2025 Ford Expedition Problems: 3 Known Issues
2025 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated November 2026
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2025 Ford Expedition has 3 documented known issues, with 2 rated critical. The most serious are 3.5L EcoBoost Engine Cup Plug Misalignment and Rapid Oil Leak (Recalls 24V851 / 25V198) ($0-$0 repair) and Electronic Brake Booster Module Malfunction and Loss of Power Brake Assist (Recall 25V823) ($0-$0 repair). DIY maintenance guides at au7o.io.
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All 3 Known Issues
NHTSA Recalls11 recalls
ENGINE AND ENGINE COOLING:ENGINE:OIL/LUBRICATION
Ford Motor Company (Ford) is recalling certain 2024-2025 F-150, Expedition, and 2024 Lincoln Navigator vehicles equipped with 3.5L GTDI engines. The engine may have a misaligned engine cup plug, which can result in a rapid oil leak.
AIR BAGS:FRONTAL
Ford Motor Company (Ford) is recalling certain 2025 Navigator and Expedition vehicles. The passenger side air bag may have been manufactured incorrectly, which can cause the air bag to deploy with excessive force during a crash.
SERVICE BRAKES, HYDRAULIC:POWER ASSIST:ELECTRIC:CONTROL MODULE:SOFTWARE
Ford Motor Company (Ford) is recalling certain 2025 Lincoln Navigator, F-150, Expedition, Bronco, and Ranger vehicles. The Electronic Brake Booster (EBB) module may malfunction while driving or when the driver is utilizing an Advanced Driver Assistance System (ADAS) feature, resulting in a loss of power brake assist.
SERVICE BRAKES, HYDRAULIC:POWER ASSIST:ELECTRIC:CONTROL MODULE
Ford Motor Company (Ford) is recalling certain 2025 Lincoln Navigator, F-150, Expedition, Bronco, and Ranger vehicles. The Electronic Brake Booster (EBB) module may malfunction while driving or when the driver is utilizing an Advanced Driver Assistance System (ADAS) feature, resulting in a loss of power brake assist.
ELECTRICAL SYSTEM: INTEGRATED TRAILER BRAKE CONTROL
Ford Motor Company (Ford) is recalling certain 2021-2026 F-150, 2022-2026 F-250 SD, F-350 SD, F-450 SD, F-550 SD, Maverick, 2024-2026 Ranger, 2023-2026 F-600 SD, 2022-2027 Lincoln Navigator, Expedition, and 2026 E-Transit vehicles. When towing a trailer, the integrated trailer module (ITRM) may lose communication with the vehicle, possibly causing a loss of brake and turn signal lights, or a loss of brake function. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 108, " Lamps, Reflective Devices, and Associated Equipment."
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Frequently Asked Questions
What are the most common Ford Expedition problems?
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2025 Ford Expedition has 3 documented issues. Documented issues include: 3.5L EcoBoost Engine Cup Plug Misalignment and Rapid Oil Leak (Recalls 24V851 / 25V198), Electronic Brake Booster Module Malfunction and Loss of Power Brake Assist (Recall 25V823), Third-Row PowerFold Seats Inoperative - Seat Module Software (SSM 53824). Of these, 2 are rated critical and should be addressed promptly.
Is the Ford Expedition reliable?
The 2025 Ford Expedition has 3 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 2 issues are rated critical: 3.5L EcoBoost Engine Cup Plug Misalignment and Rapid Oil Leak (Recalls 24V851 / 25V198) and Electronic Brake Booster Module Malfunction and Loss of Power Brake Assist (Recall 25V823). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
How much does it cost to fix common Ford Expedition problems?
Repair costs for known Ford Expedition issues range from $0 to $0, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 3.5L EcoBoost Engine Cup Plug Misalignment and Rapid Oil Leak (Recalls 24V851 / 25V198), typically costs $0-$0 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What is the 2024-2025 Ford Expedition 3.5L EcoBoost Engine Cup Plug Misalignment and Rapid Oil Leak (Recalls 24V851 / 25V198)?
On 2024-2025 Expeditions with the 3.5L GTDI EcoBoost, a cup plug in the engine cylinder head may have been installed misaligned at the engine plant. The misaligned plug can unseat and release engine oil rapidly, dropping oil pressure and stalling the engine with little warning. B… Repairs typically run $0-$0. Severity: high.
What is the 2025 Ford Expedition Electronic Brake Booster Module Malfunction and Loss of Power Brake Assist (Recall 25V823)?
Certain 2025 Expeditions have an electronic brake booster whose integrated-circuit manufacturing variation can trigger a fault state and remove brake boost, including during driver-assistance braking. Stopping distance may increase. The December 1, 2025 filing lists 17 Expedition… Repairs typically run $0-$0. Severity: high.
What is the 2025 Ford Expedition Third-Row PowerFold Seats Inoperative - Seat Module Software (SSM 53824)?
Ford SSM 53824 states that some 2025 Expedition vehicles with third-row power seats may have an inoperative power-fold function when the 3L, 3R or Both switch is pressed, which may be due to software in seat control module J (SCMJ). Ford gives a relearn procedure, notes the condi… Severity: low.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.