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 ↗2006 Ford Expedition powertrain problems
severe 16 complaints filed with NHTSA · avg repair $2,500 · see powertrain across all vehicles →
Failure mileage
Complaints
16
Recalls
0
Avg fix
$2,500
2crashes
1injury
When does it fail?
Of the 16 powertrain complaints filed for the 2006 Ford Expedition, here's the actual mileage breakdown — failures cluster heaviest at 100,000-125,000 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
No new NHTSA powertrain 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 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 ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2006 Expedition's powertrain exhibits a cluster of distinct failures across transmission, engine control, and ignition systems.
Transmission power loss is the most common complaint. Multiple owners describe sudden loss of all driving power during acceleration—the vehicle acts as if shifted into neutral, forcing the driver to manually shift into low gear to move. This occurs at various speeds (11,000 to 134,000 miles) and sometimes recurs even after dealer computer module replacement or independent torque converter service. One owner reports it happening every time he accelerates; another had it occur twice within a week following dealership oil changes. Dealerships often cannot diagnose the issue because the failure does not occur during test drives.
Engine stalling with fail-safe mode is also prevalent. Drivers report complete engine shutoff at random speeds with no warning, a wrench light or fail-safe indicator illuminating, and engine restart restoring function temporarily. One owner replaced the throttle position sensor to stop stalling for a year; another had throttle body and fuel module replacement. Failures are difficult for shops to diagnose since they're intermittent.
Spark plug breakage during routine replacement is reported by an owner at 88,000 miles: Motorcraft Platinum plugs fracture at the ceramic section, leaving pieces lodged in the cylinder head. A 2-year-old shifted the transmission out of park without the brake or ignition key, causing a rollout and tree collision—the shift actuator had been replaced under warranty but failed again.
Other issues include timing chain failure with warranty denial due to sludge, transmission slipping with whining noise, and unintended acceleration causing a collision at high mileage.
Same Ford Expedition powertrain reports on nearby years: 2005 · 2007 · 2008
Failure modes owners describe
Spark plug breakage during removal
Motorcraft Platinum ceramic spark plugs fracture at the ceramic section during removal, leaving the broken electrode and ground straps in the cylinder head. This creates a serious extraction problem and risks damage to the aluminum head.
When: 88,000 miles (narrative #1); routine spark plug replacement
Symptoms owners cite: Engine losing power under load during acceleration; No check engine light illumination despite loss of power
Repairs/costs cited: Owner replaced all 8 spark plugs and coil packs; one plug broke upon removal. NAPA sells extraction tool for removal; professional extraction needed to prevent head damage.
Recalls/TSBs owners mention: Ford acknowledged the issue exists but no recall issued despite owner's claim this is a known defect.
Transmission loss of power and limp mode
Transmission loses all driving power intermittently during normal acceleration or gear changes, forcing the vehicle into low gear or limp mode. Often triggered after dealership service. Check engine light may illuminate; wrench/fail-safe mode indicator appears. Multiple owners report this recurs even after dealer diagnosis attempts.
When: 11,000–22,000 miles (narrative #2); various mileages 30–60 mph driving (narratives #4, #5, #12); 107,000 miles (narrative #9); 141,000 miles (narrative #12); 130,000–134,587 miles (narratives #14, #15)
Symptoms owners cite: Sudden loss of forward momentum; transmission feels like it slipped into neutral; No power during 1st and 2nd gear changes; Vehicle cannot accelerate above 60 mph; Wrench light or fail-safe mode indicator illuminates; Check engine light may illuminate; Vehicle jerks into gear at 10 mph after power loss; Vehicle rolls backward when brake released; Dead pedal feeling (weak throttle response); Recurrent failures even after dealer repair attempts
Repairs/costs cited: Narrative #2: Ford replaced computer module but failure recurred within 2 miles; later suspected torque converter issue, ordered parts. Narrative #9: Independent mechanic diagnosed torque converter failure and replaced it; failure recurred, then transmission specialist found multiple failed internal transmission components.
Recalls/TSBs owners mention: Narrative #2: Computer module replacement failed; torque converter diagnostics ordered but outcome unclear. Narrative #9: Manufacturer notified; recurring failures after repair.
Transmission shift actuator failure (unintended disengagement)
Transmission can be shifted out of park without foot on brake and without ignition key in the vehicle. Shift actuator replaced under warranty but defect recurred, allowing a toddler to shift truck into neutral, resulting in vehicle rollout and collision.
When: Within first year of ownership (narrative #3); 12 months after initial repair
Symptoms owners cite: Transmission shifts out of gear without brake pedal depressed; Can shift out of park with ignition off; Unintended vehicle movement when in neutral
Repairs/costs cited: Dealership replaced shift actuator under warranty. Second failure not covered; $1,343.18 damage from vehicle rollout and tree collision not paid by Ford or dealership.
Recalls/TSBs owners mention: Dealership replaced shift actuator under original warranty; refused to cover damages from recurrent failure.
Engine stalling with fail-safe mode activation
Engine stalls completely while driving at various speeds without warning. Wrench light or fail-safe mode indicator illuminates. Engine can be restarted. Occurs intermittently over months or years, making dealer diagnosis difficult since failure does not occur during shop visits.
When: 160,000 miles (narrative #11); 114,000–116,000 miles (narrative #13); occurs at random intervals (narrative #4)
Symptoms owners cite: Complete engine stall while driving; Wrench light illuminates on dash; Fail-safe mode indicator displays; Engine deceleration prior to stall; No pattern to failure occurrence; Restarting engine restores function temporarily
Repairs/costs cited: Narrative #11: Hertrich Ford replaced throttle body and driver-side fuel module. Narrative #4: Owner replaced throttle position sensor, which prevented stalling for about one year, then stalling resumed. Failures occur 5 times in 3 months at different speeds (65, 55, 40, 30, 25 mph) with no pattern.
Recalls/TSBs owners mention: Narrative #4: Ford shop visits yielded no diagnosis because failure light does not remain on and failure does not occur during test drives. Narrative #11: Manufacturer referred contact to NHTSA.
Timing chain failure with sludge-related warranty denial
Timing chain fails, causing rough running, poor throttle response, loud noises, and engine stall at intersection. Vehicle diagnosed with excessive oil sludge; Ford denied powertrain warranty claim despite owner's regular maintenance, claiming lack of vehicle maintenance.
When: Unspecified mileage (narrative #8); vehicle has had transmission replacement at 35,000 miles and other major repairs
Symptoms owners cite: Engine stalls at traffic light; Poor driving performance; Loud noises from engine; Throttle sticks as if transmission is failing; Evidence of oil sludge in engine
Repairs/costs cited: Timing chain replacement required; owner claims regular oil maintenance and points to prior transmission replacement (35,000 miles), suspension system repair, and electrical/stereo failure as evidence of vehicle care.
Recalls/TSBs owners mention: Ford denied powertrain warranty claim citing sludge evidence and lack of maintenance, despite owner's maintenance records and history of covered repairs on same vehicle.
Overdrive disengagement and transmission interaction with cruise control
Overdrive disengages independently during driving, causing vehicle deceleration and then return to normal speed. Dealership diagnosed that cruise control was altering transmission function.
When: 110 miles (failure onset); 98,421 miles (current mileage at report) — narrative #10
Symptoms owners cite: Overdrive disengages without driver input; Vehicle decelerates temporarily; Vehicle returns to normal speed after deceleration
Repairs/costs cited: Dealership repaired but did not specify what repairs were performed.
Recalls/TSBs owners mention: Manufacturer notified; repair completed at dealer.
Unintended acceleration
Vehicle independently accelerates when accelerator pedal is depressed. Owner loses control and crashes into a fence. Wheels continue moving after vehicle is parked.
When: 220,000 miles (narrative #6); low-speed driving
Symptoms owners cite: Vehicle accelerates without warning; Loss of control leading to collision; Wheels continue moving after vehicle placed in park
Repairs/costs cited: Vehicle not diagnosed or repaired at time of report.
Recalls/TSBs owners mention: Dealer and manufacturer not notified at time of report. Air bags did not deploy on impact.
Transmission slippage and whining noise
Transmission loses forward momentum as if placed in neutral while driving in drive with overdrive on. Small whining noise precedes failure. First incident resolved by switching to low gear; recurrence noted within 50 feet. Owner suspects internal transmission wear.
When: Unspecified mileage (narrative #7); first at 30 mph in drive with overdrive on
Symptoms owners cite: Loss of forward momentum while in drive; Transmission acts as if in neutral; Small whine from transmission that increases with acceleration; Slipping recurs when attempting to drive again
Repairs/costs cited: Transmission fluid levels checked and were full and proper. Owner took vehicle to transmission garage for diagnosis.
Recalls/TSBs owners mention: No manufacturer contact recorded at time of narrative.
Synthesized from 16 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
As I am driving down the road I lose power and deaccelerate and go into fail safe mode. The little wrench light comes on the dash. Then the engine cuts off completely. This has happened at multiple speeds. It is extremely dangerous! Once I turn the key off I restart the engine and it may not happen again for a month. I replaced the throttle position sensor and it did not do this for about a year,…
Had powertrain 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 powertrain problem on the 2006 Ford Expedition?
It's a meaningful issue. 16 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 15 complaints that reported odometer mileage, most powertrain failures cluster between 59,600 and 134,587 miles, with the median around 100,000. A quarter of owners report trouble before 59,600; a quarter make it past 134,587. 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/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.