Structure Problems of Lincoln Aviator

Lincoln Aviator owners have reported 10 problems related to structure (under the structure category). The most recently reported issues are listed below. Also please check out the statistics and reliability analysis of Lincoln Aviator based on all problems reported for the Aviator.

1 Structure problem of the 2023 Lincoln Aviator

Failure Date: 08/07/2025

The contact owns a 2023 Lincoln Aviator. The contact received notification of NHTSA campaign numbers: 25v407000 (structure), 25v393000 (seats), 25v455000 (fuel system, gasoline); however, the part to do the repair was unavailable. The dealer was not contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact had not experienced a failure. The VIN was not available.

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2 Structure problem of the 2021 Lincoln Aviator

Failure Date: 06/25/2023

The contact owns a 2021 Lincoln Aviator. The contact stated while driving at an undisclosed speed, the driver's side rear door trim detached and flew off the vehicle. Additionally, the contact stated that after it rained, water entered the interior of the vehicle through the sunroof. The vehicle was taken to the dealer where it was diagnosed with a detached driver's rear door trim and clogged drain tubes in the sunroof assembly. The driver's side rear door trim was not replaced. The dealer repaired the clogged drain tubes in the sunroof assembly. The contact stated that the failure reoccurred. The vehicle was taken back to the dealer; however, the failure was not duplicated. The manufacturer was made aware of the failure. The contact referenced a recall; however, the VIN was not associated with the recall. The failure mileage was approximately 60,000.

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3 Structure problem of the 2022 Lincoln Aviator

Failure Date: 02/13/2023

The contact owns a 2022 Lincoln Aviator. The contact stated that there was an unusual sound of water running from the roof of the vehicle. The contact stated that the sound was similar gushing water. The contact also stated that when the air condition was turned on, there was a moldy odor coming through the vents. The vehicle was taken to the dealer. The failure was diagnosed with an engineering error during manufacturing. The vehicle was not repaired. The manufacturer was made aware of the failure but provided no assistance. The failure mileage was approximately 20,000.

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4 Structure problem of the 2022 Lincoln Aviator

Failure Date: 07/01/2022

The contact owns a 2022 Lincoln Aviator. The contact stated that while driving at various speeds, the vehicle would hesitate upon depression of the accelerator pedal without warning. The vehicle was taken to a dealer where they failure to diagnose the failure. The contact then received 3 recall notices for NHTSA campaign number: 25v407000(structure); NHTSA campaign number: 25v393000(seats); and NHTSA campaign number: 25v455000(fuel system, gasoline). The dealer was notified of the recalls and the contact was informed that the parts for the recalls were not available. The manufacturer had yet to be notified of the failure. The vehicle was notified repaired. The failure mileage was unknown.

5 Structure problem of the 2005 Lincoln Aviator

Failure Date: 03/01/2009

I have a Lincoln Aviator and Ford refuses to fix the liftjar crack in the back it is a concern since there is so much rain in florida how do I know what leaks in there and its their defect just because its not a safety issue doesn't mean they shouldn't honor the fix its ridiculous I made numerous calls as well as a dealership trying to help me out but Ford refused.

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6 Structure problem of the 2005 Lincoln Aviator

Failure Date: 02/01/2009

A vertical crack on plastic covering of hatch cover. Starts at the Lincoln medallion that is cut into the plastic piece and extends vertically to bottom edge. I took it to a Lincoln dealer. Estimate was $500 for a piece of plastic that measures approximately 12 inches high and the width of the hatch door. This is definitely a design error on the part of Ford. The service manager told me that he sees a lot of this same complaint and it is not covered by Ford. A $42,500 automobile with a defect in design that results in an unsightly split in plastic piece wanting an outrageous fee of $500 to replace the piece. Do you think I will ever by another Ford product. Not in this lifetime! thanks Ford who always puts quality first.

7 Structure problem of the 2004 Lincoln Aviator

Failure Date: 10/30/2008

Our 2004 Lincoln Aviator has developed a small 6 inch crack in the plastic surrounding and below the back window. When contacting the dealer we were told that this is a known problem but Ford refuses to do anything about it. We were then told to call Ford directly and were told that yes they know about it but they are not offering any help to customers. In researching this problem online there are 100's if not 1,000's of forum posts discussing this defect. A primary forum would be on the edmunds car site. My issue is that this crack could not be caused by anything but a defect and therefore Ford should be liable. The location is such that debris, etc. Could not cause this crack. Ford has quoted us over $ 1,000 to fix their problem and until we do the car is now suspect to water damage if it were to rain. Thank you .

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8 Structure problem of the 2003 Lincoln Aviator

Failure Date: 12/01/2004

Moldy odor coming from a/c unit. The consumer stated mold spots were growing on the inside and outside of the roof panel.

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9 Structure problem of the 2003 Lincoln Aviator

Failure Date: 11/01/2004

Multiple failures in 2003 Lincoln Aviator. Difficulty turning , starting, jerk in steering wheel, vibration in tires, gear changer loose and ect. The consumer purchased the vehicle with 18 inch rims but Ford requires 17 inch rims to be legal (oem) equipment. The consumer felt that this was maliciously dishonest sale of an automobile. The side fender had a gauge on the inside, the rear storage section leather ripped, the tire monitor system kept coming on with a warning sign from the computer of a mechanical defect, difficulty starting the vehicle, jerking in the steering wheel, noise in the steering wheel, noise in heating/vent bubbling, passenger front windows were rattling, there was motor noise upon acceleration, front end noise, rear hatch rattled and was shaking, the wheels squealed and rubbed, the doors did not automattically lock when the vehcile was engaged into drive, and the engine knock as if it were running rough. When the service tech tried to shift the gear lever out of park, the entire gear lever had come apart in pieces. The consumer stated that the vehicle was worse than ever. Currently when the brakes were applied the steering would go out of control, jerk left and right, shaked out of control and unable to steer.

10 Structure problem of the 2003 Lincoln Aviator

Failure Date: 09/01/2004

Consumer states that dealer put aftermarket rims tires on vehicle. The vehicle experienced the following; difficulty turning the vehicle, heater bubbling making noises, difficulty starting the vehicle, jerking in the steering wheel, noise in the steering, noise in the heating/vent bubbling, pulsating in the steering wheel, vibration of the tires, the tire monitoring system had to be cut off reconnected and adjusted, the passenger front windows rattled, motor made loud noises when the vehicle accelerated, front end noises, rear hatch rattled and would shake, the wheels squealed and rubbed, the wheel jerked when taking off, the gear changer lever was loose, the vehicle would shake and vibrated when in motion, and the engine sounded as if it was knocking or running rough.


Other Common Structure related problems of Lincoln Aviator


Aviator Service Bulletins
Aviator Safety Recalls
Aviator Defect Investigations