gas pedal stopped responding completely and the vehicle gradually lost power until it shut off. It had to be towed and the battery was fully drained afterward. It was later diagnosed as a fuel pump failure. This was a sudden loss of propulsion in traffic and created a serious safety concern. Police pulled over and were able to get me towed to the nearest safe stop as my car stopped on a bridge with no shoulder.

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On may 16, 2026, my 2023 Ford Expedition with 6,197 miles caught fire while I was driving home from work. I smelled smoke inside the cabin, and within moments smoke began coming through the air vents. I pulled over and exited the vehicle. When I got out, I saw the engine compartment was on fire and heavy smoke was coming from under the hood. As I moved away from the vehicle, there were multiple loud pops and bangs coming from the engine area. Police and fire crews responded and extinguished the fire, but the vehicle is a total loss. This was a nearly new vehicle with very low mileage. I believe this was caused by a manufacturing defect. Ford previously settled a class?action lawsuit involving 2021 Expeditions with engine fire issues, which suggests this problem has not been fully resolved. I am reporting this incident because it is a serious safety hazard and could have resulted in injury or death.

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After Fords most recent recall for a pcm software update at the dealer the car immediately runs different and after full engine temperatures sounds like marbles or valve train issues including low rpm noise and transmission shutter between shifts. Dealer says there is no problem they can find and that I need new turbos. Very suspicious that after a pcm flash the car is now unable to drive. The car had no issues prior to recall service and only has 70,000mi.

Transmission will randomly over shift or down shift when driving. When turning left I have had the transmission over shift from 2nd to 8th causing the car to bog down and could not accelerate in the intersection. I was almost hit from behind on one occasion and had hit on the side another time. I do not feel comfortable making turns without having a protected right away. Ford have changed the transmission, reset the programming for the transmission and Ford technician said it needed to be replaced by again and Ford denied even though it was under warranty and just reset again. If reset it does go away for a bit but just event returns and only gets worse.

My car is a 2018 we bought it used in 2020 we had to had the transmission flushed and coils replaced . That didn't work . We had drum issues and gear slippage . Now I. Have to put a new transmission in the car.

The contact owns a 2019 Ford Expedition. The contact stated that while the contact's husband was driving at an undisclosed speed, the check engine warning light illuminated. In addition, the transmission shifted unusually rough. The vehicle was taken to the dealer where it was diagnosed with a failed catalyst converter. The contact was informed that the catalyst converter needed to be replaced. The vehicle was not repaired. The contact stated that the transmission was replaced in November 2025. The contact referenced a manufacturer's recall 24e13. However, the contact's VIN was not associated. The manufacturer was made aware of the failure. The contact was advised to contact the NHTSA hotline and report the failure. The failure mileage was approximately 105,000.

I own a 2019 Ford Expedition with fewer than 100,000 miles equipped with the 3. 5l ecoboost engine. The vehicle began experiencing a loud cold-start rattle, engine timing issues, and check engine light illumination. The vehicle was diagnosed by a Ford dealership with internal vct/cam phaser mechanical failure affecting engine timing and performance. The dealership diagnostic identified trouble codes p0016, p0365, and p0369. The dealership also documented that the engine oil level and condition were within specification, indicating the failure was not caused by lack of maintenance or neglect. The dealership recommended replacement of all four vct units and four vct solenoids due to internal mechanical failure. This issue creates a serious safety concern because improper engine timing can cause loss of power, rough operation, stalling, or sudden engine performance issues while driving. This appears to be a widespread issue affecting Ford vehicles equipped with the 3. 5l ecoboost engine, particularly involving cam phasers, timing components, and vct systems. A major internal timing-related failure on a vehicle with under 100,000 miles should not occur under normal operating conditions. I am submitting this complaint because this defect may affect the safe operation and reliability of the vehicle.

I took my vehicle to the dealership to have all recall work done on Feb. 11th 2026. I was told I am up to date on all my recall work at that time. When I received my vehicle back it would intermittently just shut down for no apparent reason while sitting at stop lights, or just stopped in that fashion. I called and the dealership they said unless they could recreate the issue somewhat easily there was noting they could really do. So while parked in driveway the vehicle again had no power, I used my emergency key to get into vehicle and opened the hood to which I found the battery terminal connections were never tighten. I could take them off by hand. This told me the mechanic at the dealership didn't complete job and tighten my battery connections, fast forward to April 18th, it was raining, I parked vehicle, still running, went into post office ( I was only gone for 30 seconds)and I came out to white smoke billowing out from under the hood. I opened hood the large flames shooting up. I quickly grabbed a fire extinguisher I had in the car and put 90% of the fire out, it was still burning at the fuse junction box, moments later a police officer showed up with fire extinguisher and was able to put it out. The car would not stop running, so once the fire dept. Arrived they had to cut the battery terminals to shut the vehicle down. This was also the first time I drove vehicle in the rain since my recall work was done. The fire dept. And I realized the fuse box cover was not in place. So now this same mechanic that did't tighten battery terminals was also neglectful in not replacing the fuse box cover. I believe this neglect partially if not wholly caused this fire. It is highly probable that water got into the fuse box and shortened everything out which caused the fire. I have a document from the dealership that states they did the recall work for 22s36 - underhood fires. But this website says this work was not performed. No inspection from anyone has been done.

The contact owns a 2021 Ford Expedition. The contact stated that while driving at an undisclosed speed, the transmission unexpectedly downshifted and the vehicle jerked abnormally. The contact stated that there was an abnormal sound coming from the vehicle with the check engine warning light illuminated. The failure was persistent. The vehicle was taken to the dealer where it was diagnosed with transmission failure. The contact was informed that the transmission needed to be replaced. The vehicle was not repaired. The contact referenced an unknown recall; however, the VIN was not associated with a recall related to the failure. The manufacturer was made aware of the failure but provided no assistance. The contact was informed that the repair was not covered under recall. The failure mileage was approximately 62,500.

When my transmission is shifting, it almost stalls about 3-4 times everytime you start off. It is a hard shift that makes it fee like the car suddenly stops then goes back. I have had it happen 3 times that I thought my car died after stopping, making weird noises, then took off like normal. I am waiting for my car to just die as I am driving. The Ford dealership said I need a new transmission. The recall is out there for other vehicles like mine, yet mine is not listed. When you read what Ford says will happen- exactly what my car does!!!!! my 2021 Ford Expedition max has 70,000 miles on it now, but when it started had about 67,000.

The contact owns a 2012 Ford Expedition. The contact stated that while his wife was driving 30 mph, the transmission unexpectedly downshifted, causing the occupants to lunge forward. The tires squealed and the wheels locked up. The vehicle was turned off but failed to restart. No warning light was illuminated. The contact stated the failure was associated with NHTSA campaign number: 16v248000 (power train). A tow truck company was contacted, and was able to restart the vehicle, but the failure persisted. The local dealer was contacted and confirmed that there was no recall coverage associated with the VIN. The vehicle was not diagnosed or repaired. An attempt was made to contact the manufacturer, but there was no response. The failure mileage was approximately 166,000.

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Vehicle experienced catastrophic timing system failure causing engine to jump time and stall at idle, creating a safety hazard due to risk of sudden loss of power. This is a repeat issue originally documented under warranty (2020) and again during recall/service program 21n03 (2021), where repair was declined as “not severe enough. ” recall 24e13 (software update intended to prevent timing chain failure) was completed in 2025, but failed to prevent this exact condition. Vehicle is now inoperable and unsafe. This raises concerns about the effectiveness of the recall remedy and prior service handling. We've also submitted a case to Ford: cxh07545978w9w1d2.

This is a report of a recurring, life-safety defect involving unintended vehicle movement in a 2024 Ford Expedition. The vehicle has experienced two separate incidents where it was placed in 'park,' remained stationary for 13-30 seconds, and then began driving itself backward without driver intervention or throttle input. Incident 1: occurred on March 29, 2026 and I have this one on video. Incident 2: occurred on April 8, 2026. The video clearly shows the vehicle remaining stationary and in 'park' for 13 seconds before the unintended movement begins. This delay proves the movement is not a 'start-up rocking' sensation or 'normal clutch drag,' but a delayed mechanical or electronic failure of the park actuator or transmission system. I presented the vehicle for service at a Ford dealership on April 17, 2026. Despite my report of a delayed-onset rollaway, the dealership documented the issue as a 'normal and desired characteristic' of the 10-speed transmission. They characterized the event as a minor 'rocking' sensation that occurs immediately, which is factually contradicted by my video evidence showing a 13-second delay. This leaves me with an unsafe vehicle prone to unintended movement. I am requesting a formal investigation into a potential park-engagement failure.

I am writing to express concern regarding a significant engine issue with my 2018 Ford Expedition. At approximately 122,000 miles, the vehicle developed a cylinder 4 misfire accompanied by low compression, indicating an internal engine failure. This type of issue seems premature for a well-maintained vehicle and has resulted in major repair considerations, including potential engine replacement. Given Ford’s reputation for durability and reliability, I find this failure both unexpected and concerning. I have kept up with regular maintenance and did not anticipate facing a major engine issue at this mileage. I am requesting that Ford review this situation and consider a recall. I have seen and heard of a lot of folks having this same issue at such an early mileage.

The contact owns a 2004 Ford Expedition. The contact recently purchased the vehicle and stated that while driving at an undisclosed speed, the transmission hesitated before upshifting with the accelerator pedal depressed. Additionally, while stopped at a traffic light, the vehicle rolled backwards when the accelerator pedal was depressed before responding as needed. There was no warning light illuminated. The contact attempted to return the vehicle to the independent dealer where the vehicle was purchased; however, the dealer declined to assist. Recently, the vehicle stalled, and it was towed to an independent mechanic to be diagnosed. The mechanic retrieved fault codes for the engine and stated that the tcm needed to be replaced. The vehicle was not repaired. The manufacturer was not informed of the failure. The failure mileage was unknown.

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Bought the car on Feb 14th 2026. We were told avis car sales in fontana does their vehicle inspection on every car before its sold. We noticed the two back tires on the Expedition were bald and showing cords. We told tawnya and george about the tires and they said they would order them, they'd be in within two days and to bring the car back to get them replaced. When we got home we setup Ford diagnostics and found out the oil life was at 29% so they also lied and sent us out with bad oil. We checked the dip stick and yeah super dark oil. We've called two days in a row and keep getting told they are busy and they will call us back, they have not. We have tried to reach corporate but they dont have a department for this. The vehicle is currently sitting because of how bad the tires are, its 100% not safe to drive. Trying to get the dealership to honor the safety fix they promised but they are avoiding it.

I am reporting a severe, systemic manufacturing defect in the 3. 5l ecoboost engine timing system (cam phasers and timing chain) of my 2017 Ford Expedition that poses an immediate highway safety hazard. Approximately February 2026 upon start up heard odd rattle type noise, a week later heard noise again thought maybe due to recent Ford dealership changing engine belts. Searched websites discovered notable issues regarding serious known manufacturing defect, cam phasers, timing chain, water pump. Followed Ford recommendation to change oil well before normal schedule to address. At approximately 54,550 miles, the vehicle began exhibiting continuous mechanical rattling and timing instability upon startup, a condition heavily documented across Ford’s truck/SUV platform and acknowledged internally via Ford technical service bulletin TSB 23-2143. The 3. 5l ecoboost is a high-compression interference engine. A failure or skipped tooth of the timing chain or cam phaser system while operating at high speeds causes instantaneous, catastrophic engine failure. This results in an immediate stall and a complete loss of vacuum-assisted power braking and power steering. This vehicle is routinely operated on major texas highway corridors (xxx) at posted speeds of 75 mph by my [xxx] spouse, who stands[xxx] and weighs [xxx]. A sudden loss of motive power and mechanical steering/braking assistance at 75 mph presents an unsurmountable vehicle handling emergency that would likely result in a high-speed crash, rollover, or catastrophic multi-vehicle collision, as a driver of her physical stature cannot safely muscle a stalled, unassisted 5,500-pound SUV to the shoulder. To mitigate this imminent risk to human life, I was forced to perform emergency out-of-pocket repairs to replace failed factory components with Ford's updated, redesigned parts. This defect represents an inherent, dangerous engineering failure requiring a mandatory federal safety recall before highway fatalities. Information redacted pursuant to the freedom of informati.

The contact owns a 2020 Ford Expedition. The contact stated that while depressing the lock panel with the numbers on the driver’s side door, the seat unintendedly moved forward, and the seat belt retracted, and the driver was squeezed in the seat. The contact turned off the vehicle and seat belt to returned to the original position. The contact stated that coolant was added to the coolant reservoir; however, the vehicle was leaking coolant. The contact was unsure if the cap was positioned correctly. There were no warning lights illuminated. The contact received notifications of NHTSA campaign numbers: 26v344000 (seat belts) and 26v368000 (structure). The vehicle was taken to the local dealer and remained for five days. The vehicle was diagnosed, and it was determined that the seat needed to be adjusted. The dealer informed the contact that the coolant reservoir tank needed to be inspected. The manufacturer was not contacted. The approximate failure mileage was 106,920.

Vehicle experiences repeated harsh shifting, hesitation, sudden downshifts, hard downshifts with engine redlining, and loss of acceleration during normal driving. Transmission intermittently jerks violently between gears and hesitates when pulling into traffic or merging onto the highway, creating a serious safety concern. I have experienced multiple near collisions due to the vehicle hesitating or failing to accelerate properly while entering traffic and during highway merging situations. Vehicle has also unexpectedly downshifted hard while driving, causing the engine to redline and creating unsafe driving conditions. Issue has occurred multiple times and vehicle has been taken to Ford dealer for repair on several occasions. Dealer performed software updates/reprogramming, but condition persists. Vehicle currently has approximately 66,000 miles. Currently it is undrivable especially due to the fact I have children.

My engine makes a loud rattling noise upon start up and then a more discreet rattling while driving because of the cam phaser.

The contact owns a 2018 Ford Expedition. The contact stated that while driving at an undisclosed speed, there was an abnormal rattling sound coming from the engine. The vehicle was taken to a dealer, where it was diagnosed with camshaft phaser and timing chain failures. The vehicle was repaired. The manufacturer was notified of the failure. The failure mileage was 35,540.

Driving at 58 mph with cruise on, using the cruise - button to reduce speed to 50 the vehicle drastically downshifted causing the engine to over-rev and ultimately caused catastrophic engine failure, a blown engine.

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The contact owns a 2021 Ford Expedition. The contact stated that while driving at 45 mph, the engine overheated. The message “drive mode inoperable” was displayed. The contact pulled over for 20 minutes, and the vehicle was restarted. The vehicle was towed to the local dealer, who confirmed that parts were on back order for NHTSA campaign number: 22v346000 (engine). The vehicle was diagnosed, and it was determined that the failure was due to the transmission. The vehicle was not repaired. The manufacturer was contacted and opened a case. The failure mileage was approximately 99,130.

When you try to accelerate quickly, even when you’re switching lanes on the interstate or just driving down the road, the car will sometimes pop out of gear or something and almost comes to a complete stop causing you to almost get rear ended. I’ve almost been hit several times because the car stops and won’t go.