2015 Ford Expedition Electrical System

Purchased 12/2023 2015 Ford Expedition April of 2024 we began to have issues with the Sync System and Climate Control. We took it back to the original dealer and a second Ford dealer and neither was able to diagnose the issue. As they could not get it to duplicate while there. However it has happened numerous times since. The symptoms seem to have no rhyme or reason as to when they will happen, but they do follow the same pattern each time. The Sync screen will turn itself off completely and randomly. Screen goes Black System shuts down as if the power button was pushed. When you do push the power button to turn the system back on the temperature display in the left hand corner will no longer be displayed. This is the indication the system is still not working properly. The Air Conditioner will then turn itself off. Then the blower will switch to defrost and high heat, all in its own. You cannot adjust the setting or turn the heat off. It continues to blow on high heat in defrost mode until it decides to switch back to AC. This could last 2 seconds could be 20 minutes It will also read the gas gauge wrong, registering 20 miles left of gas even if you just filled up. This has all happened in the summer months causing extreme heat in the vehicle even with all the windows down. We replaced the Blower motor resistor and its wiring harness. Checked the blower at the same time, it is running smoothly. We also replaced the relay #3 responsible for climate control. We attempted the replace the intake manifold temperature sensor, but have been sent the wrong sensor twice, and it does not fit correctly. Now we have a fan running so loudly it sounds like out engine is idling high when it is not. We also now have no heat at all in the vehicle. When I checked the recalls the dates for the 2023 (22S56) are within the recall years but our vin says it's not. Manufactured 9/2014 Recall is for 1/2014-6/2017 No heat in the winter and extreme uncontrollable heat in the summer

Current recall reference# 22S56 front blower motor on some 2015–2017 Expedition SUVs and have issued a recall for affected vehicles. The front blower motor in certain vehicles may experience overheating and risk of interior fire. So my vehicle has gone thru 2 fixes for recall. But the issue caused by the blower motor was the actual risk of fire were the Wiring Harness. Which were burnt and original from the first repair that were already defaulted. So brand new motor and modular install but no new wiring harness that are already burnt. They just went ahead and plugged them back in with notice or even a heads up that you are still in danger of potential fire

The backup camera intermittently won't turn on when shifting into reverse and instead says to contact the dealer for service.

There was an open recall on our 2015 Ford Expedition for Blower Motor overheating. After fix a week later we took back in as the issue of no fan was still present and told no longer an open recall as it was marked complete, and would need to pay to have resistor and wiring harness for the blower motor replaced.

Smelled smoke, then a small amount of dark smoke was noted to be coming from A/C vents I pulled over & turned off car The smoke stopped. I exited the car & called my husband. I opened the car hood to inspect. There was nothing suspicious. No source of the smell or smoke was identified. I re-entered the car, turned on the engine, and lots of dark smoke exuded from of A/C Vents & the engine. I turned off the engine, left the car & moved away. I called 911. A passer by went into the Post office, returned with a fire extinguisher & sprayed the engine. This seemed to temporize things for a very short time. while on the phone with 911 the car fire started and rather quickly the car became nearly totally engulfed in flames. Then the Police arrived first, followed by the Fire engine. Essentially, "everything that could burn did" (except the gas tank). Known recall (manufacturer #22S56, NHTSA #22V648

The contact owns a 2015 Ford Expedition. The contact stated that while the vehicle was started, the A/C system was inoperable. The contact stated that he observed wires hanging down that were melted. The vehicle was taken to a dealer where it was diagnosed that the blower motor speed control connector needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 138,000.

My vehicle falls under recall 22V648. For has contacted me about doing the repair. I have replaced the blower motor speed controller twice in the last few months and it is bad again due to the recalled blower motor. How can this part not also get replaced as part of the recall?? The recalled part is burning up the wires going to the speed controller/resistor and melting the connection at the resistor.

I left my recalled vehicle recall 22S56 for repair at Yadkin Valley Motor Co. on 7/27/23, I told them my A/C blower was not working, I had smelled smoke and had noticed the wiring was melted on the blower resistor connection. When I retrieved my vehicle on 7/28/23 I tried the A/C and it did not activate. The service tech. told me he inspected the blower motor connection only. I was not able to leave it there, I called Ford Customer service Case No. [XXX] on 7/28/23 I informed them of my problem and asked for an appointment with a more reputable Ford service dealer near me. While on the phone with Ford and service with Randy Marion Ford West Jefferson NC. I was informed that only the blower motor that was replaced by Yadkin valley motor co. was the only part covered by the recall even though the blower motor was the cause of the resistor electrical overload. I had to replace the blower resistor part myself 7/28/23, My A/C system is working now but I was informed by Randy Marion Ford that the blower that was installed is a temporary fix until the blowers that have been redesigned are distributed. “INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).”

AC stopped and vehicle smelled of burning and smoke. Contacted dealer to have recall 22S56 completed and advised the dealer that the blower motor resister and harness appeared to be melted. Dealer stated they were only responsible for replacing the blower motor and not the damaged components due to the faulty blower motor. This repair was completed June 30, 2023. Today 7/19/2023 the AC has again intermittently stopped working and the vehicle has a much stronger smoke odor and burning smell than before. I contacted Ford who states they will follow up with me in 2 days. This is not acceptable as there is an imminent danger of fire within the vehicle. The resistor and harness are visibly burnt and melted.

Called local dealership as soon as we received recall notice in September 2022. Because we were already having issues. They said probably March for the blower motors to come in that they were on back order. Here we are now in May and still nothing. I’ve called the dealership and they said that they were going to see where they could locate a blower and call me right back. They have not yet called back and I’ve called last week and today also called the Ford customer relationship center and all they could tell me was that they were gonna put it in the books and I should receive another notice that maybe April, May or June and that they would let me know my blower motor is not blowing any air. The wires are exposed. The plastic is melted. NOT SAFE AT ALL! I am a month away from having a baby and it’s going to be the heat of the Summer where we really need the AC because this is my only form of transportation I can’t be without it.

It seems as this comes in as a common issue with heated seats. The wiring harness Carrie’s only 1 ground wire to transmit connection to the heated seat module. This causes the wire to over heat after time and create a short and burn the wiring. Research has shown this issue has melted plastic harness to the module to where consumers have to pry the connector off the module. Consumers are rewiring the connector to include 2 grounds which allows the wiring to stay cool. This seems to be a high safety issue as when an electrical component shorts and causes connectors to burn and even melt can lead to fires. Melting plastic takes high heat and is a for sure sign of safety issue.

The contact called on behalf of his wife who owns a 2015 Ford Expedition. The contact stated that while his wife was driving at an undisclosed speed, the heat intermittently operated, and his wife started to smell a burning odor throughout the vehicle. The contact also stated that on a separate occasion while driving, he started to smell a burning odor. The contact then stated that he pulled the vehicle off the road to inspect the vehicle. The contact stated that upon inspecting under the dashboard on the front passenger’s side of the vehicle, he noticed that the wires had melted with a gray cloud of smoke. No warning light was illuminated. The vehicle was taken to the dealer where it was diagnosed that the blower motor resistor melted and melted the wires and wiring harness. The wire assembly and module needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 155,000.

When the heater is operated for 15-20 minutes a burning tire or skunk smell issues from the heater. The heater blower is currently of recall concern. No immediate safety issues, but we are concerned and the smell is bad. None of the components have been inspected by anyone. We are waiting on recall notification. No warning lamps or vehicle messages have occurred. The problem was first noticed as the winter weather made outside conditions much cooler and the heater fell into common usage. When heater is turned off the smell goes away.

WHILE IDLING AT A TRAFFIC LIGHT, THE ENGINE OF MY 2015 FORD EXPEDITION BEGAN TO LABOR, EVIDENCED BY LOW AND HESITATING RPM AND REDUCED FAN SPEED OF THE AIR-CONDITIONER. ISSUE WAS RESOLVED WHEN THE AIR CONDITIONER WAS SHUT OFF, BUT HAS REAPPEARED SEVERAL TIMES AS A RESULT OF TURNING ON THE AIR CONDITIONER. I HAVE SPOKEN WITH OTHER RECENT MODEL FORD EXPLORER AND EXPEDITION OWNERS WHO HAVE REPORTED THE SAME ISSUE OCCURRING IN THEIR VEHICLES. THIS POSES A DANGER TO THE PUBLIC AS THE CAR'S ENGINE HESITATES AND NEARLY STALLS REDUCING REQUIRED ON-DEMAND POWER AND ACCELERATION. THIS HAS HAPPENED WHILE STATIONARY AND IDLING AND ALSO WHILE THE VEHICLE IS MOVING AT VARIOUS SPEEDS (0 - 55 MPH) ON BOTH CITY STREETS AND HIGHWAYS. WAS SURE I'D FIND A RECALL RELATED TO THIS ISSUE (MOST LIKELY A VEHICLE COMPUTER ISSUE) ON THIS SITE, BUT NO ACTIVE RECALLS FOR 2015 FORD EXPEDITIONS EXIST.