Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 vehicles equipped with TOD transfer cases 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 steps to remove and cap the vacuum supply line.
full bulletin at NHTSA ↗2006 Ford Expedition electrical problems
critical 22 complaints filed with NHTSA · avg repair $850 · see electrical across all vehicles →
Failure mileage
Complaints
22
Recalls
0
Avg fix
$850
1fire
2injuries
1fatality
What stands out
No new NHTSA electrical complaint has been filed on this vehicle in over 11 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 electrical 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.
When ordering a 2005 to 2008 remanufactured 5.4L 3v or 6.8L 3v engine, spark plug boots may be provided in the packaging. Replace all black spark plug boots from the original engine with the 'brown' spark plug boots, as provided. The updated 'brown' spark plug boots are longer than the black boots to accommodate a running change in the spark plug length. The ignition coil bodies and spring/resistor are transferable and only the rubber boots require replacement. Failure to install the spark plug boots provided with the replacement engine could lead to drivability concerns.
full bulletin at NHTSA ↗FORD/LINCOLN/MERCURY: MAY HAVE SLUDGE BUILDUP IN THROTTLE BODY LEADING TO LESS AIRFLOW OR ENGINE IDLING RPM FLUCTUATION AND HARD STARTS OR BATTERY DISCONNECT OR DEAD BATTERY AFTER KEEP ALIVE MEMORY (KAM) CLEAR. MODELS 2003-05 THUNDERBIRD, 05-06 MUSTANG, 06-08 FUSION, 04-05 EXPLORER, 05-06 EXPEDITION, 05-07 F-150; 2003-06 LS, 06 ZEPHYR, 05-06 NAVIGATOR; 06-08 MILAN.
full bulletin at NHTSA ↗VARIOUS ELECTRICAL CONCERNS - 3 BLOCK AUXILIARY RELAY BOX 1 CHAFING - SERVICE TIP.
full bulletin at NHTSA ↗DIAGNOSTIC TROUBLE CODES P0340/P0344/P0345/P0349 - 4.6L 3V AND 5.4L 3V.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The dominant complaint is unpredictable engine stalls triggered by 'Engine Failsafe Mode,' occurring at random speeds from idle to 70 mph with zero warning. RPMs drop below 500, throttle becomes completely unresponsive, and the vehicle limps along at crawl speed or dies entirely. Drivers have had to coast across multiple highway lanes during rush hour, creating serious accident hazards. Restart always works; the vehicle drives normally afterward until it happens again—sometimes every 6 months, sometimes 6 times in a week.
Mechanics and dealerships have been stumped. Most stalls throw no diagnostic codes at all. Owners report spending $800–$10,000 replacing throttle bodies, throttle position sensors, spark plugs, coil packs, injectors, temperature sensors, vacuum lines, intake manifolds, and even computers. Ford service managers acknowledge seeing frequent throttle body replacements on this model, yet Ford has not issued a recall. One service manager agreed a recall is needed before someone gets seriously hurt.
Secondary electrical issues include complete loss of dashboard power while driving, flickering lights, spark plugs breaking off during routine replacement (twice in one vehicle), and one documented case of an interior fire. The horn also has a defect—it only sounds if you hit a precise spot on the pad. Owners report feeling unsafe driving the vehicle with children or in heavy traffic when the next failsafe event is unknowable.
Same Ford Expedition electrical reports on nearby years: 2005 · 2007
Failure modes owners describe
Engine Failsafe Mode shutdowns
Vehicle enters 'Engine Failsafe Mode' at random, dropping RPMs below 500 and stalling without warning. In failsafe, throttle becomes unresponsive, vehicle slows to a crawl, power steering and brakes function but cannot be steered effectively. Owner must turn key off and restart to resume normal operation. No diagnostic codes are thrown.
When: Random, from 5 to 65 mph, in traffic or highway; occurs from once every 6 months to multiple times per week
Symptoms owners cite: Vehicle stalls without warning; RPMs drop below 500; Failsafe Mode message displays on dash; Throttle unresponsive in failsafe mode; Vehicle slows to idle speed, cannot accelerate; No stored diagnostic codes in most cases
Codes mentioned: None typically thrown
Repairs/costs cited: Owners report replacing throttle body ($609 reported in one case), throttle position sensor ($300 reported), spark plugs, coil packs, injectors, intake manifold, cylinder head temperature switch, temperature sensors, vacuum lines, gaskets, and computer. Multiple repairs by independent mechanics and dealerships; problem often returns.
Recalls/TSBs owners mention: Ford acknowledged seeing frequent throttle body replacements on this model per service manager (complaint #4). Throttle body replacement not covered under 100,000-mile powertrain warranty in at least one case.
Dashboard electrical flickering and loss of all electrical power
Dashboard lights flicker intermittently. In worst cases, all electrical power is lost briefly while driving; only airbag light may remain illuminated. Engine may shut off during these events. Power returns within minutes and vehicle restarts normally.
When: Intermittent over weeks; approximately 4 instances of complete electrical loss reported in one narrative
Symptoms owners cite: Dashboard lights flicker; Complete loss of electrical power while driving; Engine shuts off during electrical loss; Only airbag light remains on during failure; Electrical power returns after 5 minutes
Codes mentioned: P0119 (Engine Coolant Temperature Circuit Intermittent)
Repairs/costs cited: No repairs documented in narratives; owner suggests larger electrical/computer problem.
Engine compartment fire
Vehicle displayed low air pressure light and check engine light intermittently. Approximately 1 hour after parking, interior caught fire with no driver intervention. Driver extinguished fire but vehicle interior heavily damaged with smoke, driver-side dash and steering area burned, front windshield cracked.
When: 9 months old, still under warranty
Symptoms owners cite: Low air pressure light on/off cycling; Check engine light on/off cycling; Interior fire, no external cause; Heavy smoke damage
Repairs/costs cited: Vehicle not repaired; fire damage to interior, dashboard, steering area, windshield.
Recalls/TSBs owners mention: Ford declined further action citing insurance company involvement; vehicle was used so insurance paid only fair market value, leaving owner to cover remainder.
Misfire with stuck or broken spark plugs
Engine misfires reported in cylinders 3, 6, 7, and 8. During spark plug replacement, plugs broke off inside the engine during removal, requiring special extraction tools. Problem recurred on second spark plug replacement—plugs broke off again.
When: Not specified; second breakage documented
Symptoms owners cite: Engine bogging/lurching while driving; Improper transmission shifting; Misfire codes (cylinders 3, 6, 7, 8 mentioned)
Codes mentioned: Misfire codes cylinders 3 and 7
Repairs/costs cited: Spark plugs broke off in engine twice; special extraction tool required both times. Total repair cost over $1,500 for plug replacement and extraction.
Horn activation requires precise spot targeting
Horn pad has a very small activation area. Driver must hit the horn symbol in exactly the right spot on either side of the steering wheel/airbag center or horn will not sound. Off-center strikes do not activate horn.
When: Design issue present from vehicle operation
Symptoms owners cite: Horn does not sound with typical steering wheel strikes; Requires precise spot targeting to function
Throttle sticking causing failsafe mode
Throttle plate sticks and returns invalid data to computer, triggering engine failsafe mode. Problem occurs typically when lightly throttled around corners or in rush hour traffic. Cleaning throttle body resolves issue temporarily but problem returns.
When: After 1 year of operation following throttle body cleaning in one case
Symptoms owners cite: Engine enters failsafe mode during light throttle; Throttle plate sticking; Vehicle must be completely turned off to exit failsafe
Repairs/costs cited: Throttle body cleaning provides temporary fix lasting approximately 1 year; complete throttle body replacement may be required ($500 mentioned).
Unexpected vehicle acceleration
Vehicle accelerated by itself without driver input, resulting in fatal accident.
When: 3 months after purchase
Symptoms owners cite: Unintended acceleration
Synthesized from 22 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
Engine frequently goes in to engine failsafe mode. This happens typically when the car is being lightly throttled such as around corners or in rush hour traffic. The car restarts fine, but must be completely turned off, which disables airbags, makes power steering and power brakes impossible to use. Previously I have cleaned the throttle body of the car at the suggestion of numerous mechanics,…
Had electrical 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 electrical problem on the 2006 Ford Expedition?
It's a serious issue. 22 complaints have been filed and 1 fatality(ies). We've classified it as critical based on NHTSA's reported outcomes.
At what mileage does the electrical typically fail?
Across the 16 complaints that reported odometer mileage, most electrical failures cluster between 63,500 and 135,000 miles, with the median around 114,000. A quarter of owners report trouble before 63,500; a quarter make it past 135,000. 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 $850 for electrical 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 electrical?
No active recalls currently cover electrical 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/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.