2016 Ford Expedition

My 2016 Expedition has the same 6R80 transmission as the Ford F150, for which there is a recall for the Lead Frame. My wife was driving the vehicle on the highway and the check engine light came on and the vehicle went into "limp mode" causing the vehicle to decelerate to approximately 35 mph. Needless to say, she almost caused several accidents as she tried to move to the shoulder at a very reduced speed. The code was P0715 and P0717 which is the Turbine Shaft Speed Sensor which is part of the lead frame in the transmission. As stated before, there was a recall on this issue with the F150 but not to the Expedition since Ford did not sell as many Expeditions as F150's? I was able to have the lead frame replaced, at my cost, to remedy the situation, however, the fact that this is a known issue with this transmission and only some of the cars with this transmission were recalled is morally wrong. This could have caused a major accident resulting in serious injury or death since Expeditions were not part of the recall.

My expedition started stuttering and the speedometer, started fluctuating speeds which would also cause my cruise control to turn off. Then the speedometer quit working altogether and so did the odometer. If I turned the truck off and restarted it, it would reset everything for a few miles then it would start all over again. I went to the Ford dealership and got it fixed. It cost $2500. Later doing research, I discovered this is a problem with this transmission and can be very dangerous as the truck can downshift dramatically which our did once. If I’ve been on ice or pulling my trailer, it could’ve been catastrophic. I feel like this should be a recall. I also feel like Ford should have to pay for this.

The failed components are called "cam phasers." It is a known problem with the Ford 3.5 Ecoboost Engine (that even Ford is aware of). The cam phasers can fail, causing the timing chain to fail at any moment. They rattle upon startup of a cold engine. The failure of the original engineering is causing owners of this vehicle, along with the F150 and others, to have to spend anywhere from $3,000 to $5,000 in order to replace these. The problem has been confirmed by the Ford dealer. In order to visually examine the cam phasers, it requires something like 10+ hours to open the engine. You do not receive a warning light to replace cam phasers. It is merely an audio diagnosis. Ford SHOULD BE RESPONSIBLE for replacing these free of charge and replacing them with the newer versions of cam phasers, which apparently don't fail. Driving around with rattling cam phasers can leave you stranded!

The contact owns a 2016 Ford Expedition. The contact stated while driving 2 MPH, the accelerator was depressed, and there was a grinding sound coming from the rear-end of the vehicle. There were no warning lights illuminated. The vehicle was then taken to a dealer where it was diagnosed with rear differential failure. On a separate occasion, a year later the rear differential failure recured. The vehicle was taken to the dealer and the rear end was repaired. The manufacturer was made aware of the failure and referred the contact to the NHTSA Hotline. The failure mileage was approximately 85,913.

While driving on [XXX] at approximately 35 mph the vehicle displayed a wrench warning lamp and at same time vehicle went into limp mode. No power I had to coast to the side of road, engine running but no power. Turned engine off restarted vehicle and drove short distance home. Holiday Ford in Gordon, Texas was contacted they advised bring vehicle in for diagnostic test. Vehicle was driven to Holiday Ford dealership in Gordon, Texas for an appointment 4 days after the occurrence but on the way to dealership it occurred again turned engine off restarted an drove to dealership. Picked vehicle up same day but it occurred again . Took back to dealership, they kept vehicle for 4 days and advised they couldn’t find anything wrong. The vehicle has gone to limp mode 3 times. I was lucky very little traffic it would be very much safety hazard in moderate to heavy traffic. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact owns a 2016 Ford Expedition. The contact stated that the vehicle lost motive power and stalled while driving uphill. The contact stated while attempting to drive from a complete stop, the vehicle failed to respond. The check engine warning light illuminated. The contact turned off and restarted the vehicle, and the vehicle responded upon depressing the accelerator pedal; however, the vehicle stalled while driving. The contact was unable to veer to the side of the road. The vehicle was towed to a transmission specialist, where it was diagnosed that the transmission molded lead frame had failed. The mechanic contacted the dealer to order the part; however, the dealer informed the contact that the part #AL3Z-7G276 had been discontinued. The contact later purchased the part from an aftermarket dealer and the part was installed on the vehicle; however, the failure persisted. The contact contacted the dealer who advised him to purchase the valve body because the transmission molded lead frame had been discontinued. The transmission specialist then replaced the valve body and flushed the transmission fluid. The dealer reprogrammed the computer. The vehicle was repaired. The manufacturer was notified of the failure and a case was opened. The manufacturer referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 100,000.

The contact owns a 2016 Ford Expedition. The contact stated that on several occasions while driving at various speeds, the transmission inadvertently downshifted into a lower gear, causing the rear wheels to lock up. The vehicle was taken to an independent mechanic where it was diagnosed that the leadframe, valve body, and output shaft sensor needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 126,000.

The contact owns a 2016 Ford Expedition. The contact stated while driving at an undisclosed speed, the vehicle inadvertently lost motive power. The contact pulled over to the shoulder of the roadway and the vehicle was restarted. After restarting the vehicle, the vehicle returned to normal functionality, but the failure became a regular occurrence. The check engine warning light was illuminated. The vehicle was not taken to the dealer or an independent mechanic to be diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was 109,000.

The contact owns a 2016 Ford Expedition. The contact stated that while driving at an undisclosed speed, the vehicle lost motive power. The check engine and transmission warning lights were illuminated. The vehicle was towed to the dealer, where it was diagnosed that the lead frame needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and advised the contact to file a complaint with the NHTSA Hotline. The failure mileage was 38,484. The contact stated that the lead frame was replaced, and a sensor was added to the vehicle. However, that did not help the issue and the recall repair has yet to be performed.