Ford and Lincoln vehicles equipped with wired keyless entry keypad systems and accessory wireless keyless entry keypad systems may or may not come with a wallet card containing the master code. Unlike the integrated wired keypad, the accessory wireless keypad master code cannot be retrieved from the vehicle using a diagnostic scan tool or from the label printed on the body control module (BCM). The Factory Keyless Entry Code application within the diagnostic scan tool will not provide an applicable master code for the accessory wireless keypad. If the wallet card for an accessory keypad is not available, the "Wireless RF Keypad Diagnosis Guide" can be referenced and provides direction on how
full bulletin at NHTSA ↗2016 Ford Expedition electrical problems
severe Owners of the 2016 Ford Expedition have filed 29 NHTSA complaints about the electrical, typically surfacing around 133,000 miles at roughly $850 to repair (U.S. federal records, as of July 2026). Source: NHTSA Office of Defects Investigation. See electrical across all vehicles →
Failure mileage
Complaints
29
Recalls
0
Avg fix
$850
| Model year | electrical complaints |
|---|---|
| 2012 Expedition | 10 |
| 2013 Expedition | 7 |
| 2014 Expedition | 11 |
| 2015 Expedition | 43 |
| 2016 Expedition (this page) | 29 |
| 2017 Expedition | 80 |
| 2018 Expedition | 23 |
| 2019 Expedition | 10 |
| 2020 Expedition | 21 |
3fires
What stands out
Owners have filed 29 electrical 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.
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.
This article supersedes TSB 24-2165 to update the TSB Service Procedure. Some vehicles listed in the Model statement above may exhibit various SYNC performance related concerns including but not limited to: Display operation concerns Navigation inoperative Voice recognition concerns Phone connection issues Dropped phone connections Applink related performance Travel Link not present or showing incorrect traffic Slow system response NOTE: Ford has found some of the APIMs replaced and returned for inspection contained an outdated software level and the APIM did not require replacement. The customer concern may have been resolved by updating the APIM with latest level of softwar
full bulletin at NHTSA ↗Some 2015-2021 Ford and Lincoln vehicles may exhibit an illuminated MIL with diagnostic trouble codes (DTCs) P0011, P0012, P0014, P0015, P0016, P0017, P0018, P0019, P0021, P0022, P0024 and/or P0025. Pinpoint test HK in the Powertrain Control and Emissions Diagnosis (PC/ED) or in Section 303-14 of the Workshop Manual (WSM) has been updated to address this concern.
full bulletin at NHTSA ↗Some 2013-2023 Ford or Lincoln vehicles with modems activated through FordPass or LincolnWay may experience 12 volt battery drain symptoms when the customer uses non-Ford/Lincoln phone applications as an alternate channel to access vehicle commands such as door lock/unlock, remote start, vehicle location, etc. The battery drain may be caused by excessive calls for data through the vehicle network keeping it in an activated state. Recommend that the customer uninstall the app to ensure this is not contributing to battery symptoms experienced. Advise the customer that unaffiliated third-party app developers do not work directly with Ford to adhere to security, vehicle communication, and privac
full bulletin at NHTSA ↗Some 2016-2021 Ford and Lincoln vehicles equipped with SYNC 3 may exhibit a condition where the navigation voice prompts are inoperative after a SYNC map update. This may be due to an incomplete installation of the SYNC map software. If possible, using the original USB that installed the update, reperform the update and verify the navigation voice prompts have returned. Multiple reboots are expected when this update is being performed. Verify the Installation Is Complete message displays in the touch screen. If the original USB is not available, go to website https://syncnavigation.com/ford/home or https://syncnavigation.com/lincoln/home to download the files once more for the affected vehic
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 blower motor and electrical fire. Owners describe strong burning smells, flames and smoke erupting from the dashboard and fuse box area, and melted wiring harnesses. One vehicle caught fire while parked with only 50k miles; another at 140k. Multiple fires started while owners were driving—one forced an emergency pull-over with loss of steering and brakes. Even after recall replacement under NHTSA Campaign 22V648000, the problem recurs: new blower motors melt again, and the wiring harness keeps overheating. Ford cannot supply recall parts—dealers report backorders with no ETA for months or over a year, leaving owners with non-functional climate control in Texas heat.
The backup camera fails intermittently or blacks out completely, eliminating rear visibility while reversing. One owner replaced it 4–5 times in 5 years. A recall exists but no remedy is available.
Other electrical issues include sudden complete engine power loss due to throttle body failure (excluded from Ford's own recall on identical F-150s), Bluetooth dropping calls and not recognizing paired devices, and vent motors clicking loudly when turned on.
The pattern: Ford issues recalls but cannot deliver parts, and owners are sometimes denied coverage for related damage (melted harnesses) even when the original motor was replaced under recall.
Same Ford Expedition electrical reports on nearby years: 2014 · 2015 · 2017 · 2018
Failure modes owners describe
Blower Motor Overheating and Fire
The HVAC blower motor and its wiring harness overheat, melt, and ignite, creating electrical fires in the cabin. This occurs both in original and recall-replacement motors, often while the vehicle is in operation or shortly after. The defect causes loss of climate control and poses imminent fire risk.
When: Intermittently, some failures reported under 140k miles; one fire at ~50k miles; multiple recurrences after recall repair
Symptoms owners cite: Strong burning smell in cabin; Flames or smoke visible near dashboard/blower motor/fuse box; Wiring harness and connectors melted or charred; Excessive heat at fuse box or under dashboard; Blower motor stops functioning intermittently or completely; Blower only operates on one speed
Repairs/costs cited: Owners cite replacement of control boards, harnesses (parts AAABL3Z-19E624-B and AAAFLlZ-188518-G mentioned), blower motors, wiring assemblies, and speed controllers. Dealer labor cited at $352.56+ for non-recall harness replacement.
Recalls/TSBs owners mention: NHTSA Campaign 22V648000 (Visibility, Electrical System) recall issued; recall parts on indefinite backorder with no ETA for many months to over a year. Dealers unable to complete recall repair. Manufacturer referred owners to NHTSA Hotline. Dealers declined to cover melted harness under recall even when motor was replaced under recall.
Rear-View Camera Failure
The backup camera fails intermittently or becomes completely inoperative, eliminating rear visibility during reversing. Failures are recurrent; owners report replacing the camera annually or every 1.5 years. Active recall exists but no remedy is available.
When: Intermittent at first, progressing to complete failure; recurring annually or every 1–1.5 years; one owner reports 5-year pattern
Symptoms owners cite: Camera display goes blue or blinks in and out; Camera completely black/inoperative while reversing; Intermittent blackouts during backup; Rear actuator fails repeatedly
Repairs/costs cited: Owners cite annual or every 1.5-year replacement cycles; rear actuator replaced by Ford dealers multiple times. One owner reports replacing camera and actuator 4–5 times in 5 years.
Recalls/TSBs owners mention: Active recall exists (2015 model year has identical recall; 2016 does not appear to be formally included despite identical hardware). Recall notice issued September 2025 for some owners; no timeline or remedy communicated.
Throttle Body Electrical Failure
The throttle body experiences sudden electrical failure, cutting engine power completely while driving. Ford issued recall 16B32 for 2015 and 2016 models of other nameplates on the same assembly line, but excluded the Expedition despite identical hardware and defect.
When: While driving on freeway; one owner at under 140k miles
Symptoms owners cite: Yellow wrench warning light illuminates; Complete loss of engine power (100%); Near-accident situation due to sudden power loss
Codes mentioned: Yellow wrench warning
Repairs/costs cited: Owner paid $500 out-of-pocket for throttle body repair; not covered under warranty. Repair cost and burden placed on owner due to exclusion from recall.
Recalls/TSBs owners mention: Ford issued recall 16B32 for 2015 and 2016 F-150 and other models on the same assembly line; Expedition was not included in recall despite identical defect.
Bluetooth and Phone Connectivity Failure
Bluetooth connectivity to the vehicle's infotainment system malfunctions, causing paired devices to drop or not list, and call audio to break up or drop. Impacts emergency communication capability.
When: Chronic; one owner reports failure after purchasing the vehicle
Symptoms owners cite: Bluetooth connectivity drops unexpectedly; Paired devices not recognized or listed; Phone calls via Bluetooth break up or drop entirely; Unable to make or receive calls reliably
Repairs/costs cited: Dealer suggested APIM (Accessory Protocol Interface Module) replacement; parts and labor cost not specified.
Dash Vent and Rear Vent Motor Clicking
The dash and rear vent motors produce clicking sounds when activated. Owners report this is a known widespread issue on 2016 Expeditions not under recall.
When: When vent motors are turned on
Symptoms owners cite: Clicking noise from dash vent motors when activated; Clicking from rear vent motors when activated
Recalls/TSBs owners mention: No recall issued despite reported widespread issue.
Navigation System Malfunction
The vehicle's navigation system fails to route correctly, creating risk of the driver becoming lost or missing appointments.
When: <UNKNOWN>
Symptoms owners cite: Navigation does not route correctly; Risk of getting lost
Synthesized from 29 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 2 most recent
Rear camera is inoperable or intermittent. It has been for over a year. Ford finally issued a recall notice I believe in September 2025. They have still not corrected the problem or even sent a letter confirming when it will be completed. I feel there should be reasonable time limit for them to repair my car.
Navigation system fails, does not route correctly. Fear for getting lost or not making appointments. Phone conversations via blue tooth on connected phones to auto will break up or drop preventing emergency calls.
Had electrical trouble with your 2016 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 2016 Ford Expedition?
It's a meaningful issue. 29 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $850.
At what mileage does the electrical typically fail?
Across the 9 complaints that reported odometer mileage, most electrical failures cluster between 116,467 and 140,000 miles, with the median around 133,000. A quarter of owners report trouble before 116,467; a quarter make it past 140,000. 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/2016/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.