The 2021 Expedition has a critical fire hazard in the engine compartment that Ford initiated recall 22V346000 to address. Multiple owners report receiving recall notices but waiting months for repair parts to become available. Ford's interim guidance—park outside, away from structures, disconnect the battery—leaves owners stranded. One incident describes a fire starting in a parked, engine-off vehicle.
Separate from the recall, owners report violent engine shaking at highway speeds (45–80 mph) followed by stalling and check-engine lights. Fuel injector and catalytic converter replacements have not permanently fixed the issue in some cases; one owner required dual catalytic converter replacement (both sides) after repeated failures starting around 11,000 miles.
A design flaw is alleged in the hood-windshield junction where rain and wash water drain directly onto the intake manifold and engine components, causing active corrosion. Dealers confirm the corrosion but have not identified a remedy.
The common thread across these complaints is delayed or unavailable repair parts and unresolved drivability/safety issues. Owners express frustration that Ford has not provided timely solutions despite these problems being documented in the recall system.
Failure modes owners describe
Engine compartment fire
Fire originating under the hood or in the engine area, occurring both while driving and while the vehicle is parked and off. Owners report fear of vehicle catching fire unexpectedly.
When: While driving and while parked with engine off
Symptoms owners cite: Fire in engine compartment; Vehicle catching fire while unattended
Repairs/costs cited: NHTSA Campaign 22V346000 initiated; repair parts unavailable for extended period
Recalls/TSBs owners mention: NHTSA Campaign Number 22V346000 (Engine) - recall issued. Ford instructed owners to park vehicle outside away from structures, unhook battery cable, or use free-standing structure until repair available. Parts distribution disconnect delayed remedy availability.
Check engine light with severe vibration and stalling
Engine shaking violently at highway speeds followed by stalling. Check engine light illuminates before failure. Can recur multiple times despite dealer repairs.
When: While driving at 45-80 MPH
Symptoms owners cite: Violent shaking at highway speed; Check engine warning light illuminated; Vehicle stalls; Abnormal odor from engine
Codes mentioned: Check engine warning light
Repairs/costs cited: Initial diagnosis: fuel injector replacement; failure recurred. Subsequent visits: catalytic converter and transmission replacement attempted but not completed due to parts availability.
Catalytic converter repeated failure
Catalytic converter fails repeatedly even after replacement. Check engine light returns within months of repair. Can occur at low mileage (around 11,000 miles).
When: Approximately 11,000-18,000 miles
Symptoms owners cite: Check engine warning light illuminated; Catalytic converter warning on phone app; Engine jerking; Abnormal odor from engine
Codes mentioned: Check engine warning light, Catalytic converter failure code
Repairs/costs cited: Passenger-side catalytic converter replaced; failure recurred. Both passenger and driver-side catalytic converters replaced at second dealer; issue resolved after dual replacement. Repair costs and parts not specified by owners.
Recalls/TSBs owners mention: Manufacturer offered monetary compensation but owner stated it was inadequate to address persistent failure.
Intake manifold corrosion
Intake manifold experiencing active corrosion. Design flaw in windshield-to-hood drainage channels water and fluid directly onto intake manifold and surrounding engine components. Owner concerns about eventual engine damage and potential electrical component damage.
When: Unknown mileage; noted during ownership
Symptoms owners cite: Visible corrosion on intake manifold; Water/fluid draining onto engine from hood-windshield junction
Repairs/costs cited: Dealership confirmed corrosion but could not determine cause. No repair completed.
Synthesized from 25 NHTSA owner complaints — unverified consumer
allegations, summarized for patterns. The verbatim filings appear below.