2025 FORD EXPEDITION — Problems, Recalls & Safety Data

While driving down the road, the sunroof spontaneously exploded. The loud bang (sounded like a gun shot) and tiny pieces of glass, that luckily were caught in the sunshade, could have been disastrous for my wife and our three small children that were in the car. The glass is bowed outwards. It has been taken back to Mullinax Ford Dealership for repair. They tell me it will not be covered under any warranty. There were no warning signs before now that there could be a problem with this sunroof, we only have 5k miles on the vehicle.

In June 2025, I bought a new 2025 Ford Expedition King Ranch. While washing my SUV by hand, I discovered a manufacturing defect on the roof—Ford Manufacturing had left exposed welding and rivets. The issue is quite noticeable, with depressions around the rivets and welds so deep they could hold golf balls. More than two dozen of these rivet welds are visible and exposed. I contacted my local dealership in Sioux Falls, SD to file a warranty claim, but it was denied. During this process, the dealership informed me that their lot was filled with Expeditions and Lincoln Navigators showing the same problem, indicating that it's a widespread concern among all dealers. After my claim was denied, I reached out to Ford's nationwide customer support at [XXX] and was given case number CXh-XXX. After two conversations, it became clear that Ford's organization was not effectively communicating internally. My dealership thanked me for bringing the issue to Ford Corporate, as resolving it is financially important to them. Sioux Falls Ford contacted the local Ford Factory Representative, but no solution has been provided so far. The presence of these divots allows water to accumulate in the crevices, potentially leading to severe corrosion in southern regions exposed to salty ocean air. In northern areas, freezing and thawing cycles may cause further structural Integrity deterioration, both overtimes causing catastrophic failure. At no time did Ford disclose these defects to their dealership network, and had it been, proper disclaimers would have been required on vehicle window stickers. Nor was I informed about the exposed rivets, welds, or dents on the roof prior to purchase. Ford Manufacturing failed to disclose material information regarding this issue. Ignorance is not an excuse—Ford Manufacturing misled me by failing to reveal the roof defect. The manufacturer date of my Ford Expedition was May of 2025. See attached pictures. HELP!! Kind regards [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FO

While driving at 35mph, downhill with no traffic in front, behind, or oncoming, the dash flashed red and immediately the brakes were instantly applied harshly causing occupants to lunge forward into seat belt restraint. Vehicle deceleration almost to a stop. Brakes then released . Driver continued home and was afraid to continue operating the vehicle. Dealer was called and picked up the vehicle. Dealer inspected vehicle and could not find a problem. Per the service writer no recall or TSB found on this issue. Vehicle has been returned 1/26/2026. Collision avoidance system has been turned off per our request. Mileage 2458. In service date 07/26/2025.

While driving at 35mph, downhill with no traffic in front, behind, or oncoming, the dash flashed red and immediately the brakes were instantly applied harshly causing occupants to lunge forward into seat belt restraint. Vehicle deceleration almost to a stop. Brakes then released . Driver continued home and was afraid to continue operating the vehicle. Dealer was called and picked up the vehicle. Dealer inspected vehicle and could not find a problem. Per the service writer no recall or TSB found on this issue. Vehicle has been returned 1/26/2026. Collision avoidance system has been turned off per our request. Mileage 2458. In service date 07/26/2025.

While driving at 35mph, downhill with no traffic in front, behind, or oncoming, the dash flashed red and immediately the brakes were instantly applied harshly causing occupants to lunge forward into seat belt restraint. Vehicle deceleration almost to a stop. Brakes then released . Driver continued home and was afraid to continue operating the vehicle. Dealer was called and picked up the vehicle. Dealer inspected vehicle and could not find a problem. Per the service writer no recall or TSB found on this issue. Vehicle has been returned 1/26/2026. Collision avoidance system has been turned off per our request. Mileage 2458. In service date 07/26/2025.