NHTSA Complaint #11673647 — 2021 FORD EXPEDITION

This vehicle continues to exhibit transmission shuddering, slipping, and hesitation during acceleration—despite two full transmission replacements in two years and multiple dealership service visits. These unresolved issues compromise safe operation, especially during highway merging, rapid acceleration, and lane changes. Both dealerships were unable to permanently address the issue after extensive mechanical intervention. Ford has issued multiple Technical Service Bulletins addressing transmission concerns in the 10R80 unit used in the Expedition. The most recent bulletin, TSB 25-2132, revises procedures for harsh and delayed shifting, shudder, and internal hydraulic leakage tied to the CDF clutch drum—which aligns directly with the findings from my own transmission overhaul documented in June 2023. Previous service entries noted suspected internal leakage around the CDF clutch, RPM flare during shifts, gear hesitation, and recurring drivability issues despite component replacement. These match symptoms targeted in prior TSBs, including: TSB 23-2123: Harsh engagement and shift delays TSB 24-2101: Hydraulic leakage diagnosis linked to clutch cylinder TSB 25-2023: Update to inspection and service steps for gear shift quality While dealerships performed repairs and even full transmission replacements, the lack of lasting resolution and repeat issues reflect a broader mechanical defect addressed reactively rather than proactively through these bulletins. Despite awareness at the manufacturer level, I experienced significant delays, financial burden, and ongoing drivability risks. I respectfully request that NHTSA further investigate Ford’s handling of repeated 10R80 transmission failures in the Expedition, particularly concerning the effectiveness of these bulletins in preventing recurrence and mitigating safety impact