2,044 of the
12,004 complaints filed about the Ford Expedition
are about the engine —
100% of everything owners reported.
The worst model year for it is 1999.
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.
NHTSA complaint #11763749 — an unverified report by a vehicle owner.
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)
NHTSA complaint #11763468 — an unverified report by a vehicle owner.
EXHAUST FUMES ENTER CABIN WHEN DRIVING LOW SPEEDS AND AT IDLE, ODORS CONFIRMED BY DEALER REPAIR ATTEMPTS MADE BUT PROBLEM STILL EXSIST. FUMES STRONG ENOUGH TO MAKE EYES WATER AND GIVE OCCUPANTS HEADACHES
NHTSA complaint #11762108 — an unverified report by a vehicle owner.
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.
NHTSA complaint #11753596 — an unverified report by a vehicle owner.
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.
NHTSA complaint #11750763 — an unverified report by a vehicle owner.
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
NHTSA complaint #11748552 — an unverified report by a vehicle owner.
Engine light stays on along with manual light and charging system service now. Battery, alternator changed out, 3 mechanic repair shops can not find what is wrong. Vehicle bogs down and does not run right when the Manuel light comes one which is about 2 times a week.
NHTSA complaint #11747439 — an unverified report by a vehicle owner.
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.
NHTSA complaint #11747128 — an unverified report by a vehicle owner.
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.
NHTSA complaint #11746539 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR
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.
NHTSA complaint #11746539 — an unverified report by a vehicle owner.
- 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.
NHTSA complaint #11746565 — an unverified report by a vehicle owner.
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
NHTSA complaint #11745999 — an unverified report by a vehicle owner.
The contact owns a 2019 Ford Expedition. The contact stated that while driving at an undisclosed speed, there was a loud chattering sound coming from the engine before the vehicle stalled. The vehicle was taken to the local dealer who replaced the cam phasers and the vehicle was repaired. The contact stated that the failure reoccurred. Additionally, the A/C failed to blow cool air due to a condenser failure. During the failure, the windows failed to properly defrost, causing a visibility hazard. The vehicle also experienced hard shifting and a shift fault code message was displayed. The cause of the failure was not yet determined. The manufacturer was not contacted. The failure mileage was 40,000.
NHTSA complaint #11744679 — an unverified report by a vehicle owner.
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.
NHTSA complaint #11744803 — an unverified report by a vehicle owner.
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.
NHTSA complaint #11744477 — an unverified report by a vehicle owner.
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.
NHTSA complaint #11743193 — an unverified report by a vehicle owner.