The contact owns a 2016 Ford Expedition. The contact stated that the vehicle was making an abnormal rattling sound on cold starts. The contact stated that the failure recurred while driving from a complete stop and while coming to a stop. The contact also stated that the vehicle was experiencing rough idling. Additionally, the contact stated while driving at approximately 35 MPH, the vehicle…
2016 Ford Expedition engine problems
moderate 23 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
23
Recalls
0
Avg fix
$3,100
1fire
When does it fail?
Of the 23 engine complaints filed for the 2016 Ford Expedition, here's the actual mileage breakdown — failures cluster heaviest at 125,000-150,000 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.
The failure pattern owners describe
Buyer takeaway: Multiple 2016 Expeditions experience severe throttle body failures causing sudden, complete power loss on the highway—a genuine safety hazard that can lead to rear-end collisions or stalling in traffic. Engine catastrophic failures (holes in block) occurring around 120k miles, along with exhaust manifold leaks and other drivetrain issues, point to systemic reliability problems that make this generation a risky used purchase even at moderate mileage.
The 2016 Ford Expedition engine cluster shows a pattern of serious failures across multiple systems. The throttle body actuator (P2112 code) is the most frequent complaint: vehicle suddenly loses all power, drops into limp mode, and can only idle at 5 mph. This happens unpredictably at speeds from 15 to 75 mph and resolves only after a complete shutdown and restart. Owners report this occurring multiple times within days or weeks, making the vehicle unsafe for family hauling or highway driving. Dealers initially dismissed the problem or said no stored codes prevented repair; some have since replaced the throttle body at warranty, though owners report doing so out-of-pocket once past the warranty period.
Engine catastrophic failure is the second major concern: two separate owners experienced holes punched in the engine block at 120k miles. One involved turbo line failure and turbo strike; another had the hole appear with no clear cause. Ford reportedly has engines backlogged six months deep. Other engine issues include cam phaser failures (rough idle, knock at startup, stalling), valve cover gasket leaks, and an AC blower fire on the passenger side at 120k miles. Exhaust manifold separation, causing chirping noise and cabin exhaust smell, appears chronic. One owner reported water accumulation in the charge air cooler discharging into the intake during hard acceleration, triggering limp mode. Multiple owners note Ford's slow response to recalls and delayed parts availability.
Same Ford Expedition engine reports on nearby years: 2015 · 2017 · 2018 · 2019
Failure modes owners describe
Throttle Body Actuator Failure (P2112 Limp Mode)
Throttle actuator gets stuck closed, forcing vehicle into limp mode with severe power loss. Vehicle can only idle at 5 mph or loses all acceleration. Problem resolves temporarily after restart but recurs unpredictably.
When: Multiple occurrences reported between 55k–148k miles; some owners report repeated failures within days or weeks
Symptoms owners cite: Sudden complete loss of power while driving; Vehicle forced into limp mode; Wrench warning light and check engine light illuminate; Vehicle limited to idle speed only (5 mph or less); Engine runs very rough after restart; Problem clears after vehicle shutdown and restart
Codes mentioned: P2112
Repairs/costs cited: Throttle body replacement required. One owner reported purchasing unit for $225 and installing themselves. Dealers have replaced units under warranty; replacement appears permanent in at least one case.
Recalls/TSBs owners mention: Ford dealers initially told owners to 'drive it till it broke' or that no stored codes prevented warranty repair. Some dealers completed replacements. Owner research indicates this is a known issue on multiple Ford vehicles with recalls issued for some models but not the 2016 Expedition.
Engine Knock/Noise at Startup and Rough Idle
Abnormal knocking or rattling sound occurs at cold start, during acceleration from stops, and during deceleration. Associated with rough idling and stalling at low speeds.
When: Approximately 128k miles; one owner with 148k miles reported knock on startup
Symptoms owners cite: Loud knocking or rattling on cold starts; Abnormal sounds on acceleration from complete stop; Abnormal sounds during deceleration; Rough idling; Stalling while driving at 35 mph; Check engine light illuminated
Repairs/costs cited: Cam phasers diagnosed as failed and requiring replacement. Vehicle not yet repaired by owner.
Recalls/TSBs owners mention: Dealer and manufacturer notified; manufacturer referred owner to NHTSA Hotline for assistance.
Engine Catastrophic Failure / Hole in Block
Engine develops hole in block, sometimes accompanied by turbo line failure and turbo striking the engine. Extremely dangerous as failure occurs suddenly during normal driving.
When: 120k miles (two separate incidents reported at same mileage)
Symptoms owners cite: Loud explosion sound from engine compartment; Engine oil leaks rapidly; Visible hole in engine block
Repairs/costs cited: Complete engine replacement required. One mechanic reported Ford backordered on engines with 400+ units backordered in region alone; 6-month wait cited. Parts not available for repair at time of complaint.
Recalls/TSBs owners mention: Manufacturer notified but no assistance offered. One owner stated manufacturer would contact back but no resolution documented.
Turbo Line Failure and Turbo Strike
Turbo line fails under normal driving, causing turbo to strike the engine block and create a hole. Results in catastrophic engine damage.
When: 120k miles
Symptoms owners cite: Loud explosion noise from engine compartment; Engine oil leak
Repairs/costs cited: Engine and turbo replacement required. Vehicle not yet repaired due to part unavailability.
Recalls/TSBs owners mention: Manufacturer notified; no assistance offered.
AC Blower Motor Fire (Passenger Side)
Air conditioning blower motor catches fire under the glove compartment on passenger side. Smoke and flames develop rapidly with little warning.
When: 120k miles
Symptoms owners cite: AC stops functioning while driving at 20 mph; Popping sound heard; Smoke visible under glove compartment; Flames develop under glove compartment
Repairs/costs cited: Vehicle deemed total loss by insurance. Fire department determined cause as AC blower on passenger side.
Recalls/TSBs owners mention: Manufacturer contacted and stated they would contact owner back; no follow-up documented. Police report filed.
Valve Cover Gasket Leak / Catalytic Converter Failure
Valve cover gasket fractures, causing unknown fluid leaks in two locations. Vehicle also requires catalytic converter and vacuum pump replacement.
When: Approximately 125k miles
Symptoms owners cite: Fluid leaking from two locations on vehicle; Engine warning light illuminated
Repairs/costs cited: Valve cover gasket fractured, catalytic converter and vacuum pump required replacement. Dealer applied silicon to gasket as temporary fix. Parts were not available at time of complaint.
Recalls/TSBs owners mention: Manufacturer contacted and referred owner to NHTSA Hotline. Vehicle not repaired.
Engine Fan Failure / Abnormal Engine Compartment Noise
Engine fan fails, producing abnormal sound when accelerator is depressed. Related to NHTSA recall campaign but parts unavailable.
When: Unknown mileage; complaint notes delay in recall repair
Symptoms owners cite: Abnormal sound from engine compartment when accelerating; Engine fan inoperative
Repairs/costs cited: Engine fan replacement needed. Parts not available at time of complaint.
Recalls/TSBs owners mention: Owner notified of NHTSA Campaign Number 25V572000 (Back Over Prevention); however, replacement part not available. Owner stated manufacturer exceeded reasonable repair timeframe.
Exhaust Manifold Separation / Leaking Studs
Exhaust manifold separates from engine or warps, causing exhaust leaks into cabin or externally. Broken studs on engine block reported.
When: Not specified; exhaust smell reported since vehicle purchase in August 2016
Symptoms owners cite: Chirping noise; Exhaust odor inside vehicle when rear windows open; Exhaust smell during acceleration or idling; Exhaust leaking without passing through muffler
Repairs/costs cited: One owner reports thousands of incidents reported online; specific repair costs not cited.
Charge Air Cooler Condensation Discharge
Water and condensation build-up in charge air cooler discharges into intake manifold during hard acceleration, causing limp mode and complete power loss.
When: Not specified
Symptoms owners cite: Vehicle enters limp mode during quick acceleration from stopped position; Vehicle loses all power during 'punching it' to pass traffic; Occurs in high-traffic conditions where dangerous
Rearview Camera Intermittent Failure
Rearview camera becomes inoperative intermittently while in reverse. Related to NHTSA recall but repair delayed due to parts availability.
When: Unknown mileage
Symptoms owners cite: Rearview camera intermittently inoperative
Repairs/costs cited: Part for recall repair not available at time of complaint.
Recalls/TSBs owners mention: Owner notified of NHTSA Campaign Number 25V572000 (Back Over Prevention); parts not available.
Synthesized from 23 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
Had engine 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 engine problem on the 2016 Ford Expedition?
It's a documented issue but not catastrophic. 23 complaints have been filed. Repairs average $3,100 and most owners catch it before it causes a breakdown.
At what mileage does the engine typically fail?
Across the 12 complaints that reported odometer mileage, most engine failures cluster between 63,000 and 125,000 miles, with the median around 70,000. A quarter of owners report trouble before 63,000; a quarter make it past 125,000. 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 $3,100 for engine 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 engine?
No active recalls currently cover engine 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.