Ford recalls 41,748 vehicles after contaminated LED chips threaten required headlight performance on newer models.
Ford is recalling 41,748 vehicles after discovering a headlight problem that could leave them out of compliance with federal safety standards, according to documents filed with the National Highway Traffic Safety Administration.
The recall covers 2025–2027 Ford Expedition SUVs and 2026 Super Duty trucks, including the F-250, F-350, F-450, and F-550.
The problem involves contaminants found beneath an LED chip inside the headlight assembly. According to NHTSA documents, the contamination originated during manufacturing at the chip supplier.
Ford estimates that about 1 percent of the recalled vehicles are expected to contain the affected chips.
On vehicles with the contaminated components, the daytime running lights, parking lights, low-beams, or high-beams could become dim or stop working. A warning indicator on the dashboard will alert drivers to reduced low- and/or high-beam performance.
Owners affected by the recall will receive notices by mail and be instructed to take their vehicle to a Ford or Lincoln dealer. A technician will inspect both headlights.
If the headlights pass inspection, no further work will be required. If either headlight fails, the defective unit will be replaced at no cost to the owner.
Ford will begin mailing recall notices to dealers on October 26, 2026. Owner letters are scheduled to go out November 6.
Starting October 26, customers who want to check whether their vehicle is included will be able to search for the recall on the NHTSA website.