Problems owners report
Complaints filed with NHTSA about the 2005 Ford Expedition, by the system named in each complaint. One complaint can name several.
- Electrical system76
- Vehicle speed control66
- Engine57
- Engine and engine cooling47
- Power train44
- Fuel system, gasoline36
- Fuel/propulsion system20
- Structure15
- Steering10
- Fuel system, other9
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 20 injuries and 0 deaths reported
Compared with other years
199719981999200020012002200320042005200620072008200920102011201220132014201520162017201820192020202120222023202420252026
NHTSA ODI complaints by model year
Fatal crashes in the US
From 2020 to 2023, 51 2005 Expedition vehicles were involved in crashes on US public roads in which someone died; 24 people died inside them, and 13 of the vehicles rolled over. This is a count, not a crash rate: it grows with the number of cars on the road.
NHTSA Fatality Analysis Reporting System (FARS), crash years 2020–2023 (public domain)
New York safety inspections
At its first New York inspection the 2005 Ford Expedition failed the safety check 2.22% of the time — 4% less often than the average 2005 passenger car (2.30%). Median odometer at inspection: 150,986 miles.
1,667first inspections
2.22%failed on safety
150,986 mimedian odometer
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
In New Zealand
1 2005 cars are on the New Zealand register; 100% arrived as used imports, 0% were sold new in New Zealand.
NZ Transport Agency Waka Kotahi, Motor Vehicle Register (March 2026) · CC BY 4.0
Fuel consumption
Official Canadian test results for 1 variant: combined 16.6 L/100 km (about 14 mpg US), CO₂ 382 g/km.
| Variant | City | Highway | Combined |
|---|---|---|---|
| Expedition 4X4 · Sport utility vehicle · Regular gasoline | 18.5 | 14.2 | 16.6 |
Litres per 100 km. Natural Resources Canada, Fuel consumption ratings (open.canada.ca) · Open Government Licence – Canada
Recalls
No recall campaigns cover the 2005 Ford Expedition.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Ford told its dealers about the 2005 Ford Expedition: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 11005305 | This article supersedes TSB 22-2219 to update the Parts List and Service Procedure to clarify applicable steps by vehicle application. Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 (non-Raptor) vehicles equipped with 4WD may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (IWE). To correct this condition, follow the Service Procedure to remove and cap the vacuum supply line or to reprogram the transfer case control module (TCCM) and replace any worn vacuum and/or IWE components. |
| 10235153 | For 2000-2024 Ford and Lincoln vehicles, swapping a module from a vehicle for diagnosis purposes is likely to cause errors and is not recommended. It is also not recommended to order a replacement module using a vehicle identification number (VIN) from a different vehicle. Most modules on these affected vehicles are VIN/vehicle specific and hardware variations between modules do exist. Swapping a module from a vehicle or ordering a module using a different vehicle/VIN can cause ineffective repairs and additional vehicle down time. Make sure all appropriate Workshop Manual (WSM) procedures are |
| 10214754 | Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 (non-Raptor) vehicles equipped with 4WD may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (IWE). To correct this condition, follow the Service Procedure to remove and cap the vacuum supply line or to reprogram the transfer case control module (TCCM) and replace any worn vacuum and/or IWE components. |
| 10181917 | Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 vehicles equipped with TOD transfer cases may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (IWE). To correct this condition, follow the Service Procedure steps to remove and cap the vacuum supply line. |
| 10177863 | This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. |
| 10156863 | Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition |
| 10155551 | Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition |
| 10143079 | Various vehicles equipped with a 4.6L, 5.4L, 6.8L modular 3 valve engine built on or before 8-Jan-2016 may exhibit symptoms that may include upper end engine noise, rough running, misfire and/or engine damage. If diagnosis leads to only camshaft/camshaft roller follower(s) requiring replacement, replace all of the camshaft roller followers on both banks/cylinder heads with part number 3L3Z-6564-A, not just the faulty roller follower(s). When replacing the camshaft roller followers, refer to Workshop Manual (WSM), Section 303-01. |
| 10109070 | The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate when reading these PIDs and cannot display quickly enough to validate a concern. The PCM automatically monitors these inputs more accurately and will set diagnostic trouble codes (DTCs) when appropriate. Using these PIDs for diagnostics will lead to inaccurate results and improper ETB replacements. If a concern is intermittent and no DTCs are present, refer |
| 10109021 | When ordering a 2005 to 2008 remanufactured 5.4L 3v or 6.8L 3v engine, spark plug boots may be provided in the packaging. Replace all black spark plug boots from the original engine with the 'brown' spark plug boots, as provided. The updated 'brown' spark plug boots are longer than the black boots to accommodate a running change in the spark plug length. The ignition coil bodies and spring/resistor are transferable and only the rubber boots require replacement. Failure to install the spark plug boots provided with the replacement engine could lead to drivability concerns. |
| 10056148 | LINCOLN/FORD: WHEN DRIVING FROM IDLE UP TO 1200 RPM, THERE MAY BE AN INTERMITTENT RATTLE NOISE COMING FROM ENGINE. 2004-2013 F-150, F-250, F-350, EXPEDITION, MARK LT, NAVIGATOR. *PE |
| 10048099 | FORD/LINCOLN/MERCURY: MAY HAVE SLUDGE BUILDUP IN THROTTLE BODY LEADING TO LESS AIRFLOW OR ENGINE IDLING RPM FLUCTUATION AND HARD STARTS OR BATTERY DISCONNECT OR DEAD BATTERY AFTER KEEP ALIVE MEMORY (KAM) CLEAR. MODELS 2003-05 THUNDERBIRD, 05-06 MUSTANG, 06-08 FUSION, 04-05 EXPLORER, 05-06 EXPEDITION, 05-07 F-150; 2003-06 LS, 06 ZEPHYR, 05-06 NAVIGATOR; 06-08 MILAN. *PE |
| 10032614 | FORD: SOME HYBRID VEHICLES MAY EXHIBIT AN INTERMITTENT RED TRIANGLE ON AND STOP SAFELY NOW MESSAGE DISPLAYED ON THE MESSAGE CENTER, ACCOMPANIED BY A SUDDEN RPM LOSS/NO START WITH A DIAGNOSTIC TROUBLE CODE (DTC) P1A0C. *PE |
| 10028736 | FORD: SOME VEHICLES MAY EXHIBIT OIL SEPARATION FROM THE INTERNAL LUBE FOUND IN THE UNITIZED CARTRIDGE SEAL. OIL SEPARATION APPEARS TO BE AND IS OFTEN MISDIAGNOSED, AS AN AXLE LUBE LEAK. *PE |
| 10024141 | FORD\LINCOLN SERVICE CAMPAIGN: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. CUSTOMER SATISFACTION PROGRAM 07M08: CERTAIN 2005 MODEL YEAR F-150, F-SUPER DUTY, EXPEDITION, AND NAVIGATOR VEHICLES WITH 5.4L 3V ENGINES-EXTENDED WARRANTY COVERAGE ON FUEL INJECTORS. CSC WAS RECEIVED. *NJ UPDATED 5/20/09. *PE |
| 10021072 | AIR SUSPENSION PERFORMANCE - HEIGHT SENSOR LINKAGE ARM DISENGAGING. *KB |
| 10021048 | SPARK PLUG REMOVAL INSTRUCTIONS - 5.4 3V. *KB |
| 10020792 | DIAGNOSTIC TROUBLE CODES (DTC) P0340, P0344, P0345, P0349. ARE FOUND. *KB |
| 10020676 | UN-COMMANDED TCC APPLY ON THE 1-2 SHIFT CAUSING PERCEPTION OF HESITATION AND/OR LACK OF POWER DURING SHIFT. *KB |
| 10020132 | BRAKE SHUDDER. *TT |
| 10019415 | UNINTENDED BRAKE ASSIST. *TT |
| 10019384 | LOW TIRE INDICATOR ON - TPMS SYSTEM SENSOR WAKE UP. *TT |
| 10019383 | 5.4L 3V WITH P030X AND/OR P0316 ACCOMPANIED BY SPARK KNOCK. *TT |
| 10019378 | DIAGNOSTIC TROUBLE CODES P0340/P0344/P0345/P0349 - 4.6L 3V AND 5.4L 3V. *TT |
| 10019064 | VARIOUS ELECTRICAL CONCERNS - 3 BLOCK AUXILIARY RELAY BOX 1 CHAFING - SERVICE TIP. *TT |
NHTSA manufacturer communications (public domain)
NHTSA investigations
PE08070 · Wheelsopened 9 Dec 2008 · closed 15 Apr 2009
STEEL WHEEL FRACTURE
NHTSA Office of Defects Investigation