Should I buy a 2006 Ford Expedition with documented body problems?

Depends on the price and the specific vehicle. Documented body issues should be priced into the purchase — if the seller is asking full retail, negotiate down by the expected repair cost. A pre-purchase inspection from an independent shop tells you whether THIS specific vehicle has already shown the symptoms or not.

2006 Ford Expedition body problems

severe 14 complaints filed with NHTSA · avg repair $1,500 · see body across all vehicles →

Failure mileage

Complaints

Recalls

Avg fix

$1,500

1injury

What stands out

Among the 14 model years of Ford Expedition in our records for body problems, this one ranks #2 by owner-complaint volume.

No new NHTSA body complaint has been filed on this vehicle in over 17 years — the issue may be aging out of the active population.

The failure pattern owners describe

Buyer takeaway: Paint defects—bubbling and peeling on hood and tailgate—are widespread on 2006 Expeditions and occur early with low mileage, but Ford denies warranty coverage. Additionally, some units have cold-weather door lock failures and structural rust issues at low mileage.

Paint blistering and bubbling on the hood and tailgate appears to be the dominant complaint across these 2006 Expeditions. Multiple owners report the problem manifesting within two to five years and at mileages as low as 26,000 to 31,000 miles. The paint doesn't just bubble—it cracks, peels, and pops off, exposing the underlying metal. Dealership technicians have acknowledged this as a known issue, yet Ford repeatedly denies warranty claims. One owner was told the shop won't touch it until actual corrosion holes develop. Repair costs cited run $1,200 out of pocket.

Corrosion problems extend beyond just paint: owners report rust penetrating completely through roof channel sheet metal and rusting of painted trim at window bottoms, all at low mileage on well-maintained vehicles.

A few owners report additional structural defects. One notes the driver-side door won't lock or unlock in freezing temperatures and has opened while driving—an issue that started under warranty but was denied repair. Another reports automatic door locks pinching a passenger's arm. A third raises a safety concern: third-row passengers have no way to open the rear windows or tailgate in an emergency.

Ford's standard response has been denial or deferral, citing that claims cannot be reopened once initially rejected.

Same Ford Expedition body reports on nearby years: 2005 · 2008

Failure modes owners describe

Paint Blistering and Bubbling on Hood and Tailgate

Paint bubbles, cracks, and blisters develop on the hood and tailgate, progressing to peeling and corrosion. Owners report this occurred within the first few years and at relatively low mileage. Ford dealership personnel have acknowledged this as a known problem, but the manufacturer has denied warranty coverage. One owner was told the dealership would not address it until metal corrosion appeared.

When: Under 5 years old; 2 years old; 31,000 miles; 82,000 miles; 26,000 miles

Symptoms owners cite: Paint bubbles on hood and tailgate (inside and outside surfaces); Paint cracking and blistering; Paint peeling; Paint popping off the surface

Repairs/costs cited: One owner cited $1,200 out-of-pocket repair cost. Dealership service centers refused to repair until metal corrosion became visible.

Recalls/TSBs owners mention: Ford rep denied claim. Customer service acknowledged the paint blistering problem but refused to act after initial denial. Manufacturer stated it would only review a claim for one issue one time and would not reassess after denial.

Rust and Corrosion on Roof Channel, Window Trim, and Tailgate

Rust penetrates completely through sheet metal in roof channels. Painted metal trim at the bottom of side windows exhibits rust with peeling paint. Corrosion appears on tailgate, roof, and hood at low mileage. Owner reports Ford denies responsibility despite the problem appearing across multiple Expeditions.

When: 26,000 miles; well-maintained vehicle

Symptoms owners cite: Rust in roof channel penetrating completely through sheet metal; Rusting of painted metal trim at window bottoms; Paint peeling from trim; Corrosion on tailgate, roof, and hood

Recalls/TSBs owners mention: Ford denies the problem is their responsibility despite the issue being observed on multiple Expeditions.

Driver-Side Door Lock Failure in Cold Weather

Driver-side door will not lock or unlock when ambient temperature is below freezing. Door opens while vehicle is being driven. Problem has persisted since the vehicle was new and covered under warranty, but dealership and factory refused to repair it.

When: Since vehicle was new; under warranty at time of complaint

Symptoms owners cite: Driver door will not lock or unlock in freezing temperatures; Door opens while driving in cold weather

Recalls/TSBs owners mention: Dealership and factory declined to repair under warranty or as goodwill.

Automatic Door Lock Pinching Hazard

Automatic door locks pinched a passenger's arm, leaving a bruise. This occurred at low mileage. Dealer has not inspected the vehicle.

When: 21,000 miles

Symptoms owners cite: Automatic door locks pinching arm

Third-Row Seat Emergency Egress Issue

The third-row seating area has no window opening mechanism and no tailgate release device available to occupants, creating a potential safety concern in the event of a crash or emergency requiring rapid evacuation.

Symptoms owners cite: No switch or release mechanism for rear windows in third-row seating area; No device to open tailgate from inside vehicle for passengers in third row

Synthesized from 14 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.

What owners are reporting 1 most recent

body · filed 12/18/2008

Thankfully no crash has happened yet. However, my complaint deals with my 2006 limited Ford expedition. In the back where the third row seats are located, there is no possible way for those passengers to escape in the event of a crash. The back window does not have a switch/release to open any windows. The door does not have any type of device to open the tail gate. *tr

Had body trouble with your 2006 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 body problem on the 2006 Ford Expedition?

It's a meaningful issue. 14 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $1,500.

At what mileage does the body typically fail?

Across the 10 complaints that reported odometer mileage, most body failures cluster between 48,000 and 84,900 miles, with the median around 65,000. A quarter of owners report trouble before 48,000; a quarter make it past 84,900. 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 $1,500 for body 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 body?

No active recalls currently cover body 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.

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/2006/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.