Ford is recalling 41,748 vehicles because a contaminated LED chip inside the headlight assembly can knock out critical lighting functions. The campaign covers the 2025 to 2027 Expedition SUV and the 2026 F-250, F-350, F-450, and F-550 Super Duty pickups.
Ford says only about 1 percent of the recall population likely carries the defective part. Every covered truck and SUV gets inspected anyway, and owners can start checking their vehicle identification number through NHTSA once dealers are notified.
The recall spans three model years of Expedition and a single model year of heavy-duty Super Duty trucks. Falling inside that range doesn't mean a given truck has the faulty chip, since Ford pulled in every unit that might carry the suspect headlamp assemblies.
Ford traced the issue to a contaminated LED chip used in the headlight assemblies on both platforms. It's a parts-level flaw rather than a wiring or software bug, and that distinction matters for how dealers handle inspections as the fix is physical, not a software reflash.
Ford plans to notify dealers about the campaign before the end of October 2026, based on the schedule in its filing with NHTSA. Owner notification letters are expected to follow in November 2026, with specific mail dates that vary by model line.
This isn't Ford's only active recall touching its SUV and truck lineup this fall. The automaker separately flagged nearly 420,000 vehicles over faulty seat belts in the Expedition, and another campaign covered wiring concerns in 140,000 trucks.
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