Nearly 42,000 Ford Expeditions And Super Duty Trucks Recalled Over Defective LED Headlights

Ford’s campaign covers select Expedition and Super Duty model years, with dealer inspections determining which headlight assemblies actually need replacement.

2025 Ford Expedition Platinum

Photo by: Ford

Brian Potter

By: Brian Potter

Oct 8, at 5:01am ET

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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.

Which Expedition And Super Duty Trucks Are Covered?

2026 Ford Super Duty F-350 Platinum Plus

2026 Ford Super Duty F-350 Platinum Plus

Photo by: Ford

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.

Which Headlight Functions Could Go Dark?

2025 Ford Expedition Platinum

2025 Ford Expedition Platinum

Photo by: Ford

The defect can dim or disable daytime running lights, parking lights, low beams, or high beams. Reduced visibility at night or in poor weather is the core safety concern behind the campaign.

Ford built in a warning system with a dashboard indicator light that illuminates when the truck detects reduced low beam or high beam performance. That gives owners a heads up before a headlight fails completely, rather than leaving them to notice only after dark.

Ford has logged six warranty claims and six field reports tied to the issue so far. No crashes or injuries have been linked to it. The automaker's own estimate, a 1 percent defect rate across nearly 42,000 vehicles, suggests the inspection is mostly precautionary and focuses dealer time on a few hundred likely bad units.

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The remedy is straightforward once a truck reaches the shop. A dealer inspects the headlight assembly, and any unit that fails gets replaced at no cost.

Owners who want to check status before letters arrive can search their VIN on NHTSA's recall lookup once the campaign posts under number 26V606.