Owners report a wide range of electrical failures in the 2020 Expedition. The most common complaint involves the APIM (infotainment module), which fails early—sometimes under 9,000 miles—causing GPS loss, Bluetooth dropout, radio malfunction, and backup camera failure. Resets don't fix the problem permanently, requiring module replacement that dealerships sometimes can't complete.
Multiple owners describe sudden loss of motive power and stalling while driving at highway speeds. Power returns on its own, but dealers cannot diagnose the root cause after multiple visits. One owner lost power at 70 mph during lane changes.
Water intrusion is another recurring issue. One owner's A/C operation caused condensation to pool on the fuse box and destroy the body control module, leaving the transmission stuck in park. Ford issued TSB 20-2170 addressing water on the right front floor during A/C use.
There are several fire-risk failures: a washout of the windshield washer line that flooded the dashboard electrical system, a faulty 120V auxiliary outlet that arced and caught fire inside the cabin with a non-functional circuit breaker, a charging system failure that caused continuous starter engagement and electrical fire requiring battery disconnect, and one completely unprovoked vehicle fire while parked that destroyed the car and damaged the owner's home.
Other concerns include instrument cluster blackouts, airbags and seat belts failing to deploy during a crash, the vehicle rolling backward while parked, and a chronic power delivery issue lasting 4–5 years. One owner identified parts shortage for a fire-risk battery junction box recall (22S36/22S48) that dealers cannot fulfill.
Failure modes owners describe
Washer fluid line rupture flooding dashboard electrical systems
Windshield washer line on front passenger side and rear window exploded due to fluid accumulation, causing washer fluid and refrigerant to leak into the body control module and passenger floor area, disabling the vehicle.
When: 68,305 miles
Symptoms owners cite: Intermittent windshield wipers; Vehicle failed to respond when attempting to drive from complete stop; Vehicle would not turn off; Fluid pooling inside dashboard
Repairs/costs cited: Dealer replaced BCM, reprogrammed RCM communication circuit and BCM, installed alarm module and auxiliary evaporator cord
Recalls/TSBs owners mention: Referred contact to NHTSA Hotline
APIM (Accessory Protocol Interface Module) failure
Infotainment module failure causing loss of GPS, Bluetooth, radio, backup camera display, and other integrated functions. Multiple owners report recurring failures with module resets ineffective.
When: Under 9,000 miles to 45,000 miles
Symptoms owners cite: GPS inoperative; Bluetooth connectivity loss; Radio malfunction; Backup camera disabled or stuck on display; Vehicle settings reset; Center screen black or fails to light up; Screen requires power reset multiple times per drive; Loss of camera guide lines on display; No WiFi functionality
Repairs/costs cited: Dealer reset/replaced APIM module; resets reported as ineffective; replacement attempted but not completed in some cases
Recalls/TSBs owners mention: Referred contacts to NHTSA Hotline; issue noted in owner forums but no recall action specified
120V auxiliary power outlet connector failure and fire risk
Auxiliary 150-watt 120V outlet connector fails to grip plugs securely, causing plugs to fall out or come partially loose, creating electrical shock and arc fire hazards. Owner reports circuit breaker did not function as safety shutoff.
When: Not specified
Symptoms owners cite: Electrical plug falls or pulls halfway out of socket; Electrical shock from loose connection; Electrical arcing and small fire inside vehicle; Circuit breaker failed to trip and shut off power
Repairs/costs cited: Dealer acknowledged need for outlet replacement after owner demonstrated connector defect comparison with 2021 F350; repair delayed over 6 months without resolution
Recalls/TSBs owners mention: No manufacturer statement documented; dealer acknowledged replacement needed
Condensation intrusion into fuse box during A/C operation
Water accumulation on passenger side fuse box when A/C is activated, corroding fuse box contacts and causing body control module failure. Related to Technical Service Bulletin 20-2170 regarding water leaking on right front floor after A/C use.
When: 63,000 miles
Symptoms owners cite: Condensation pooling on passenger side fuse box; Transmission unable to shift out of park; Multiple warning lights illuminated; Headlights unable to turn off
Repairs/costs cited: Vehicle not repaired; diagnostic determined fuse box and body control module damaged
Recalls/TSBs owners mention: Technical Service Bulletin 20-2170 issued; manufacturer not directly notified by this contact
Auto stop/start system unintended engine shutdown
Stop/start system causes complete engine shutdown while vehicle is stationary at traffic control devices and during acceleration from stops, disabling vehicle operation without warning.
When: Not specified
Symptoms owners cite: Engine shuts off completely while stopped at stop sign; Engine shuts off while accelerating from stop light; Auto stop/start light illuminates; Battery warning light illuminates; Engine warning light illuminates
Repairs/costs cited: Not specified
Recalls/TSBs owners mention: Not specified
Loss of motive power and engine stalling while driving
Vehicle loses engine power and stalls intermittently while driving at highway speeds. Power returns automatically; cause remains undiagnosed despite multiple dealer visits.
When: 45-86,000 miles (two separate incidents reported)
Symptoms owners cite: Vehicle loses motive power and stalls; Vehicle regains power independently; Engine cessation with loss of acceleration capability; Crowbar indicator illuminated (limp mode indicator)
Repairs/costs cited: Dealer unable to determine root cause; no repair completed
Recalls/TSBs owners mention: Manufacturer notified; case filed
Instrument cluster display failure
Instrument cluster screen becomes black or blinks on and off intermittently, rendering safety information unavailable to driver while operating vehicle.
When: 50,000 miles
Symptoms owners cite: Instrument cluster displays black screen; Screen blinks on and off independently; Safety features become unavailable
Repairs/costs cited: Vehicle not diagnosed or repaired
Recalls/TSBs owners mention: Manufacturer not made aware; contact referenced unknown recall with similar failure
Electrical system complete shutdown
Electrical system unexpectedly shuts down during vehicle operation without apparent trigger. Gate module replacement attempted but failure persists.
When: 49,000 miles
Symptoms owners cite: Electrical system unexpectedly shutdown
Repairs/costs cited: Gate module replaced; failure persisted after repair
Recalls/TSBs owners mention: Manufacturer notified
Charging system failure with uncontrolled starter engagement and electrical fire
Check charging system light illuminates, vehicle enters park and shuts off. Starter engages continuously without responding to brake/gear selector controls, triggering electrical fire. Battery disconnect required to stop electrical fire.
When: Not specified
Symptoms owners cite: Check charging system warning light illuminates; Vehicle enters park unintentionally; Engine shuts off; Engine cranks continuously without starting; Electrical fire in engine compartment; Transmission locked in park despite brake/pedal inputs
Repairs/costs cited: Battery disconnection was only method to stop electrical fire; vehicle required towing
Recalls/TSBs owners mention: Not specified
Backup camera intermittent operation and display failure
Rear backup camera intermittently non-functional; when active, display freezes or screen turns black. Guide lines fail to display on some units despite camera operation. APIM module responsible in confirmed cases.
When: Not specified
Symptoms owners cite: Backup camera intermittent operation; Rearview camera remains activated when not in reverse; Display screen turns black; Guide lines missing from backup camera display; Infotainment system becomes inoperable
Repairs/costs cited: APIM module replacement diagnosed in one case but not completed; camera identified through disassembly in another case due to VIN mismatch in service records
Recalls/TSBs owners mention: Referred to NHTSA Hotline; camera not included in recall for some units despite identical part numbers across model year
Unintended vehicle rollback while parked
Vehicle rolls backward down driveway after parking and locking, despite no driver input. Owner has video documentation of occurrence.
When: Not specified
Symptoms owners cite: Vehicle rolls backward down driveway; Occurs after parking and locking vehicle
Repairs/costs cited: Not specified
Recalls/TSBs owners mention: Not specified
Chronic power delivery and battery charging issues
Vehicle experiences recurring power delivery problems since purchase, including loss of power during highway driving and complete electrical flickering upon startup. Issue persists for 4-5 years despite multiple dealer visits.
When: Throughout vehicle life; loss of power event at 70 MPH
Symptoms owners cite: Loss of power while driving at highway speeds; Electrical flickering and flashing upon startup; Multiple warning lights illuminate
Repairs/costs cited: Dealer unable to isolate issue; problem manifests intermittently and does not appear during diagnostic
Recalls/TSBs owners mention: Not specified
Battery junction box fire risk with parts shortage
Recall 22S36/22S48 addresses fire risk in battery junction box, but replacement parts are not being supplied to dealers. Owners unable to complete safety repair despite confirmed recall applicability.
When: Not specified
Symptoms owners cite: Fire risk identified in recall
Repairs/costs cited: Replacement battery junction box not available from suppliers; larger dealers also unable to obtain parts
Recalls/TSBs owners mention: Recall 22S36/22S48 issued but parts supply chain failure prevents repair implementation
Uncontrolled vehicle fire with no warning
Vehicle caught fire while parked in driveway with no apparent warning signs. Fire became total loss within minutes, with complete vehicle destruction and minor house damage.
When: Not specified
Symptoms owners cite: Vehicle smoking without warning; Alarms activated; Vehicle engulfed in flames
Repairs/costs cited: Vehicle total loss; cause not investigated in narrative
Recalls/TSBs owners mention: Not specified
Airbag and seat belt non-deployment during crash
Vehicle hydroplaned and struck two other vehicles at 50 MPH. Airbags failed to deploy and seat belts failed to lock despite impact. No warning lights appeared.
When: 53,000 miles
Symptoms owners cite: Airbags did not deploy on impact; Seat belts did not lock; No warning lights prior to impact
Repairs/costs cited: Not repaired; vehicle drivable after accident
Recalls/TSBs owners mention: Manufacturer notified and referred contact to NHTSA
Synthesized from 21 NHTSA owner complaints — unverified consumer
allegations, summarized for patterns. The verbatim filings appear below.