There are 2 stored owner reports matching the body & structure leading-label group for the 2025 Ford Expedition in our NHTSA-sourced dataset. These are unverified consumer reports and may not reflect confirmed defects.
This group counts stored reports whose component label starts with one of this site's matching prefixes, ignoring case. Each matching report counts once within the group. Components mentioned later in the label or only in the narrative are not searched. How component counts work
Loaded 2 of 2 matching reports.
Open the full vehicle complaint log (all categories)In June 2025, I bought a new 2025 Ford Expedition King Ranch. While washing my SUV by hand, I discovered a manufacturing defect on the roof—Ford Manufacturing had left exposed welding and rivets. The issue is quite noticeable, with depressions around the rivets and welds so deep they could hold golf balls. More than two dozen of these rivet welds are visible and exposed. I contacted my local dealership in Sioux Falls, SD to file a warranty claim, but it was denied. During this process, the dealership informed me that their lot was filled with Expeditions and Lincoln Navigators showing the same problem, indicating that it's a widespread concern among all dealers. After my claim was denied, I reached out to Ford's nationwide customer support at [XXX] and was given case number CXh-XXX. After two conversations, it became clear that Ford's organization was not effectively communicating internally. My dealership thanked me for bringing the issue to Ford Corporate, as resolving it is financially important to them. Sioux Falls Ford contacted the local Ford Factory Representative, but no solution has been provided so far. The presence of these divots allows water to accumulate in the crevices, potentially leading to severe corrosion in southern regions exposed to salty ocean air. In northern areas, freezing and thawing cycles may cause further structural Integrity deterioration, both overtimes causing catastrophic failure. At no time did Ford disclose these defects to their dealership network, and had it been, proper disclaimers would have been required on vehicle window stickers. Nor was I informed about the exposed rivets, welds, or dents on the roof prior to purchase. Ford Manufacturing failed to disclose material information regarding this issue. Ignorance is not an excuse—Ford Manufacturing misled me by failing to reveal the roof defect. The manufacturer date of my Ford Expedition was May of 2025. See attached pictures. HELP!! Kind regards [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
The contact rented a 2025 Ford Expedition Max. The contact stated that while stopped at a gas station, the front driver's side door was opened and was cut by the edge of the door. The bottom of the door was at a 90-degree angle, and the edge of the door was sharp. The contact sustained a 2 1/2 in. cut on the right front lower part of the leg. No medical attention was received. The contact stated that the cut left a scar on his leg. The manufacturer was not notified of the failure. The failure mileage was approximately 7,300. The VIN was not available.
Complaints are unverified consumer reports submitted to NHTSA. A high complaint count may reflect vehicle popularity, not defect severity. Data sourced from NHTSA public records.
NHTSA source checks for this vehicle year
Checks are recorded separately for each dataset, not for the whole page. Dates use UTC. A missing check date does not mean no records exist.
Vehicle import recorded: May 4, 2026. This is the stored import date, not confirmation that every source was successfully refreshed.