2022 Expedition - Cracked Roof Panel; Cracked Lift gate Spoiler

[Lanaya]

2022 Expedition Timberline built 01/22
Just lost my spoiler on the highway and almost caused a 1 ton pulling a gooseneck to hit the ditch. Turned back to get my spoiler pieces and looked on the roof…funny it looks to be the exact same dent! Wish me luck when I go to the dealer for warranty! Thank you all for all your hard work, I didn’t even know what to think but recalled seeing this a year back.

 

[SyndicateZ]

So the spoiler detaching from your roof, due to faulty design from manufacturing and almost caused a vehicle behind you to crash.?... sounds like this needs to be an official recall by NHTSA. Too many cases with these spoilers with these years

 

[Lanaya]

The dent which I did not notice allowed air to go under the spoiler at hiway speeds and caused the spoiler to get ripped off almost hitting another vehicle…major safety concern. Calling ford customer service this morning.

 

[1775SS]

The dent which I did not notice allowed air to go under the spoiler at hiway speeds and caused the spoiler to get ripped off almost hitting another vehicle…major safety concern. Calling ford customer service this morning.

Let us know how that call turns out.
Hopefully, not a goat rope.

 

[DieselMonk]

My 22 built in May has the rubber flap/gasket under the gap. Maybe it was a part shortage somewhere during the build process that some didn't get it.

Same as my 2024 Limited SPP.

 

[Lanaya]

It’s out of the dealers hands, although they have the vehicle and will be getting the estimate. I spoke to ford Canada and have a claim going now. I strongly suggest anyone who has had this issue to call ford and submit a claim. Based on how many people have had this exact issue, this is obviously not due to owner negligence but bad fitment, missing gasket/seal while manufacturing the 2022s and until enough people reach out they won’t recall. That said, it’s a major safety concern. Hopefully Ford does the right thing. Ford Canada said to save receipts and should this turn into a recall we would be reimbursed. For now I must wait to hear back on my claim based on the estimate. Fingers crossed.

 

[SyndicateZ]

It’s out of the dealers hands, although they have the vehicle and will be getting the estimate. I spoke to ford Canada and have a claim going now. I strongly suggest anyone who has had this issue to call ford and submit a claim. Based on how many people have had this exact issue, this is obviously not due to owner negligence but bad fitment, missing gasket/seal while manufacturing the 2022s and until enough people reach out they won’t recall. That said, it’s a major safety concern. Hopefully Ford does the right thing. Ford Canada said to save receipts and should this turn into a recall we would be reimbursed. For now I must wait to hear back on my claim based on the estimate. Fingers crossed.

Ford wont take it seriously until someone dies. Untill then, I will NOT be behind any Ford Expeditions on the highway....

 

[markb]

I want to provide an update to this group. As I mentioned in an earlier post, we had a bit of snow and ice during MLK weekend, and my 2022 Expedition had serious damage to the roof and spoiler. My spoiler sounded like it was going to fall off if I traveled at highway speeds. I am glad I avoided driving on the highway, as it sounds like Lanaya had a dangerous situation with his spoiler falling off.

I was able to get my local Ford dealer to handle the repairs. The key was the Special Service Message. Once the dealer discovered they could charge the repair back to the manufacturer, they were very helpful. I ended up going to the dealer to get some pictures taken, and they sent me to their local body shop for an in-person inspection and estimate. A few days later Ford (the manufacturer) confirmed to the Ford dealer they would cover the repair, and everything then went into motion. The body shop decided to change the entire roof and spoiler; the estimated total cost was about $14,000! I'm sure that bill left some profit for the body shop and the Ford dealer!

I dropped the car off at the Ford affiliated local body shop, and the Ford dealer gave us a loaner vehicle (a 2022 Ford Escape - much smaller!). The body shop had the car for 3 weeks, but that included a few extra days because I couldn't immediately pick up the car when it was ready. The car looked great when I picked it up, they even gave me a full exterior detail with a buffing and waxing job.

I took a small step ladder to check the roof spacing when I picked up the car. It appears to have more space at the center line of the roof between the roof and spoiler. However, the spoiler seems a bit closer than I would like on the left (driver side), so I am a bit skeptical if the problem is 100% resolved. The owner of the body shop pointed out that all of the parts are pre-drilled and there is only so much slack to adjust the roof distance during assembly. He said they weren't going to re-drill new holes to create new spacing beyond what the manufacturer allowed. He said if I have issues in the future, Ford and the dealer should take care of it. I hope a new roof and new spoiler will protect me from this issue happening again. I will definitely carefully clean the roof before opening the hatch in the snow and ice in the future. They have made me paranoid about this risk, especially since my 3-year warranty expires January 2026 (mid-winter!).

I wish everyone else who encountered this issue the best of luck getting their trucks repaired. I want to thank everyone on this forum for sharing information, I would not have been able to get my truck fixed (for free) without the information provided on the Expedition Forum. The users here are great!

 

[SyndicateZ]

I want to provide an update to this group. As I mentioned in an earlier post, we had a bit of snow and ice during MLK weekend, and my 2022 Expedition had serious damage to the roof and spoiler. My spoiler sounded like it was going to fall off if I traveled at highway speeds. I am glad I avoided driving on the highway, as it sounds like Lanaya had a dangerous situation with his spoiler falling off.

I was able to get my local Ford dealer to handle the repairs. The key was the Special Service Message. Once the dealer discovered they could charge the repair back to the manufacturer, they were very helpful. I ended up going to the dealer to get some pictures taken, and they sent me to their local body shop for an in-person inspection and estimate. A few days later Ford (the manufacturer) confirmed to the Ford dealer they would cover the repair, and everything then went into motion. The body shop decided to change the entire roof and spoiler; the estimated total cost was about $14,000! I'm sure that bill left some profit for the body shop and the Ford dealer!

I dropped the car off at the Ford affiliated local body shop, and the Ford dealer gave us a loaner vehicle (a 2022 Ford Escape - much smaller!). The body shop had the car for 3 weeks, but that included a few extra days because I couldn't immediately pick up the car when it was ready. The car looked great when I picked it up, they even gave me a full exterior detail with a buffing and waxing job.

I took a small step ladder to check the roof spacing when I picked up the car. It appears to have more space at the center line of the roof between the roof and spoiler. However, the spoiler seems a bit closer than I would like on the left (driver side), so I am a bit skeptical if the problem is 100% resolved. The owner of the body shop pointed out that all of the parts are pre-drilled and there is only so much slack to adjust the roof distance during assembly. He said they weren't going to re-drill new holes to create new spacing beyond what the manufacturer allowed. He said if I have issues in the future, Ford and the dealer should take care of it. I hope a new roof and new spoiler will protect me from this issue happening again. I will definitely carefully clean the roof before opening the hatch in the snow and ice in the future. They have made me paranoid about this risk, especially since my 3-year warranty expires January 2026 (mid-winter!).

I wish everyone else who encountered this issue the best of luck getting their trucks repaired. I want to thank everyone on this forum for sharing information, I would not have been able to get my truck fixed (for free) without the information provided on the Expedition Forum. The users here are great!

Gotta love Happy Endings ay!

 

[DieselMonk]

2022 Expedition Timberline built 01/22
Just lost my spoiler on the highway and almost caused a 1 ton pulling a gooseneck to hit the ditch. Turned back to get my spoiler pieces and looked on the roof…funny it looks to be the exact same dent! Wish me luck when I go to the dealer for warranty! Thank you all for all your hard work, I didn’t even know what to think but recalled seeing this a year back.

Hmm… funny thing I just noticed. Your 22 Timberline has a different roof than my 24 SPP!? No crap. Notice these 5 long ribs if you count from left to right that are going towards the spoiler on your post 221. Well mine roof is like 4 full ribs from left to right, but the last rib is only like a 1/4 or a 1/3rd of the length! Wonder why that is? Does your new roof have 5 full ribs or did they change it? Gonna post a pic of my roof tomorrow.

 

[DieselMonk]

Here is a pic of my roof:

 

[Hellwig]

Here is a pic of my roof:View attachment 84157

It absolutely a defect.

 

[DieselMonk]

It absolutely a defect.

I think @ my dealers lot there is still a 24 Expy Timberline. I guess I have to have a look at that one. Just curious if that’s really a defect or actually has a purpose.

 

[Hellwig]

I think @ my dealers lot there is still a 24 Expy Timberline. I guess I have to have a look at that one. Just curious if that’s really a defect or actually has a purpose.

Well, although it looks ugly, it doesn't affect any functionality. And most people are not even tall enough to see it. No worries please. It doesn't matter.

 

[Benztech]

I'm guessing it isn't a defect. My wife's 23 Max is the same way. I can't see production going on that long and nobody catching it.

 

[DieselMonk]

I am not worried about it. Just wonder why that is or maybe it has a functionality in the winter clearing snow off easier. I don't know.
However... went to the dealership to get a part for my GT500. While I was there, I had a look on the remaining 24 Expy Timberline on the lot. It alsol had that new "roof feature". lol
It also had that same misaligned sunroof. Exact same way as mine was.

 

[Ray D]

Let us know how it goes. Jist bring in a copy of the Ford TSB. The TSB well just help with the fact that Ford knows about this and is a very common issue. With a fix.

(Which should be a RECALL IMO)

Well it's been 5+ months. Short story, Ford also sent me to insurance. At first they were going to fix the spoiler and not fix the roof. Strange but true. I asked the dealership to step up and offer a goodwill gesture, they agreed to pay the insurance deductible plus expenses for fuel and time due to multiple dealership visits and bodyshop to try and get this resolved. Insurance/bodyshop replaced entire Aluminium roof and spoiler... The end. After nearly 30 years of buying Ford, the loyalty has also ended. :-(

 

[SilverStealth]

Well it's been 5+ months. Short story, Ford also sent me to insurance. At first they were going to fix the spoiler and not fix the roof. Strange but true. I asked the dealership to step up and offer a goodwill gesture, they agreed to pay the insurance deductible plus expenses for fuel and time due to multiple dealership visits and bodyshop to try and get this resolved. Insurance/bodyshop replaced entire Aluminium roof and spoiler... The end. After nearly 30 years of buying Ford, the loyalty has also ended. :-(

Sorry to hear Ford is being Ford, but glad to hear the dealership took care of you.

 

[lgloeb]

We have a ford expedition limited 2021. We went to dinner after our kids winter concert. There was no snow or ice in the car, but it was very very cold that day. My husband went to open the lift gate to put our leftovers in the back. We heard this awful tearing/crunching metal sound and discovered that the tailgate had somehow "freddy kruegered" (as I have been calling this ridiculous damage) the roof of our car and damaged the spoiler. I took it to the dealership and got a quote for a little over $7000. The dealership said there was an SSM but for 2022-2023 models but not my 2021. So I had them make a claim with ford and of course they denied it. I've been doing research before going through insurance, because I don't want my rates increased over something that wasn't due to negligence or stupidity or whatever. It is a manufacturing defect that the dealership told me was all completely due to a gasket. They had never seen or heard of this before but when looking into it they discovered the gasket is primarily the cause of this damage. I am currently making my own case and going to send it to FORD to try to get them to cover their mistake in manufacturing. I also discovered this information about the difference between the 2021 model and 2022-2023.
---
The 2022 Ford Expedition is a mid-cycle refresh with key updates over the 2021 model, primarily focused on a modernized interior featuring larger, available screens (standard 12-inch, optional 15.5-inch), enhanced tech like wireless Apple CarPlay/Android Auto, new standard driver-assist features (Co-Pilot Assist 2.0), and a new off-road-focused Timberline trim, while the core engine and capability remain similar but with a slight power bump.
Key Differences:

• Infotainment & Tech:
  • 2021: SYNC 3, standard 8-inch touchscreen, wired smartphone integration.
  • 2022: Standard 12-inch screen, available 15.5-inch touchscreen, standard 12.4-inch digital instrument cluster on some trims, wireless Apple CarPlay/Android Auto, available Amazon Fire TV built into rear entertainment.
• Exterior: Minor styling tweaks, including restyled grilles and new LED headlights.
• Safety & Driver-Assist:
  • 2021: Standard Ford Co-Pilot360 features.
  • 2022: Adds more advanced standard features like Road Edge Detection, Intersection Assist, Reverse Brake Assist, and Evasive Steering Assist (Co-Pilot Assist 2.0).
• New Trim: Introduction of the off-road-capable Timberline model.
• Engine: Minor power increase; base engine jumps from 375 hp (2021) to 380 hp (2022).
• Audio: Available 22-speaker Bang & Olufsen system (vs. 12-speaker in 2021).

Similarities:

• Core twin-turbo 3.5L V6 engine and transmission.
• Strong towing capability (up to 9,300 lbs).
• Overall large size and cargo capacity.

In Summary: The 2022 model offers significant tech and interior upgrades, making it feel more modern and connected, while the 2021 provides similar core performance at a potentially lower price point if the latest tech isn't a priority
---
So essentially it was simply a refresh of interior and tech. Also the introduction of the timberline body style which mine is not. The vehicle body is exactly the same with small difference like a newer looking grill.

This is completely a manufacturing defect and my dealership agrees. However when they submitted a claim to ford they denied it. Ridiculous. But I appreciate the dealership doing it.

Does anyone have a 2021 that this happened to? Does anyone know more specific key difference between the 2021 and 2022 body, because I feel like I might have a chance with them. I did look up the part numbers of what the dealership said would need to be replaced and on the OEM website the parts listed ALL said these parts were for 2018-2024 ford expedition models.

Worst case scenario I have to go through insurance but I truly feel like this is a ford problem and I don't know that I would buy one again, even though I love my expedition. A liftgate should not do something like this. I just want ford to make it right. Hopefully.

Thanks.