Ford Expedition
3.5L EcoBoost V6 Gen2 — revised twin-turbo with port injection (no more carbon). Cam phaser failure on 2017-2020 is THE topic (Ford Customer Satisfaction Program 21N03, expired). Exhaust manifold studs break from turbo heat. Plastic valve covers crack. Still: the most popular F-150 engine and in Gen2 form significantly more reliable than Gen1.
Expedition — full-size family SUV with F-150 problems
375 hp 3.5L EcoBoost in a big SUV: room for 7-8, enough power to tow. Same cam phaser and 10R80 transmission issues as the F-150. Cooling system leaks and shock absorber early wear as Expedition-specific topics. Not an adventure SUV — a comfortable family hauler with known weaknesses.
Engine Weaknesses 6
THE Gen2 topic: hydraulic phasers fail from ~50k miles. Ford CSP 21N03 (expired). $3-5k repair. July 2018 and October 2019 revisions improved the parts.
Symptoms: Knock/tick at warm idle, CEL P0011/P0012
Turbo heat + original design with too few studs → warping and breakage. Ticking on cold start.
Symptoms: Ticking/squeaking on cold start
The bi-turbo coolant supply and return lines become brittle from thermal cycling and leak. Sudden coolant loss under load can cause overheating — especially dangerous when towing.
Symptoms: Sweet smell, low coolant without visible puddle, overheat warning while towing
HPFP failures are a known issue on the 3.5 EcoBoost. In severe cases the pump can fragment and damage the cylinder head — resulting in $4,800+ repairs. Some trucks have needed three pumps before 100k miles.
Symptoms: Hard start, P0087 fuel rail pressure low, hesitation under boost, metallic knock on pump failure
Plastic + heat cycles + mechanic error → crack. Oil on exhaust manifold. Parts backordered >6 months at times.
Symptoms: Oil smell, oil on exhaust manifold
Well-known Gen2 issue: both turbo wastegate flaps develop excessive play and rattle loudly. Can recur after turbo replacement. When the flap no longer seals, underboost codes are triggered.
Symptoms: Loud rattle on cold start lasting up to a minute, P0299 underboost when flap play is severe
Vehicle Weaknesses 4
Same 10R80 issue as F-150: vibration at 35-45 mph, CDF clutch drum, TSB 20-2028.
Heater hose tee connections fail. Slow coolant loss. Turbo cooling line may require engine removal in severe cases.
High failure rate at low mileage. CCD dampers hold up better.
Some vehicles worn at 30k miles without towing.