NHTSA Complaint #11690000 — 2022 FORD EXPEDITION

Recently, the rear evaporator core failed, causing a refrigerant leak that disabled the entire A/C system. This left both the front and rear HVAC units inoperable, which not only compromises passenger comfort but also directly impacts safety by reducing the system’s ability to defrost and dehumidify the windshield in hot and humid conditions. After researching this issue, I have confirmed that rear evaporator core failures are being reported by numerous 2021–2023 Expedition owners, many of whom describe identical failures at relatively low mileage. These failures often result in costly repairs ranging from $2,000–$3,500. While Ford has issued Technical Service Bulletins (e.g., TSB 22-2089) related to evaporator and sensor issues on Expeditions, there is currently no recall or extended coverage program for rear evaporator core failures. However, the pattern of owner complaints, dealer diagnoses, and additional NHTSA filings shows that this is a known defect affecting a critical vehicle system. Given: •The premature and widespread nature of these failures, •The documented safety concerns raised in NHTSA complaints, and •The high financial burden placed on customers for what appears to be a design defect, I contacted my local dealer who filed a claim with Ford customer support. My claim was immediately denied and they did not offer any financial support. The year of the vehicle was within 3yr/36,000 warranty however current mileage is ~44,000 and exceeded threshold for warranty assistance.