The Expedition, along with the F-250, F-350, F-450, and F-550, could all suffer from a contaminated LED chip in the headlight assembly.

Ford issued a recall for 41,748 vehicles because the headlights may fail to comply with federal safety standards, according to paperwork filed with the National Highway Traffic Safety Administration (NHTSA). The recall covers the 2025–2027 Expedition SUV, as well as 2026 versions of the Super Duty range: F-250, F-350, F-450, and the F-550.

According to the NHTSA documents, the recall stems from potential contaminants located under an LED chip in the headlight assemblies. The paperwork shows that the contaminants originated at the chip supplier’s manufacturing facility.

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Only 1 percent of the recall population is expected to have the contaminated chips. For the trucks and SUVs that are impacted, the paperwork shows that owners may experience diminished or inoperative daytime running lights, parking lights, low-beams, and high-beams. As a warning to owners, an indicator light will illuminate on the dashboard to alert customers to the reduced low- and/or high-beam performance.

Owners of the affected vehicles will be notified by mail and asked to bring their car to a Ford or Lincoln dealer to have both headlights inspected by a technician. If the headlights pass inspection, customers will be sent on their way. If either headlight fails, technicians will replace the faulty unit with a replacement at no charge to the customer.

Ford will begin mailing notification letters to its dealers on October 26, 2026.

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