Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 (non-Raptor) vehicles equipped with 4WD may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (IWE). To correct this condition, follow the Service Procedure to remove and cap the vacuum supply line or to reprogram the transfer case control module (TCCM) and replace any worn vacuum and/or IWE components.
full bulletin at NHTSA ↗2005 Ford Expedition powertrain problems
severe 38 complaints filed with NHTSA · avg repair $2,500 · see powertrain across all vehicles →
Failure mileage
Complaints
38
Recalls
0
Avg fix
$2,500
3crashes
When does it fail?
Of the 38 powertrain complaints filed for the 2005 Ford Expedition, here's the actual mileage breakdown — failures cluster heaviest at 50,000-75,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Owners have filed 38 powertrain complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
No new NHTSA powertrain complaint has been filed on this vehicle in over 14 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering powertrain on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
A CLUNK/THUMP NOISE FROM THE REAR WHEN THE TRANSMISSION IS ENGAGED OR SHIFTED, DURING A CHANGE IN VEHICLE DIRECTION OR ON ACCELERATION.
full bulletin at NHTSA ↗CLUNK/GRIND/THUMP NOISE FROM REAR OF VEHICLE WHEN TRANSMISSION IS SHIFTED - VEHICLES BUILT BEFORE 6/13/2005.
full bulletin at NHTSA ↗TINY CRACK OR CRACKS AROUND THE TRANSFER CASE DRAIN PLUG.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2005 Expedition's powertrain emerges as unreliable from these 38 complaints. Electronic throttle control failures dominate—the "CHECK ELECTRONIC THROTTLE CONTROL" warning light appears suddenly, killing engine power mid-drive at any speed (10 mph in a residential area to 70 mph on highways). Owners report losing acceleration without warning, forcing emergency roadside stops or coasts. Restarting the engine temporarily fixes the problem, but it recurs. Dealers have replaced throttle bodies ($514–$700), sensors, coil packs, and cleaned fuel delivery systems, with limited success. One owner confirmed a fouled throttle body caused a dramatic 70 mph failure where the accelerator stuck fully depressed, brakes proved ineffective, and the truck skidded 100–150 feet before stopping.
Transmission issues are equally chronic. Slipping between gears, hesitation before moving, and refusal to upshift on highways appear as early as 15,000 miles. Some transmissions completely lose forward gears while retaining only reverse. Owners report transmission replacements at 28,000 and 63,000 miles, with repair bills reaching $2,500. One transmission replacement under warranty still left a clunking noise, which recurred after a second replacement. Transmission cooler lines corrode and leak, forcing Ford special-order parts with lengthy waits. Combined with rough idle, stalling, and hard starts that persist after spark plug and battery replacement, the powertrain's durability is suspect across multiple systems.
Same Ford Expedition powertrain reports on nearby years: 2006 · 2007 · 2008
Failure modes owners describe
Electronic Throttle Control (ETC) Loss of Acceleration
Engine remains running but accelerator pedal becomes unresponsive or dead, preventing vehicle acceleration. Often accompanied by 'CHECK ELECTRONIC THROTTLE CONTROL' warning light and limp-home/fail-safe mode. Loss of power can occur at any speed without warning. Restarting vehicle temporarily restores function.
When: Intermittent, occurs at various speeds (10–70 mph) and driving conditions; some owners report multiple occurrences over months or years
Symptoms owners cite: Accelerator pedal unresponsive or dead; CHECK ELECTRONIC THROTTLE CONTROL warning light; Engine stalls or goes into limp-home mode; Loss of acceleration without warning; Vehicle coasts to a stop; Temporary restoration of function after restart
Repairs/costs cited: Throttle body cleaning or replacement ($514–$700 reported); throttle control unit replacement; some dealers replaced spark plugs, MAF, coil packs, VCT solenoids, or camshaft position sensors without resolving issue
Recalls/TSBs owners mention: Ford aware of P2106 defect since at least February 2013 (court case 12-7222); dealers sometimes unable to diagnose or fix; Ford reportedly advises calling back when failure is complete or code reappears
Transmission Slipping and Hesitation
Transmission hesitates to move forward when accelerator is depressed, then jerks; slips between gears or fails to upshift on highway. Vehicle may only move in reverse or refuse to shift into drive. Overdrive warning light may illuminate.
When: Early in ownership (as low as 15,000 miles); some failures at 28,000–63,000 miles
Symptoms owners cite: Transmission slips when accelerator depressed; Jerks forward or hesitates before moving; Fails to upshift on freeway; Only reverse gear functions; O/D (overdrive) warning light illuminated; Abnormally loud transmission noises; Vehicle stalls when attempting to shift
Repairs/costs cited: Transmission replacement ($2,500 reported); valve body, solenoids, and servos replaced on some vehicles without resolution; one transmission replaced at 28,000 miles, another at 63,000 miles (out of warranty, no assist)
Recalls/TSBs owners mention: Manufacturer denied assistance when vehicle out of warranty; no recalls identified in narratives
Throttle Body Fouling and Mechanical Sticking
Throttle body becomes fouled or dirty, causing stuck or partially depressed accelerator pedal. One incident at highway speed (70 mph) resulted in complete loss of braking and steering control, skid of 100–150 feet, and transmission downshift to reverse with wheel lockup.
When: At 90,000 miles (one case); another with catalytic converter failure at 46,000 miles preceding throttle issue
Symptoms owners cite: Stuck accelerator pedal (fully depressed); Inability to release accelerator despite force applied; Burning brake smell (from hard braking); Loss of braking and steering control; Wheel lockup and skidding; Inability to shift into neutral to reduce engine speed
Repairs/costs cited: Independent mechanic found fouled throttle body; catalytic converter failure at 46,000 miles may have contributed
Rough Running, Hesitation, and Stalling
Engine runs rough, hesitates, sputters, or jerks during acceleration. Vehicle may cough and heave when attempting to accelerate and may stall. Check engine light comes on but diagnostics show no codes. RPM limited to 3,500 or below. Engine feels like it's dying.
When: Intermittent across various mileages; one owner reports persistent issue despite previous transmission replacement
Symptoms owners cite: Engine runs rough or coughs; Hesitation or sputtering around 40–50 mph; Engine heaves and acts like it's dying; RPM climbs but vehicle acts like shutting down; Check engine light (no codes showing); RPM limited to 3,500 maximum; Stalling
Repairs/costs cited: Previous transmission replacement did not resolve; MAF replaced; coil packs replaced; VCT solenoids checked and cleaned; camshaft position sensor replaced; none resolved issue
Transmission Fluid Leak and Corrosion
Transmission fluid leaks from corroded transmission cooler lines and external cooler connections near radiator. Vehicle enters limp-home mode with 'CHECK ELECTRONIC THROTTLE POSITION' warning. Aftermarket replacement lines unavailable; Ford service kits special-ordered with long lead times and limited stock.
When: Timing not specified; leak detected during owner investigation
Symptoms owners cite: Transmission fluid leak near radiator; Corroded transmission cooler lines and fittings; CHECK ELECTRONIC THROTTLE POSITION warning; Vehicle enters limp-home mode
Repairs/costs cited: Corroded cooler lines required special-order Ford kits; aftermarket lines unavailable; Ford had only 15 kits available with one-month wait for next shipment
Hard Starts and Starting Issues
Vehicle gives hard starts, turns over slowly or not fully, or produces unusual sounds ('elephant trumpeting'). May shut off immediately after starting. Hesitates to pick up speed and stumbles or jerks. Issue persists after battery and spark plug replacement.
When: At intermittent intervals
Symptoms owners cite: Hard starting; Incomplete turn-over; Unusual sounds during start attempt; Shuts off immediately after starting; Hesitates to pick up speed; Stumbling and jerking
Repairs/costs cited: New battery installed; spark plugs and boots replaced without resolving issue
Unintended Transmission Shift to Reverse (Parked Vehicle)
Vehicle parked on incline in Park gear spontaneously shifts to Reverse without operator input, rolling down hill or across driveway. Vehicle may sit idle and running for extended period before shifting.
When: Two instances: one on driveway (vehicle running, parked on slight incline); another near building (vehicle running 10+ minutes in Park)
Symptoms owners cite: Vehicle shifts from Park to Reverse without operator input; Vehicle rolls down driveway or hill; Vehicle strikes property or trees; Gear indicator shows Reverse position; No operator present in vehicle during shifts
Repairs/costs cited: One case: dealer could not duplicate incident or determine cause; property damage occurred (tree strike, fan strike)
Transmission Holding Issues on Hills (Prior Symptom, Early 2005)
Vehicle rolls out of control when stopped on hill and foot removed from brake, whether in Reverse going downhill or Drive going uphill. Transmission shifts at odd times during normal driving.
When: November 2005 (early in vehicle ownership); referred to in one dealership complaint as pre-existing defect to be repaired
Symptoms owners cite: Vehicle rolls out of control when brakes released on hill; Transmission shifts at inappropriate times; Loss of engine braking on incline
Repairs/costs cited: Transmission replacement promised by dealership; repair status unclear from complaint
Recalls/TSBs owners mention: Dealership assured owner transmission would be replaced; Ford aware of bad tire issue and promised replacement
Transmission Noise and Clunking
Clunk or thump noise from rear when transmission is engaged, shifted, or during acceleration or direction change. One owner had transmission replaced under warranty but same noise returned.
When: Recurring after transmission replacement
Symptoms owners cite: Clunk or thump from rear; Occurs during transmission engagement or shift; Occurs during acceleration or direction change; Recurring after transmission replacement
Repairs/costs cited: Transmission replaced once under warranty; recurred after repair
Synthesized from 38 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 5 most recent
Traveling in a parking lot car died and said check electric throttle control. Wont run or crank. Left stuck in a parking lot had to get towed home. *tr
Transmission on 2005 expedition is slipping. When the vehicle is placed into drive and the foot throttle is depressed the vehicle hesitates to move forward, but then jerks forward. Other times it seems like it doesn't want to upshift when driving on the freeway. I must also state that the paint on the tip of the hood and on the tailgate are starting to bubble /blister, the vehicle is only 5…
"check electronic throttle" message appeared and accelerator pedal became unresponsive in traffic. Pulled over, restarted engine and issue corrected itself. *tr
"check electronic throttle" message appeared and accelerator pedal became inoperative. This is the second time this has occurred. Shifted vehicle into neutral, restarted engine while rolling along and error was corrected. *tr
George newcomb landers mclarty 2609 south walton bentonville, ar 72712 I purchased a 2005 expedition from you a few weeks ago. On 11-23-05 I brought it over to have some defects repaired. Defects that were to be fixed. Transmission. When stopped on a hill if you remove your foot from the brake the vehicle will roll out of control. This happens if you are stopped with the vehicle…
Had powertrain trouble with your 2005 Ford Expedition?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the powertrain problem on the 2005 Ford Expedition?
It's a meaningful issue. 38 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $2,500.
At what mileage does the powertrain typically fail?
Across the 34 complaints that reported odometer mileage, most powertrain failures cluster between 59,991 and 110,000 miles, with the median around 81,024. A quarter of owners report trouble before 59,991; a quarter make it past 110,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $2,500 for powertrain repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to powertrain?
No active recalls currently cover powertrain issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2005/Ford/Expedition.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.