NHTSA Complaint #11521666 — 2019 FORD EXPEDITION

This vehicle with 72,000 miles on it was experiencing a rattle upon start on cold mornings for about two months, it didn't happen every time and only on initial start. Mechanic couldn't get the incident to happen in his presence to diagnose and no codes reported from computer diagnostic equipment. In February 2023, the vehicle lost power while highway driving and seemed to having problems shifting. The check engine and powertrain malfunction indicator both came on. Drove the vehicle immediately to mechanic. Booster sensor replacement was indicated by computer diagnostic and was replaced. On 4/16/2023 the check engine light came on briefly while driving and then went out and did not come back on. On 4/18/2023 while driving on the highway the vehicle started making a loud clanking with black smoke from exhaust pipe. We had the vehicle towed to mechanic. Over 30 diagnostic codes reported and mechanic recommended we take the vehicle to a Ford dealership. We had the vehicle towed to the local Ford dealership and have been informed that this 4 year old, 72,000 mile vehicle needs a complete engine replacement for $18,222. They do not know what caused the problem without pulling the whole engine and opening it up, but recommend a full replacement. We have contacted Ford and opened a case with them, but since the vehicle had a 60,000 mile power train warranty there is nothing that Ford is willing to do.