Ford Recalls Thousands of 2020 Expedition and Navigator Models Due to Fire Risk

Ford Motor Company is initiating a safety recall for 4,632 model year 2020 Ford Expedition and Lincoln Navigator vehicles. This action is being taken due to a defect in the battery junction box that could lead to an electrical short and a potential underhood fire, even when the vehicle is parked and turned off. Owners of affected vehicles are advised to park their vehicles outside and away from structures as a precautionary measure.

The defect stems from issues with the printed circuit boards within the battery junction box, specifically concerning the solder mask coverage and conformal coating. These manufacturing deficiencies can expose a circuit to water and contaminants, leading to corrosion and dendritic growth. This process can ultimately cause an electrical short, generating enough heat to overheat the printed circuit board. The affected circuit boards were reportedly produced by a supplier that transitioned to a different manufacturing facility during the early stages of the COVID-19 pandemic in 2020.

The recall encompasses 3,730 Ford Expedition vehicles and 902 Lincoln Navigator vehicles manufactured between November 17, 2020, and December 1, 2020. Within the affected Expedition population, 2,558 units are equipped with a standard duty radiator fan motor (700W), and 1,172 are equipped with a heavy duty radiator fan motor (800W). For the Lincoln Navigator, 471 vehicles have the standard duty fan motor, and 431 have the heavy duty fan motor.

Ford has developed two distinct repair procedures based on the type of radiator fan motor installed. Owners of vehicles equipped with the heavy duty radiator fan motor will be notified that a remedy is available. Dealerships will first inspect the battery junction box for any signs of damage and replace any affected units. Following this inspection, a ground wire will be removed from the battery junction box at no cost to the owner.

For vehicles with the standard duty radiator fan motor, the remedy will also involve an inspection and potential replacement of the battery junction box. Additionally, a ground circuit will be removed, and an auxiliary electrical box with a wire jumper will be installed.

Ford has indicated that owners of vehicles produced within the specified date range will receive notification by mail. These letters will instruct owners to bring their vehicles to a Ford or Lincoln dealer for the necessary repairs. The company has stated that there will be no charge for this service. A reimbursement plan is in place for owners who may have already incurred costs for remedies prior to the official recall notification, with eligibility for reimbursement estimated to extend until October 20, 2025.

Owners seeking to determine if their specific vehicle is part of this recall can contact Ford’s toll-free line at 1-866-436-7332 or reach out to their local Ford or Lincoln dealer. Dealers can access detailed vehicle information through the Ford On-line Automotive Service Information System (OASIS) database. The VINs for affected vehicles are expected to be searchable beginning September 23, 2025. Dealer notification is scheduled for September 23, 2025, with owner notification letters expected to be mailed between September 29, 2025, and October 3, 2025.

The potential safety risk associated with this defect includes the possibility of an underhood fire. Some customers have reported experiencing a burning smell and smoke emanating from the engine compartment while driving, which could serve as a warning sign.

Article by Mel Anara, based upon information from Ford Motor Company.

---