Ford Expedition misfire problems

Filed Sep 30, 2026 · Seat belts · FL · 1 injury

While operating the vehicle, the seatbelt retractor unexpectedly misfired and deployed with explosive force directly adjacent to my left ear. As a military veteran who already manages service-connected tinnitus, the concussive sound—comparable to a gunshot—significantly aggravated my condition, resulting in elevated ringing and heightened health impacts. ​Furthermore, the seatbelt mechanism is now permanently locked in a compromised position. This creates an unsafe driving environment, as it squeezes me tightly against the seat and distances me improperly from the steering wheel. ​This failure has severely impacted multiple aspects of my daily life: ​Professional Impact: My role as a Security Project Manager requires frequent travel between various operational sites. The current condition of the vehicle makes commuting unsafe and directly impedes my ability to perform my job duties. ​Health & Lifestyle: The physical discomfort, combined with the severe aggravation of my pre-existing ear condition and the general disruption to my family's routine, has caused significant distress. ​Following the incident, I contacted Ford frontline support, documented the situation, and received a case number. I was advised to bring this case number to my local Ford service department to secure a courtesy vehicle or loaner. They could not provide loaner and has sent me to Hertz ​As a loyal, repeat Ford customer who has purchased multiple vehicles from the brand. Given the safety implications and the disruption to my work and health, I request immediate assistance regarding a safe, long-term resolution and appropriate temporary transportation. ​

Filed Mar 21, 2026 · Engine · TX

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

Filed Jan 7, 2026 · Transmission · IL

At approximately 100,500 miles, my 2018 Ford Expedition XLT 3.5L EcoBoost developed loud rattling noises consistent with cam phaser failure. Zeigler Ford confirmed the failed cam phasers on October 20, 2025. These phasers were previously replaced on the vehicle at 51,000 miles on February 10, 2022, at Al Piemonte Ford under the Customer Satisfaction Program 21N03. They used the old phasers HL3Z-6C525-CD which are known to be defective rather than the new updated phasers ML3Z-6C525. Cam phaser failure can cause engine misfires, loss of power, and potential engine damage, creating a serious safety risk, especially at highway speeds. This issue has been reported by multiple Ford Expedition owners, indicating it is not isolated. I request that the federal safety agency investigate whether this defect warrants a recall or expanded coverage for vehicles like mine that exceed CSP mileage limits. My vehicle has been properly maintained, and the failure is due to a known defect in the 3.5L EcoBoost cam.

Filed Aug 20, 2025 · Engine, Fuel system · FL

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.

Filed May 9, 2025 · Engine, Transmission · VA

1. The issue involves the transmission and camshaft components of the vehicle. Despite the fact that both the transmission and camshaft were replaced by the Ford dealership after purchase in 2018, the vehicle continues to experience problems. These components have been inspected by the dealership, and the vehicle is available for further inspection upon request. 2. The vehicle’s loss of power during highway driving and while attempting to accelerate poses a significant safety risk. On several occasions, the vehicle has lost power while making turns or driving on the highway, nearly causing accidents with other vehicles. This has been a very frightening experience for us, as the sudden loss of power could have led to a collision. 3. Yes, the problem has been confirmed by the Ford dealership, which replaced the transmission and camshaft components. However, the vehicle continues to run roughly, indicating that the issues have not been fully resolved. These repairs were not covered under warranty, and we had to pay for them out of pocket. 4. The vehicle has been inspected by the Ford dealership multiple times. Despite the repairs, the problems persist. The vehicle has been regularly maintained and garage-kept. 5. There were no warning lamps, messages, or error codes indicating the problem before the failure. However, there has been a loud ticking sound when the vehicle is started and running, which started to occur after the initial repairs. The vehicle has had no other prior indicators to suggest the underlying issue. We purchased the vehicle brand new with only 11 miles on it it currently barely has 70k miles on it. We dropped the vehicle off at the beginning of August 2024 and didn't get it back until almost the end of October, with us needing to bring it back to the dealership for more checks/repairs in December of 2024. We have to pay out of pocket and are without a vehicle because of the constant issues and safety concerns. we can provide receipts and more docs

Filed Nov 19, 2024 · Engine · 128,000 miles · IN

The contact owns a 2016 Ford Expedition. The contact stated that the vehicle was making an abnormal rattling sound on cold starts. The contact stated that the failure recurred while driving from a complete stop and while coming to a stop. The contact also stated that the vehicle was experiencing rough idling. Additionally, the contact stated while driving at approximately 35 MPH, the vehicle inadvertently stalled. The check engine warning light was illuminated. The vehicle was taken to P&B Auto Repair Shop, where it was diagnosed that the cam phasers had failed and needed to be replaced. The vehicle was not repaired. The dealer was notified of the failure. The manufacturer was notified of the failure and referred the contact to the federal safety agency Hotline for assistance. The failure mileage was approximately 128,000.

Filed Nov 14, 2024 · Engine · 107,884 miles · AK

My expedition was reprogrammed when I bought it due to the Cam phaser rattle. This did not help. I was told this was normal and would not effect the engine. I had taken it in a second time to be reprogrammed an given the same information. My Ford service says fifth cylinder misfire. The car shakes and idles hard. The spark plug and parts were replaced as suggested with no change. Took it to the shop and was told I now need a new engine due to an internal failure of the engine. I called Ford and they said there is no recall on this year. The Cam phaser reprogram was a customer satisfaction and not a recall. I asked if they would offer assistance since now I need a new engine. They will not. I called about ordering a new engine. Iwas was told there is over 250 people waiting for an engine as they are backordered by the Ford service department. It will be $10,000 plus 1200 for the core plus install. There are no availble engine due to the backorder and you must pay for the parts to get on the waitlist. The earliest they will release them is in November. How are there this many people waiting for an engine and no recall? This is a safety issue as all cylinders are not firing and there is not enough compression to make the vehicle run correctly. The check engine light appears solid upon starting the car and then will start blinking. The vehicle was inspected by an independent shop as I took my expedition to Ford for 60,000 service and they put the wrong fluid in my differential and then I had to have this rebuilt by them. After telling them something was wrong multiple times after they gave it back. So I do not trust to take it back to them. The independent shop confirmed this is a problem with these engines. I took it in due to the check engine light and hard idle that was getting worse.

Filed Oct 28, 2024 · Engine, Transmission · 20,000 miles · FL

The contact owns a 2019 Ford Expedition. The contact stated that the vehicle was making an abnormal rattling sound on cold starts. The vehicle was taken to the dealer, where the powertrain control module (PCM) was flashed under Ford Campaign Number: 21N03; however, the failure recurred. The dealer was contacted and informed the contact that the vehicle needed to be left with the dealer for three weeks for the cam phasers replacement; however, the contact declined because the dealer did not offer vehicle rental assistance. The contact stated that the failure progressively worsened. The contact stated while driving at various speeds and depressing the accelerator pedal, the engine misfired. The check engine warning light was illuminated. The dealer was notified of the failure and informed the contact that the vehicle was no longer covered under warranty. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 20,000.

Filed Oct 11, 2024 · Transmission · 117,836 miles · AZ

The contact owns a 2018 Ford Expedition. The contact stated while driving at an undisclosed speed, the accelerator pedal was depressed, however, the vehicle failed to accelerate as intended. The contact stated that the vehicle was shaking and jerking. In addition, the contact stated that the vehicle misfired. The vehicle was taken to an independent mechanic where it was diagnosed with a failed transmission. The contact was informed that the transmission needed to be replaced. The vehicle was not repaired. The dealer was made aware of the failure and advised the contact that the repair was not covered under any unknown recall. The manufacturer was made aware of the failure but provided no assistance. The failure mileage was approximately 117,836.

Filed Oct 8, 2024 · Electrical, Engine · MS

I read that there is a recall on 2021/2022 Fords with Eco Boost but not the 2020. I have had my vehicle into the dealership multiple times due to misfires and loss of all power which has almost caused multiple accidents on the interstate. I accelerate to get into the left lane and lose all power and do not get power back until my vehicle decelerates down to around 40 mph/or a lower gear, causing semi’s and other vehicles to have to slam on their brakes so that they do no run into the back of me. It idles very roughly and overall has been the worst vehicle mechanically that I have ever owned. The dealerships always say they cannot find anything wrong with it or cannot reproduce it but it happens on a daily basis and keeps getting worse. I have had the transmission updated, changed the cool packs, and changed the plugs which has not helped at all. I want to know why the 2020 Expedition is not included in this recall? This is the most expensive vehicle I have ever purchased and I would expect it to run smoothly with no issues and I am very disappointed. Not only disappointed in the vehicle, but in Ford itself for not acknowledging this issue. I have read many complaints from other customers experiencing the same issues and unable to find a fix for it. I would like some answers and for Ford to make things right with my Expedition. I am not able to trade it in or sell it due to having all the issues that it has and frankly I’m not sure I trust Ford anymore or if I’ll ever buy a Ford product again and we have been faithful Ford owners for years. Thank you for your time and I’ll be looking forward to hearing back from you soon regarding this issue. Sincerely, [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)