NHTSA Complaint #11692517 — 2018 FORD EXPEDITION

The sunroof on my 2018 Ford Expedition is leaking at multiple points and has become stuck and inoperable. The dealership advised that the brackets are broken and the entire sunroof assembly must be replaced. The leak occurs in several areas across the Vista Roof, causing water to enter the cabin. This appears to be related to known design defects already referenced in multiple Ford Technical Service Bulletins (TSB 18-2374, TSB 19-2374, and TSB 21-2292). Details: I purchased this 2018 Ford Expedition on August 17, 2024, from Battlefield Ford in Culpeper, Virginia, where it underwent a Ford Blue Warranty inspection before sale. The vehicle had approximately 98,000 miles at purchase and now has around 109,000 miles. Shortly after purchase, I noticed water intrusion from the sunroof area. The vehicle was inspected at Sheridan Ford in Smyrna, Delaware, where technicians confirmed leaks at four separate points, broken sunroof brackets, and recommended complete sunroof replacement. In addition to the leaks, the sunroof is stuck and will not operate properly. Ford customer service was contacted, but they stated that no assistance or goodwill coverage would be provided. I find this unacceptable given the severity of the issue, the existence of related TSBs, and the potential safety hazards associated with electrical and visibility impairment due to water intrusion. The vehicle also required brake replacement shortly after purchase, despite being reported as low 3 mm during the Blue Warranty inspection, which raises additional concerns about the adequacy of Ford’s inspection process and potential oversight of critical components. Safety Concerns: Water intrusion may affect electrical components, airbags, or roof-mounted sensors, increasing the risk of malfunction or short circuits. The sunroof’s inability to close or seal properly could result in driver distraction, loss of visibility, or mold and corrosion inside the cabin.