2005 Ford Expedition structure problems
15 owner complaints filed with NHTSA name the structure on the 2005 Ford Expedition — 5% of all complaints for this model year.
What owners report
“Aluminum body panels are corroding underneath the paint, causing bubbling, flaking, and chipping of the paint. This is not caused naturally, this is a failure on the part of ford and their quality control. The aluminum underneath was contaminated from the factory with iron causing corrosion. While…”
filed Oct 21, 2017
“The paint is peeling on the exterior and interior in large patches for no obvious reasons including rust or environmental factors like being close to salt water. The peeling paint is primarily on the back hatch but also some paint bubbling is occurring on a few other small spots on the vehicle…”
filed Oct 7, 2017
Verbatim excerpts from complaints filed with NHTSA. Reports are not independently verified.
Related service bulletins
For 2000-2024 Ford and Lincoln vehicles, swapping a module from a vehicle for diagnosis purposes is likely to cause errors and is not recommended. It is also not recommended to order a replacement module using a vehicle…
SSM 51536 · Service Bulletin/Repair Instructions · issued Apr 4, 2023This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled…
TSB 20-2233 · Service Bulletin/Repair Instructions · issued Jul 13, 2020Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel…
TSB 19-2026 · Service Bulletin/Repair Instructions · issued Feb 7, 2019
Structure problems in other Expedition years
| Year | Reports | Share |
|---|---|---|
| 2025 Expedition | 2 | 7% |
| 2024 Expedition | 4 | 6% |
| 2023 Expedition | 4 | 6% |
| 2022 Expedition | 12 | 11% |
| 2021 Expedition | 10 | 4% |
| 2020 Expedition | 16 | 4% |
| 2019 Expedition | 10 | 2% |
| 2018 Expedition | 13 | 4% |
| 2017 Expedition | 6 | 2% |
| 2016 Expedition | 3 | 1% |
| 2015 Expedition | 8 | 5% |
| 2014 Expedition | 6 | 8% |
Other reported problem areas on the 2005 Ford Expedition
Counts are unique NHTSA complaints naming this component group. Complaints are unverified owner reports; mileage is computed only from complaints that included a usable odometer reading.