Other Fuel System Problems of Ford Expedition - part 1

It made a loud boom I stopped thought it was a tire when I got out of the car flames started to come out of the driver side wheel well.

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The fuel line/fuel pump was leaking. Smelled fumes from the gasoline. Fuel was leaking over the fuel tank from the top of the tank. The vehicle was drivable when fuel was leaking. Very concerned that their could have been a fire due to the fuel leak. Took the vehicle to the Ford service department where it was purchased. Service shop stated that during inspection they noticed that something chewed through the fuel line/fuel pump. Comments made by the service advisors stated that they have seen squirrels/rodents attracted to the soy based ingredients of the parts/wiring. The repair would not be covered under warranty due to "outside influence". The manufacturer is installing a similar part and not covering under warranty. No warning lights; no warning messages. If the same type of soy based part is being installed, what is going to prevent the same thing from happening. Ford is not offering different types of parts and they do not have a way to prevent additional damage. No shield/tape/covering is being offered. Numerous instances of this referenced online due to soy based parts and Ford knowingly installing these parts without a fix or prevention. Consumer is responsible for all repairs. No warranty.

See all problems of the 2024 Ford Expedition 🔎.

The vehicle stopped running while driving, my wife stopped at a stop sign after vehicle had run ~ 10 minutes. Upon entering the inter-section the vehicle started to run rough, and ultimately stalled and would not restart. She was able to coast into a parking lot entrance within on top of world subdivision where we live and get off of main road. After multiple aaa attempts to jump start, aaa confirmed the vehicle was unable to be jump started, therefore vehicle was towed to local Ford dealership for diagnostics. They tried to jump start multiple times and after 2 days, pushed it into garage. They confirmed fuel pump failure and replaced with current design. We were charged for towing, new battery, and fuel pump system replacement with current design and advised we would have to bring it back in when Ford identified remedy for current recall. No loaner vehicle provided. We are very concerned as if this event had occurred on an interstate, there is a high risk of accident/injury. After repair with existing part designs we are worried about another failure on busy road/interstate.

See all problems of the 2022 Ford Expedition 🔎.

Fuel pump failed in express lane, unable to move the vehicle from travel lane under its own power.

See all problems of the 2021 Ford Expedition 🔎.

The fuel pump failed without warning leaving the vehicle stranded in the express lane of a highway. This exposed the vehicle and occupants to serious risk of collision. The vehicle does not allow the transmission to shift to neutral to move the vehicle from live traffic lane when the engine is not running. This is the same fuel pump model at the heart of the ongoing recall on other Ford vehicles.

Fuel pump part number jl1z*9h307*g failed at highway speed leaving vehicle stranded in express traffic lanes. But for the prompt response from fhp this would have resulted in a serious crash. The vehicle has almost never been operated below 30% of fuel capacity and has never been operated to near empty fuel. There are no known wear or accidents that impact the fuel system. There were no warnings or other symptoms prior to the complete pump failure.

My transmission started losing power on acceleration, hard jerk/bang when shifting into gear, transmission slipping, loss of power between shifts.

See all problems of the 2019 Ford Expedition 🔎.

What component or system failed or malfunctioned, and is it available for inspection upon request? the powertrain control module (pcm), which manages engine-transmission communication and regulates cooling system performance, malfunctioned, resulting in a cascade of related failures: transmission system: delayed shifting, hesitation, and eventually a “transmission stuck in park” code. Cooling system: repeated overheating that led to a ruptured radiator. These issues stem from the faulty pcm referenced in Ford recall 24e13, issued on April 25, 2025. Yes, the failed components remain in the possession of harbin motor company in scottsboro, al, where the vehicle is still located. The vehicle has not been repaired and is available for inspection upon request. How was your safety or the safety of others put at risk? this vehicle was operated while exhibiting documented powertrain and overheating symptoms—including while transporting children. Harbin Ford repeatedly instructed continued use despite: diagnostic scans on April 10, 2025 confirming pcm-related failures including “transmission stuck in park” and overheating. A coolant leak that occurred without warning lamps, leading to the radiator bursting. These failures put occupants at serious risk of breakdown or fire, especially in high-traffic or high-temperature driving conditions. Operating a vehicle with a malfunctioning pcm increases the likelihood of gear slippage, sudden deceleration, or complete transmission failure. Has the problem been reproduced or confirmed by a dealer or independent service center? yes. The issue has been repeatedly confirmed by harbin motor company, an authorized Ford dealer: on April 10, 2025, a scan identified “transmission stuck in park,” overheating, and a third unidentified code. On may 15, 2025, the service manager craig davis confirmed the transmission had an internal issue requiring a full rebuild and located a coolant leak. These confirmations were documented via servi.

See all problems of the 2020 Ford Expedition 🔎.

On several occasions the engine has slipped/stalled. Vehicle has only 27k miles on it, single owner. When moving from a stoplight the engine "slipped", all lights came on "service alert" or something similar. Vehicle recovered but I am very uneasy as I am a 52 year old female usually driving alone and often on a very busy section of I-85. (this has occurred multiple times) when increasing speed, as to pass a vehicle or otherwise, vehicle is unresponsive or lags. To be clear this happens at speeds of 40-50 mph. It is unpredictable when this will occur nor why. I will likely sell this vehicle due to this safety issue. I spoke with a service rep at the local Ford dealership who was able to look into the vehicle computer remotely but there was no record of the "alert" or otherwise. I took the vehicle to my local mechanic who drove it and was able to replicate the danger/slipping. I was advised to do "zip code" driving only. I believe this "engine slipping" is related to the recall just issued except the 2020 Ford Expedition is not included in this recall. Others have noted this issue as well with NHTSA.

Hurricane helene inundated our parking lot on September 27 with approximately 3-4 feet of storm surge. Many vehicles (20-25) were trapped and flooded. This vehicle caught fire and was totally consumed over the course of a 5-6 hour burn. Although all vehicles in our lot were flooded, this was the only vehicle to catch fire. By reports of eyewitnesses, the fire started underwater at the front of the vehicle and proceeded to consume it entirely. It did not blow up. Also reported is that the flashers and alarm/horn were active when the fire started (same was true for most other vehicles in the lot that did not burn). This vehicle is not a hybrid or ev, it is a stock gasoline vehicle with no modifications. The vehicle was towed away by auto-owners insurance company. It is unknown if they have done any form of inspection or investigation. This was not reported to the police but the fire department made a call to extinguish the flames at 4:55 am when the water receded enough for them to access the parking lot.

Vehicle randomly downshifts into first gear and get stuck in higher gears, allowing no acceleration, causing serious traffic accident.

While driving on the highway my vehicle shut down and service lamp came on and while drifting tried to put transmission in neutral and restart but had to come to complete stop to restart engine in park. I was in third lane and had no warning before shut down and could not get to the shoulder. (almost got hit trying). I reported to the dealer and they said there was no fault codes stored. I was driving to work on a 4 lane street a week later and again it shut down without previous warning again and had to crash up onto the curb to get off street to again restart in park. Dealer said again no codes and could not get it to duplicate problem after driving. It happened two more times so I looked into it myself and I read online that the throttle body is the likely issue. I returned and paid to have the throttle body replaced. They said would not guarantee the issue would be resolved. It has been months and have had no issues since I had it replaced. They charged me $563. 31 not including tax. I can not believe that you have to put a vehicle in park when it stalls to begin with but I also can not believe this issue was never recalled since it is a major safety issue and see lots of people and complained of the same issue.

See all problems of the 2016 Ford Expedition 🔎.

We were out of town driving to a baseball tournament going 80 miles an hour when the car completely lost power and a wrench came up. My husband barely coasted us to a shoulder. The car would not reset or restart unless it was in park. Happens twice. Took it for code read they said it is a throttle body issue but that instead of check engine light it shuts the whole car down until reset. Very scary on the interstate. Could have easily been in a bad collision.

See all problems of the 2017 Ford Expedition 🔎.

Applied brakes and instead of braking, vehicle accelerated on its own. Please note, when brake applied, felt resistance and simultaneously vehicle accelerated into lane of traffic. Rate of speed was very low, as I was coming to a stop in a parking lot. No warning lights on dash, dealership confirmed it was not the floor mats, there are no loose items in vehicle. My safety was put at risk as well as anyone walking/crossing the walk area and any vehicles that may have been in the lane of traffic. I immediately contacted dealership and was told to bring it in. The dealership has the vehicle currently, information provided to me by dealership. The vehicle was running self tests. Now the tech has opened a Ford hotline report, have not been able to duplicate issue and now awaiting response from Ford as to how proceed in diagnosing vehicle. Incident occurred July 25, 2024.

In 2022, around mileage of 67000, our SUV was climbing a steep road when it suddenly made a pop sound & went into limp mode with the wrench light showing and the engine sounding rough. It felt like no fuel was getting to the engine & the gas pedal was non-responsive. The rpms didn't change when the gas pedal was pressed. The grade was so steep, we barely made it to the side of the road without rolling backwards into traffic behind us. After turning the engine off and sitting about 10 mins, we tried starting the engine again. The car seemed to have reset itself! it ran fine; the wrench light turned off, and the gas pedal was responsive again. (at the time, we were on vacation at the coast and had traveled from our home at about elevation 3500'. We had also recently had to buy gas from a small no name gas station, so we feared we may have gotten bad fuel). From there, we returned home without re-occurrence, and we used fuel cleaning additive to our chevron fuel for the next 2 fill ups. Then, approximately 600 miles later on a flat grade, it happened again without the pop sound. We immediately went to our Ford dealer who found no error code but found our purge valve stuck open. They recommended we replace it, which we did, and we operated the vehicle for 2 years without re-occurrence and using only chevron gas. Recently, it happened again! luckily, we weren't on a steep grade this time or on the freeway, but if a car would have been behind us, we would have likely been rear ended, especially had we been on the freeway. Once again, we shut the engine off, and it reset with the wrench light disappearing, so no diagnostic code got thrown again! based on many complaints, this appears to be a common problem. It's very dangerous as the car immediately losses power to a crawl no matter what speed you are traveling at the time. It seems to be the electronic throttle body in instances where the SUV can stay running, so a code can be obtained before it resets.

In June 2024, my 2019 Ford Expedition experienced serious transmission and powertrain problems. Diagnostic testing identified catalyst efficiency codes (p0430), and I was given a repair estimate that included catalytic converter replacement. The vehicle also displayed repeated “service engine soon” and “powertrain malfunction/reduced power” warnings. Because the vehicle became undrivable and the repair costs were unaffordable, I was forced to release it to auction in June 2024, resulting in a significant financial loss. In April 2025, Ford issued recall 24e13 acknowledging that pcm programming errors could falsely trigger catalyst efficiency codes (such as p0430), potentially leading to unnecessary catalytic converter replacements, exactly the condition my vehicle experienced. This recall defect directly contributed to the loss I suffered, as I still owed about $11,000 on the vehicle when I could no longer use it. I have already opened a case with Ford (case #cxh05645573c2w6r6), but I have not received meaningful assistance. When I contacted Ford customer service, I was not offered escalation or resolution. I was only told to call another phone number, which left my case unresolved. I respectfully request that NHTSA review Ford’s handling of this defect, including the financial impact on owners like myself who incurred substantial losses before the recall was announced.

My catalytic converter of my 2021 Expedition is going out. We had a 2019 Ford Expedition texas edition and I had the same issue. We purchased our current Expedition in April of 2023. This spring the converter was signaled with the check engine light and since then my vehicle has had issues with acceleration, it consumes gas at an extremely high rate and my engine works harder over time. My concern is that my vehicle will have an engine malfunction or put me into bankruptcy by the amount of gas it consumes per trip. I found that many other Expeditions from the years 2018-2022 have similar issues to mine, in fact one of my friends in town had the same issue. I reported my issue to Ford and they said they would not repair. My vehicle has less than 80k miles on it.

Fuel leaking from emissions vents on fuel tank. Non reparable part.

See all problems of the 2003 Ford Expedition 🔎.

We own a Ford Expedition 2020. In 2023, we started noticing jerky, harsh, and aggressive “slips” when the vehicle was trying to change gears - upon multiple occasions. But, in 2024, we experienced three, major, different instances - all were extremely scary and it was miraculous they didn’t cause accidents, car pile ups, or worse! the first instance, the vehicle jerked and sputtered just as I was pulling out into a busy intersection. I thought it was going to die in the middle of the road. The second instance, several weeks later, it happened, again, as our family was driving in pouring rain down the interstate; it jerked so hard it felt like we hit a small wall. The third and final instance, we were on our way to vacation - 9 hours away with our family. It sputtered, jerked, and laid in 1st gear. Thank god, we were right at a hotel and able to pull in. We found a local mechanic to take the Expedition in and begin work on it. He was so kind to loan us his car to take on to PA to the sight & sound theater so we wouldn’t lose our money on the tickets. We ended up losing 2 full days of our 4 day vacation; had to rent a vehicle to drive back home; and left our Expedition in va for 6 weeks while they rebuilt a transmission and cleaned the catalytic converter. $12,160 to the mechanic + $1000 in car rentals. Here we are, now in August 2025, and there’s been a recall on the powertrain control module and that’s being replaced. Lo, and behold, what does the pcm do? it acts as the vehicle’s main computer, managing and controlling various engine and transmission functions (adjusting engine parameters like fuel injection, ignition timing, and transmission shift points) - imagine that!.

There is a shudder and whining noise with confused shifting gears behavior.

The service engine light continues to turn on. The timing belt continues to fail and has already been replaced once. The camshaft on both sides have been replaced. The solenoids have also been replaced and the diagnostics codes still pop up (p0022) (p0021) are just some that I can remember. The engine does not have enough power on the driver side and throws the timing belt off which causes the loud rattle coming from the engine. When reaching the speed of 40-45 mph the truck begins to shake. Recently in November 2023, when fueling up with gas , the truck began to shake and not respond. When accelerating, the truck takes off very slowly and the gears dont kick in on time. When the gas light comes on , the truck begins to function well. But as soon as I put gas again. It feels like the truck is going to fall apart. The driver door gets stuck when trying to open from the inside. The back door on the left does not open from the outside. The gear handle can be moved up and down while the truck is not turned on. Please help!!.

See all problems of the 2006 Ford Expedition 🔎.

My Ford Expedition started randomly stalling and it stalled in the highway. The engine just shut down in the middle of the highway and it was such a scary a life endangering experience. This total loss of power in the middle of the highway when vehicles are traveling at highway speeds can cause death very, very easily to the occupants of the Ford Expeditions suffering this defect. . Read more...

Electronic throttle body will go into a limp mode and has no power to accelerate. This happens while driving down the street or highway and you might have enough power to pull to side of the road or street and not get run over. I have seen other reports of this and Ford extended their warranty on some vehicles to 10 years or 150,000 miles. These are mainly the eco boost motors. My vehicle has 88,000 miles and is regularly serviced. One occurrence was on a road under construction with no place to pull over quickly when this happened.

While driving on the freeway our 2016 Ford Expedition's engine went into "limp mode" causing total loss of power. We barely were able to move into the slow lane and place hazard lights on while cars ran up on us slamming on their brakes to avoid a collison with our disabled vehicle. There was less than three feet of shoulder against a concrete barrier for us to stop. The dash showed a large yellow wrench and engine was running extremely rough. After turning engine off and back on we accelerated into on coming traffic to find the nearest exit hoping that the engine would keep running. We were very lucky to not have been killed. When we returned home my son pulled the code "p2112" which is "throttle actuator control system - stuck closed". There is a technical service bullentin #TSB 16-0139 that was put out by Ford for their techs to diagnose and repair the issue. So they are aware this is an ongoing safety issue. Nhtsa is aware this is an ongoing safety issue. The dealer wants $590 labor plus $258 for the throttle body to replace and diagnose the code we have already pulled and supplied them with the TSB bulletin. I wonder how many accidents and/or lives will it cost for the NHTSA and/or Ford to step up and recall these unsafe throttle bodies that are obviously defective.

The 10r80 transmission started delayed shifts between 8,9,10. After 50 miles the issue spread to the lower gears. When going from 3rd to 4th or 5th the engine speeds up vehicle loses speed. To recover let your foot off the gas and then apply gas very gently. After another 50 miles shifting became more erratic, sometimes with a load clunk. My safety has been at risk because you cannot count on the vehicle to do a smooth acceleration during a traffic merge. If you are in a lineup doing a merge suddenly you cannot keep pace because the transmission is shifting erratically. The vehicle has been at the dealer from October 3rd within in line for repair. They have stated Ford is just overwhelmed with 10r80 repairs. Based upon public information the Ford 10r80 transmission has some major flaws. Received an orange wrench message telling me repairs are required. I know that by its behavior. Filed a case with Ford customer care program, so far no help.

My vehicle has been making a very loud rattling sound upon starting. I reached out to the Ford service department about this and they said the cam phaser is failing but the customer satisfaction program has expired and they will no longer cover it. I never received a letter from Ford regarding this customer satisfaction program (I hadn't moved since buying the car, so it wasn't an address problem); they blamed the dmv and said they are the ones that mail out the letters and don't know why I didn't receive it. They quoted me $3,300 to fix it. I obviously can't afford that so I took my vehicle back and continued to drive it. Today the check engine light came on and I noticed my vehicle is sluggish to accelerate. Upon researching cam phasers failing I found this: "you could also lose power suddenly while you are driving. This problem puts you at risk of an accident and exposes others on the road to a dangerous situation. ". I believe the cam phaser problems in the 2018-2020 Expeditions should be a recall. It is a safety issue.

See all problems of the 2018 Ford Expedition 🔎.

While driving my children, my 2017 Ford Expedition lost power and went into 'limp' mode (wrench appears on the dash) along with an incredibly rough idle. This is at least the 3rd time that this has happened (twice before replacing the current throttle bottle) and now. This is incredibly dangerous as the vehicle loses power and leaves my family and I at the mercy of other drivers around us. It has happened on a 6 lane freeway, a 2 lane highway, and, most recently, on a city street. After a very quick search of the internet, it is no secret that there are throttle body problems with 2017 Ford Expeditions. Ford is responsible for manufacturing a vehicle that is safe and free of mechanical defects. While some problems do arise unexpectedly, it is ignorant of Ford to continue to put passengers in harms way until an injury or death happens when there is a known issue.

Our 2018 Ford Expedition max caught fire while on a test drive after repairs at canby Ford. It completely caught fire and is a total loss. We were supposed to pick up the car an hour later. If our kids were in the car strapped into car seats, there may not have been enough time to get them out. They could have died. The mechanic who was driving saw the engine smoking and jumped out (he was at risk). The whole car was gone within 2-3 minutes. In my opinion it exploded as all the windows were blown out. The motor block melted, and the front end of the car is gone. There is a report with canby oregon fire department. Most people would assume it was overheating, get out and open the hood with their family still in the car. If that had happened people could have died. There were no check engine lights on when we took it to Ford. It was just close to the end of a warranty and there was an engine rattle we wanted fixed. Please come look at the car to investigate. It is at an independent insurance valuation company. I asked the manager of canby Ford if he would report it to Ford motor company, he said no it would just go through their insurance. Ford needs to recall all of the Expeditions so someone doesn't die in a fire. Ford already settled on the 2021 Ford Expedition and there are fires on older models and similar f150 trucks. There are many reported fires without a recall. Please recall all the Expeditions and investigate all the other Ford vehicle fires swept under the rug. We don't want someone else to die due to a lack of action. The previous Ford Expedition settlement is not enough as it only covers 2021. If nothing is done, we plan to go public on the news with the photos, hopefully we can say NHTSA did something (or we can say NHTSA did nothing). Other families are at risk, they need to know to get out fast cause it could catch fire or explode. They need to not assume the engine is overheating (as I would have done 2 months ago) it could be on fire .

The throttle body failed, and my car lost power as I was turning into traffic on the road outside of my subdivision. My car went from approximately 45-50 miles an hour to no acceleration. My car would only go forward at the speed at which it idles. It was very dangerous to me and to others because it was a sudden power failure. The problem was reproduced by the local Ford dealer. I don't know if the component has been inspected by anyone. The first time it happened, there was an orange wrench on my dash with "see owner's manual" under it. This happened at least three times before we took it to our local Ford dealer. The dealership said they couldn't find anything wrong with my car and that I should "drive it till it broke".

My truck does this during, gears shifts 3-4- them 3,4,t complete gri g like people noise somewhere around 15 mph - 20 mph. Happens 80% of the time when I'm slowing down coming around a curve on a slight inclin, 5gear sounds like it's grinding in then it dowm shifts to 4th and slows down very fast. . Then downs hard shift with clunk upto 5th when speeding up after that slight turn . Seem to get worse after 95,500 miles.

Driving through a mile-long tunnel on an interstate highway (speed limit 55 mph), the vehicle ceased to respond to the gas pedal and would not accelerate or maintain speed. Attempted to shift gears but that produced no change - it was as if the transmission was stuck in neutral, but pushing the gas pedal did not increase the rpm. As we exited the tunnel at approximately 30 mph, the driver attempted to pull over and stop the vehicle, and found that the power assist for the brakes was not working, making stopping difficult - the driver had to push the brakes very hard, multiple times, to stop the car. We did contact 911 dispatch when we thought we were going to likely impede traffic, as the tunnel only had two lanes traveling the same direction. However, no intervention was required as we reached the end of the tunnel and were able to pull over before the call was completed. The vehicle was towed to a dealership and they diagnosed a fuel pump and/or fuel pump module problem, but have ceased to respond to our calls for the past 48 hours, so we have no further information. The check engine light turned on when the car was restarted, but then later turned off, without any repair work having been completed.

While travelling on highway uphill around 60 mph in heavy traffic, vehicle lost all power and went to idle. I had to maneuver 3 lanes to reach shoulder. Wrench icon showed on dash. Restarted engine and code cleared and had power again. It happened 4 more times over next 2 months then gave p2112 code. Research showed to replace throttle body which I did. Now doing some watchful waiting to see if it reoccurs. I believe this is a safety gap that requires a recall and a redesign of the logic to prevent the disabling the power train all the way back to idle.

While driving on the 58 freeway in the fast lane amongst semi trucks my Expedition lost power and had no acceleration, I was forced to the left shoulder of the freeway putting my family and I in danger. While stopped I had no response from my gas peddle but the engine was still on and a wrench appeared on my dash lights. I turned off the car and when I restarted it the car worked again and the wrench was gone. Very very very dangerous.

Transmission cooler lines snapped at 60mph. No crash able to get SUV on side of road. Transmission is totaled needs replaced. Repairs are underway at Ford dealership in groveport ohio. Milage of failure around 101100 miles on the odometer. Rust metal fatigue are the cause of what transpired. Cost of repairs at this moment is around 9 grand.

See all problems of the 2015 Ford Expedition 🔎.

My 2019 Ford Expedition is experiencing engine shudder. This started about 3 weeks ago and is starting to happen more and more.