2022 Ford Expedition Body & structure Problems

The contact owns a 2022 Ford Expedition. The contact received notification of NHTSA Campaign Numbers: 25V455000 (Fuel System, Gasoline), 26V204000 (Visibility), and 26V368000 (Structure); however, the part to do the recall repair was not yet available. The local dealer was 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.

NHTSA ID

11749999

Incident

Jul 13, 2026

The contact owns a 2022 Ford Expedition. The contact stated that while driving approximately 75 MPH, the sunroof windscreen flew off and landed on the highway. The vehicle was taken to a dealer, where it was determined that the sunroof windscreen needed to be replaced. The vehicle was repaired; however, the failure reoccurred approximately five months later. The contact stated that while driving approximately 75 MPH, the sunroof windscreen flew off onto the highway again. The vehicle was taken to the same dealer, where it was determined that the sunroof windscreen needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 32,065.

NHTSA ID

11733250

Incident

May 20, 2025

Mileage

32,065 mi

Moonroof rubber sealant allowing water in

NHTSA ID

11718858

Incident

Feb 16, 2026

The contact's father owns a 2022 Ford Expedition. The contact stated that while driving 70 MPH on the highway, the roof rail trim, and the area in front of the roof rail trim detached. The local dealer was contacted. The vehicle was not diagnosed or repaired. The manufacturer was contacted, and a case was opened. The manufacturer informed the contact that assistance could be provided after the dealer had determined the cause of the failure. The failure mileage was approximately 50,000.

NHTSA ID

11677454

Incident

Jul 27, 2025

Mileage

50,000 mi

The contact owns a 2022 Ford Expedition. The contact stated that while opening the hatch by engaging the automatic release switch, a hole formed in the sheet material, and the spoiler was fractured. The contact stated that there was an abnormal loud clicking sound prior to the failure. There was no warning light illuminated. The vehicle was taken to the local dealer but was not diagnosed or repaired. The manufacturer was contacted and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 40,000.

NHTSA ID

11666464

Incident

Jan 1, 2025

Mileage

40,000 mi

A-pillar/hinge integrity engineering concern. While opening my door in a parking lot, the wind caught the door before I could catch the door. The door met the hinge stop and flexed enough for the edge of the door panel to contact a bolt on the A-pillar door hinge assembly, causing a small crease in the aluminum door panel. My concern is that in 30 years of driving, I have had a door caught be wind before but never had damage to the vehicle. This was not a strong wind, just enough to catch the door. The A-pillar is now flexed slightly such that the door panel gap is larger and seems related to the actual A-pillar flex, not a hinge failure. Vehicle testing of the 22 Ford Expedition has show some poor performance in the A-pillar area and I am concerned that this door issue is due to poor engineering and strength of the A-pillar. I have had the vehicle inspected at the Ford dealership and a customer service complain with Ford is in process. I do not feel this issue can be attributed to user error or considered "accidental" but is due to structural/safety deficiency of the A-pillar structure. [XXX] [XXX] Thank you INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6

NHTSA ID

11661451

Incident

Nov 3, 2023

The contact owns a 2022 Ford Expedition. The contact stated while the vehicle was parked, the contact opened the liftgate, and the liftgate failed to operate as intended. The contact stated that the liftgate struck the roof and caused the liftgate to be damaged. The contact stated that when it was cold, the liftgate failed to operate as intended. The vehicle was taken to a dealer and diagnosed that there was insufficient margin between the liftgate and roof spoiler. The contact was provided with Manufacturer's Recall Number: SSM 53469. The manufacturer was made aware of the failure but provided no assistance. The failure mileage was approximately 37,000.

NHTSA ID

11657278

Incident

Jan 28, 2025

Mileage

37,000 mi

I am writing to formally report a significant issue with my vehicle that has resulted in damage to the roof and potential long-term integrity concerns. The liftgate spoiler is contacting the roof in freezing temperatures, which creates a hole in the roof when opening the liftgate. Upon inspection, it appears there is an insufficient margin between the liftgate spoiler and the roof area centerline. This problem is particularly concerning because a hole in the roof allows moisture to penetrate, jeopardizing the structural integrity of the roof and potentially leading to further damage, such as rust or water intrusion into the vehicle. I believe this issue may be the result of a design flaw and would like to request an immediate inspection and resolution. As this defect directly impacts the durability and safety of the vehicle, I urge you to treat this matter as a priority. Please let me know how this issue can be resolved, including any repairs, adjustments, or recalls that may apply. I am happy to provide photographs or additional documentation if needed.

NHTSA ID

11635707

Incident

Jan 10, 2025

The contact owns a 2022 Ford Expedition. The contact stated that while starting the vehicle, there was a moldy odor coming from the vents. The vehicle was not diagnosed or repaired by an independent mechanic or local dealer. The manufacturer was made aware of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 30,000. The VIN was not available.

NHTSA ID

11603220

Incident

Apr 23, 2024

Mileage

30,000 mi

We started to notice some body issues -rear side fenders popping out, the front grill popping out,, the inside screen would go blank, fuel tank lid pops open. As if this was not enough - we then encountered more issues - sunroof was falling on our heads, the step up railing is falling apart....WAIT- there's more - paint coming off the hood...And to top it all off - there is a cracking noise thru the inside. We cannot control the noise. We lose all function and use of controls (radio, climate, etc.).

NHTSA ID

11579525

Incident

Dec 14, 2022

In December of 2023 (not even one full year after purchasing my brand new Ford Expedition) I used the FOB to remotely open the trunk on my 2022 Ford Expedition. Upon doing so, I heard popping and cracking sounds. I didn't see any damage, so I didn't think anything of it until I drove on the interstate and immediately heard a violent slapping noise coming from the back of my vehicle. I took the truck to the dealership (where I purchased my vehicle). They inspected the vehicle and said that the spoiler is misaligned and loose - causing the sound and also resulting in a dent on the roof of the vehicle. The dealership said that Ford would not cover the repair under their FULL BUMPER TO BUMPER WARRANTY. Three other people with new Ford Expeditions at my dealership have experienced this exact issue. (Also a simple Google search of "Ford spoiler issue" will demonstrate that many others have experienced this issue.) I am extremely nervous to drive my vehicle anywhere as it sounds and feels like the spoiler is going to fly off of the vehicle especially when I drive on the interstate. This is a HUGE safety issue. The spoiler is loose and could fly off on the highway and cause an accident or hit another vehicle. NHTSA is aware of this issue and submitted an SSM to Ford [XXX] ), but Ford will not recall or cover repairs to their vehicles that have a defect and pose a safety risk. This needs to be immediately rectified before someone is seriously hurt. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11570021

Incident

Dec 7, 2023

The contact owns a 2022 Ford Expedition. The contact stated that the vehicle had collected snow and while opening the trunk, the spoiler fractured. The vehicle was taken to an Auto Body shop, where it was determined that the spoiler needed to be replaced. The vehicle was not repaired. An unknown dealer was contacted, and a voicemail message was left. The manufacturer was not notified of the failure. The failure mileage was approximately 19,000.

NHTSA ID

11566963

Incident

Jan 20, 2024

Mileage

19,000 mi