Head-to-head reliability
FORD Fusion vs FORD Expedition
How the FORD Fusion and FORD Expedition compare on NHTSA complaints, recalls and crash reports — and which is the lower-risk used buy.
Based on NHTSA owner-complaint & recall records
FORD Fusion vs FORD Expedition: The Fusion averaged 1,367 complaints per year over 10 years, while the Expedition averaged 219. The Fusion also had 7 deaths and 313 injuries reported, compared to 0 deaths and 151 injuries for the Expedition. Both have similar recall counts. Source: NHTSA owner complaints.
The picture
Is the FORD Fusion or FORD Expedition more reliable?
A plain-English read on what the NHTSA record says about living with each vehicle.
FORD Fusion
The Ford Fusion is a mid-size sedan that, over ten years, generated 13,668 complaints—about 1,367 per year—and 91 recalls. The most common trouble spots are steering, engine, and power train, with owners describing snapped suspension parts, overheating engines, and transmission fluid leaks. With 474 crash-related reports, 313 injuries, and 7 deaths, the data suggests that some failures can escalate quickly, so a thorough pre-purchase inspection is essential.
FORD Expedition
The Ford Expedition is a full-size SUV that averaged 219 complaints per year over the same period, totaling 2,193, along with 94 recalls. Power train and engine issues dominate, including vibrations, sudden loss of acceleration, and even engine fires in low-mileage examples. Although crash-related reports are lower at 64, the 151 injuries and 0 deaths still point to serious safety concerns that buyers should weigh.
The numbers
Side-by-side NHTSA record
Lower is better in every category. The highlighted cell is the stronger result.
| Category | FORD Fusion | FORD Expedition |
|---|---|---|
| Total complaintsAll model years combined | 13,668 | 2,193 Better |
| Safety recallsFederal recall campaigns | 91 Better | 94 |
| Crash reportsCrash-related complaints | 474 | 64 Better |
| Complaints per yearAveraged across model years | 1366.8 | 219.3 Better |
| Reported injuriesTied to owner complaints | 313 | 151 Better |
| Reported deathsTied to owner complaints | 7 | 0 Better |
Source: NHTSA owner complaints & recall records.
What actually goes wrong
The problems owners report
The most-complained-about systems on each vehicle — what fails, and what owners say in their own words.
FORD Fusion
- 01STEERING4,155
- 02ENGINE2,563
- 03POWER TRAIN2,029
- 04ELECTRICAL SYSTEM1,301
- 05UNKNOWN OR OTHER1,164
Owners report the front lower control arm snapping while turning, which can cause loss of control, and also chronic horn failures that require repeated fuse replacements. These are not just annoyances—a broken control arm is a direct safety risk.
Complaints include engine cooling fan failure that blows fuses and leads to overheating, head gasket damage, and complete engine replacement. Another owner noted unusual shifting behavior in sport mode, suggesting transmission-related engine stress.
A failed transmission cooling line can leak fluid without warning, causing loud knocking and vibration, and sometimes requiring major repairs. Owners say the vehicle may not show any warning lights before the problem becomes severe.
Reports include a 2020 Fusion PHEV suffering sudden engine failure, smoke, and fire from the high-voltage battery, as well as situations where the car cannot be moved after being placed in park. These electrical faults can be life-threatening and expensive to fix.
“I’ve learned a while ago that the vehicle doesn’t have a working horn, I’ve replaced the fuse at least five times and it’s still not working. Yes the car was sold to me this way. Also I’ve been getting this warning to my ford app: “The Blind Spot Information…”
“The front left lower control arm (driver's side) snapped off (broke) while turning a corner. There was no reason for the breakage other than turning. It was repaired through insurance. The driver's safety as well as the safety of pedestrians were put at risk…”
FORD Expedition
- 01POWER TRAIN826
- 02ENGINE374
- 03UNKNOWN OR OTHER265
- 04ELECTRICAL SYSTEM258
- 05SEAT BELTS168
Owners describe strong vibrations at highway speeds and instances where the vehicle acts like it is in neutral, refusing to accelerate. These issues make long trips uncomfortable and can leave you stranded or in a dangerous situation.
A 2023 Expedition with only 6,197 miles caught fire while driving, and another owner reported the engine stopping and restarting while driving due to an Android Auto communication error. Such failures are rare but potentially catastrophic.
Complaints include brake failure where the pedal goes to the floor and all warning lights illuminate, as well as power running boards that fail to deploy. Brake issues are especially critical because they directly affect your ability to stop.
Owners report rear A/C compressor failure and power running board malfunctions, which can be costly to repair and may affect comfort or accessibility. These are not safety-critical but add to ownership costs.
“I purchased a new 2025 Ford Expedition Max. Since I left the dealer’s lot, the vehicle has had a strong vibration at any speed over 60 miles per hour, which makes highway driving and longer distance trips very challenging or impossible. Since I bought the veh…”
“Driving on highway, tried to accelerate, the car was acting like it was in neutral and would not accelerate. Checked to ensure I was not. the car began decelerating and I started to pull over. As I entered the brake down lane - the car automatically switched…”
Official recalls
Safety recalls on record
Federal recall campaigns — the defect, the risk, and the fix. Confirm any open recall was completed before you buy.
FORD Fusion — 91 recalls
The defect: Ford Motor Company (Ford) is recalling certain 2019-2020 Fusion PHEV vehicles. The battery energy control module (BECM) may become damaged due to excessive voltage and current flow.
The risk: A damaged BECM can result in a loss of drive power or fire, increasing the risk of a crash.
The fix: Owners are advised not to charge their vehicles until the remedy is completed. Dealers will replace the battery and update the BECM software for free, or Ford will repurchase the vehicle. If your vehicle is currently operating normally, Fo…
The defect: Ford Motor Company (Ford) is recalling certain 2018-2022 Transit Connect, 2019-2020 MKZ, MKX, Edge, Continental, F-150, Nautilus, Fusion, 2019-2023 Ranger, Mustang, 2020-2021 EcoSport, Expedition, Navigator, 2020-2022 Escape, F-250 SD, Corsair, 2020-2023 Aviator, Transit, 2020-2024 Explorer, 2021-2…
The risk: A rearview camera that displays a blank image can reduce the driver's view behind the vehicle. A rearview image that continues to be displayed after the vehicle is shifted out of reverse may distract the driver. Both of these situations ca…
The fix: Dealers will update the rearview camera software, free of charge. Owner notification letters were mailed September 4, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S72.
The defect: Ford Motor Company (Ford) is recalling certain 2016-2019 Lincoln MKC, 2016-2023 Explorer, 2019-2020 Fusion, 2019-2024 Ranger, 2020-2022 Lincoln Corsair, Escape, 2021-2024 Bronco, Bronco Sport, and 2022-2024 Maverick vehicles. The engine block heater may crack and develop a coolant leak, causing it…
The risk: An electrical short circuit can increase the risk of a fire.
The fix: Owners are advised not to plug in their block heater until the vehicle is remedied. Dealers will replace the block heater, free of charge. Owners will also have a alternative option to replace engine block heater element with a threaded bl…
The defect: Ford Motor Company (Ford) is recalling certain 2019-2020 Fusion PHEV vehicles. The battery energy control module (BECM) may become damaged due to excessive voltage and current flow.
The risk: A damaged BECM can result in a loss of drive power or fire, increasing the risk of a crash.
The fix: Owners are advised not to charge their vehicles until the remedy is completed. Dealers will replace the battery and update the BECM software for free, or Ford will repurchase the vehicle. If your vehicle is currently operating normally, Fo…
FORD Expedition — 94 recalls
The defect: Ford Motor Company (Ford) is recalling certain 2024-2025 F-150, Expedition, and 2024 Lincoln Navigator vehicles equipped with 3.5L GTDI engines. The engine may have a misaligned engine cup plug, which can result in a rapid oil leak.
The risk: A rapid oil leak can result in an engine stall, increasing the risk of a crash. In addition, an oil leak in the presence of an ignition source such as hot engine or exhaust components, can increase the risk of a fire.
The fix: Dealers will inspect the engine cup plug alignment, and replace the plug if necessary, free of charge. Owner notification letters were mailed May 22, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this…
The defect: Ford Motor Company (Ford) is recalling certain 2025 Navigator and Expedition vehicles. The passenger side air bag may have been manufactured incorrectly, which can cause the air bag to deploy with excessive force during a crash.
The risk: An air bag that deploys with excessive force can increase the risk of injury during a crash.
The fix: Dealers will replace the passenger side air bags, free of charge. Owner notification letters were mailed August 8, 2025. Owners may contact Ford Customer Service at 1-866-436-7332. Ford's number for this recall is 25S51.
The defect: Ford Motor Company (Ford) is recalling certain 2025 Lincoln Navigator, F-150, Expedition, Bronco, and Ranger vehicles. The Electronic Brake Booster (EBB) module may malfunction while driving or when the driver is utilizing an Advanced Driver Assistance System (ADAS) feature, resulting in a loss of…
The risk: An unexpected loss of power brake assist while driving can extend stopping distance and increase the risk of a crash. Additionally, a loss of power brake assist while ADAS features are engaged can result in the vehicle not braking as expec…
The fix: The EBB module software will be updated over-the-air (OTA) or by a dealer, free of charge. Owner notification letters were mailed on August 22, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall…
The defect: Ford Motor Company (Ford) is recalling certain 2025 Lincoln Navigator, F-150, Expedition, Bronco, and Ranger vehicles. The Electronic Brake Booster (EBB) module may malfunction while driving or when the driver is utilizing an Advanced Driver Assistance System (ADAS) feature, resulting in a loss of…
The risk: An unexpected loss of power brake assist while driving can extend stopping distance and increase the risk of a crash. Additionally, a loss of power brake assist while ADAS features are engaged can result in the vehicle not braking as expec…
The fix: Dealers will replace the electronic brake booster, free of charge. Owner notification letters were mailed February 26, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25SD4. Vehicle Identi…
Buyer analysis
FORD Fusion or FORD Expedition: which should you buy?
The Ford Expedition has far fewer complaints per year (about 219 vs. 1,367 for the Fusion), but both have similar numbers of recalls. In practice, the Expedition may have fewer day-to-day problems, but the Fusion's higher complaint volume means you are more likely to encounter a wide range of issues, from steering to electrical.
Key differences
- The Fusion has over six times as many complaints per year as the Expedition, with steering and engine problems being the most common.
- The Expedition's complaints are concentrated in power train and engine, including vibrations and sudden loss of power, while the Fusion's issues span steering, engine, power train, and electrical systems.
- The Fusion has 7 reported deaths and 313 injuries in NHTSA data, compared to 0 deaths and 151 injuries for the Expedition, though both have safety-related complaints.
- Recalls are nearly equal (91 for Fusion, 94 for Expedition), but the Fusion's recalls include high-voltage battery and back-over prevention software, while the Expedition's include brake assist and trailer brake control.
- Inspect the front lower control arms for cracks or previous repairs, as owners report them snapping during turns.
- Check the engine cooling fan operation and look for blown fuses or signs of overheating, which can lead to head gasket failure.
- Test drive at highway speeds to feel for strong vibrations, and listen for unusual noises from the power train.
- Check for brake pedal feel and any warning lights related to the braking system, as owners report sudden brake failure.
Before you buy
- Obtain a full vehicle history report and check for open recalls on the NHTSA website using the VIN.
- Have a certified mechanic inspect the steering and suspension components, especially the control arms and horn function on the Fusion.
- For the Expedition, test the brakes at low and high speeds and scan for any stored error codes in the brake control module.
- Ask the seller for maintenance records, particularly for transmission fluid changes and cooling system repairs.
- During a test drive, pay attention to any unusual shifting, vibrations, or warning lights that may indicate pending failures.
Year by year
Which model years to avoid
Complaints per model year for both vehicles — lower is better. The spikes are the years to scrutinize.
| Year | FORD Fusion | FORD Expedition |
|---|---|---|
| 2020 | 183 | 419 |
| 2019 | 377 | 504 |
| 2018 | 441 | 375 |
| 2017 | 1110 | 357 |
Check the actual car
Comparing models is smart. Checking the VIN is essential.
Brand averages tell you the trend. A VIN check tells you what's wrong with the specific FORD Fusion or FORD Expedition in front of you — accident history, open recalls and title records.
Go deeper
Full reliability reports
- Comparison
- FORD Fusion vs FORD Expedition
- FORD Fusion total complaints
- 13,668
- FORD Expedition total complaints
- 2,193
- FORD Fusion total recalls
- 91
- FORD Expedition total recalls
- 94
- FORD Fusion avg complaints/year
- 1366.8
- FORD Expedition avg complaints/year
- 219.3
- More reliable overall
- FORD Expedition
- FORD Fusion top complaint area
- STEERING
- FORD Expedition top complaint area
- POWER TRAIN