Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2006 Ford Expedition owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2006 Ford Expedition. The contact stated that while driving 35 MPH, the contact stated that there were exhaust fumes inside the vehicle. The engine warning light was illuminated. The vehicle was diagnosed by an independent mechanic and confirmed the failure was a defective charcoal canister for the evac system. The vehicle had not been repaired. The manufacturer was made aware of the failure however, the part was not available. The failure mileage was approximately 70,000.
the service engine light continues to turn on. the timing belt continues to fail and has already been replaced once. the camshaft on both sides have been replaced. the solenoids have also been replaced and the diagnostics codes still pop up (p0022) (p0021) are just some that i can remember. the engine does not have enough power on the driver side and throws the timing belt off which causes the loud rattle coming from the engine. when reaching the speed of 40-45 mph the truck begins to shake. recently in november 2023, when fueling up with gas , the truck began to shake and not respond. when accelerating, the truck takes off very slowly and the gears dont kick in on time. when the gas light comes on , the truck begins to function well. but as soon as i put gas again. it feels like the truck is going to fall apart. the driver door gets stuck when trying to open from the inside. …
Tl* the contact owns a 2006 Ford Expedition. The contact was driving approximately 55 MPH when the vehicle began to decelerate independently. The vehicle was moved from the roadway and when the contac exited, there was an abnormal burning odor and black smoke emitting from the tailpipe. The police were dispatched and when they arrived and opened the rear driver side door, thick black smoke was pouring out from the inside of the vehicle. There were also flames from the interior and under the frame. The fire was extinguished by the local fire department. The fire chief advised that there was a hole in the fuel line and an electrical problem that could have caused the fire but the results were inconclusive. The vehicle was towed by the contacts insurance company. …
Tl* the contact owns a 2006 Ford Expedition. While driving various speeds, the vehicle stalled without warning. The contact stated that the "fail safe mode" indicator displayed. Hertrich Ford in milford, delaware was made aware of the failure and replaced the throttle body and the driver's side fuel module. The manufacturer was made aware of the failure and referred the contact to NHTSA. The failure mileage was approximately 160,000.
As I was slowing down and made a right turn into a parking space, the vehicle accelerated on its own, running over the concrete stop and the curve. The car continued to accelerate and ran head on into a tree that was approximately 10 feet away from the parking space. The driver airbag did not deploy. My car was totaled as a result of this accident.
While driving at 45 MPH on 2 lane road the truck acted as if it had run out of gas. I shifted into neutral and coasted to a parking lot at a store on the other side of the road. Thankfully there was not opposing traffic or I would have stopped in my lane and blocked traffic.
This complaint is in reference to our 2006 Ford Expedition. This failure at this time seems to be occurring during normal vehicle operation, at random intervals. The failure is being reported by the OBD to be "throttle body stuck wide open" which results in the vehicle entering failsafe mode, which appears to restrict the RPM's of the engine. Upon entering failsafe mode the vehicle tends to stall and subsequently will not start for a short period of time following the failure. This failure occurs weekly at various times of the day. At this time the concern is that if there is any failure on the part of the "failsafe" mode, the vehicle will be unresponsive to the operators throttle control and if the throttle body is in fact stuck wide open the vehicle will proceed to increase speed without regard to the operators controls, rendering the vehicle out of control. …
Three separate times the car shut off in different types of "engine failsafe mode" within the past 7weeks. Engine failsafe mode causes the vehicle to lose all power. Last time this happened on the highway at 60 MPH with two small children in the vehicle. Other two times it occurred when slowing down to turn. There is great potential for this to lead to a very dangerous situation. Owner's manual points to cruise control or throttle system stuck although the cruise control was not in use. Each time vehicle restarted with no issues. Dealer reported it was an issue with the throttle body and possibly the throttle getting stuck wide open . No explanation or investigation was done to determine specific issues with the throttle body, except it just needed to be replaced. Repair at this particular dealer runs $800. No diagnostics were done on the throttle position sensor. …
Tl contact owns a 2006 Ford Expedition. The contact stated that while driving the check engine light illuminated. The vehicle was taken to an authorized dealership where the contact was informed that the fuel injectors were stuck open and flooded the engine. The dealer also stated that both catalytic converters were ruined and needed to be replaced, and the engine was possibly damaged. The contact stated that there was a recall related to the failure for previous model years and warranties were extended as a result. The contact called the manufacturer who stated that they would not extend the warranty on the vehicle. The contact filed a complaint. The current and failure mileages were approximately 65,000. Updated 11/19/10. Updated 10/27/10. The consumer stated a new engine was put in the vehicle. However, he continued to experience problems. …
I was coming across arizona, interstate 10 in my 2006 Expedition heading home to san diego when my "engine failsafe mode" indicator came on, the engine warning light was on and shut the engine down. The engine warning light never went off until I took it to a mechanic the following morning. The mechanic stated that I need to have the throttle cleaned out and May need a new sensor for the side of the throttle replaced. I have 59K miles on my vehicle and have the maint. Completed every 4K to 6K and have owned this vehicle from the start. I had 2 miles on the vehicle when we purchased this vehicle in oct 2005. After reading about this problem with other owners I think Ford should be able to repair or replace the problem without charging the customer. This is the second time this has happened to me. Both times we had the cruise control turned on. …
Fuel System complaints in other Expedition years
Frequently asked questions
How common are fuel system problems on the 2006 Ford Expedition?
NHTSA has 24 complaints about the fuel & propulsion system of the 2006 Ford Expedition, 8% of the model year's 299 complaints. The component named most often is fuel injection system › injectors (1 mentions).
Is there a recall for 2006 Ford Expedition fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2006 Ford Expedition, though it has 2 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2006 Ford Expedition fuel system problems start?
Half of the complaints with a recorded mileage happened before about 85,000 miles.
Is it dangerous?
Owners linked 1 crash, 2 fires and 1 injury to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.