Ford is recalling nearly 550,000 Expedition SUVs after discovering that peeling chrome trim inside the cabin can create sharp edges capable of cutting occupants.
According to documents filed with the National Highway Traffic Safety Administration (NHTSA), the recall affects 548,463 Ford Expedition models from the 2018 through 2024 model years. The issue centers around chrome-plated trim pieces located on the center console, where the chrome surface may bubble, crack, or peel away from the underlying material over time.
While the defect sounds cosmetic at first glance, federal safety regulators determined the peeling trim can expose sharp edges that pose an injury risk to drivers and passengers.
Ford says customers may accidentally come into contact with the peeling chrome while driving, potentially leading to cuts or lacerations.
The Problem Has Already Caused Dozens Of Injuries
According to the recall documents, Ford’s investigation began after customer complaints and NHTSA Vehicle Owner Questionnaires revealed multiple injuries linked to the defective trim.
The automaker has so far connected the issue to 65 injuries globally, including several cases involving cuts serious enough to require professional medical treatment. The defect has also reportedly been associated with one accident.
Ford first identified the growing number of complaints in September of last year. An internal investigation initially focused on 2019-2021 Expeditions, with the company’s Critical Concern Review Group originally deciding that a formal recall was unnecessary because the defect was considered visible and easy for owners to notice.
However, additional testing later revealed that even trim pieces without visible bubbling or peeling could eventually develop dangerous sharp edges. After reevaluating the severity of potential injuries, Ford’s Field Review Committee approved a recall earlier this month.
The automaker estimates that roughly 12.8 percent of recalled vehicles may actually contain the defect.
Owners Will Wait Until 2027 For A Permanent Fix
One of the most unusual aspects of the recall is how long owners may need to wait for repairs. Ford says suppliers are still developing improved replacement trim components that meet updated durability specifications.
As a result, the company will initially send interim notification letters to affected owners between June 29 and July 2 of this year, informing them of the issue. The actual repair campaign, however, is not expected to begin until early 2027.
Once redesigned replacement parts become available, dealers will inspect affected vehicles and replace peeling or bubbling center console trim free of charge.
The replacement components are expected to feature improved chrome plating designed to better withstand wear and prevent future peeling.
A Cosmetic Defect Turned Into A Genuine Safety Issue
Vehicle recalls are typically associated with major mechanical or electronic failures involving brakes, steering systems, airbags, or engines. This recall stands out because it involves interior trim rather than core vehicle systems.
Still, the growing number of injuries demonstrates how even seemingly small defects can become legitimate safety concerns.
Chrome-plated interior trim has become increasingly common across the industry as automakers pursue more upscale cabin designs without using solid metal materials.
In some cases, however, the thin decorative plating can separate from plastic substrates over time due to heat, humidity, or manufacturing inconsistencies. In Ford’s case, the peeling edges became sharp enough to cut skin during normal use.
The Expedition remains one of Ford’s most important full-size SUVs, particularly in North America where large family SUVs continue selling strongly. While the recall does not affect drivability or vehicle performance, the unusually long timeline for a permanent fix may frustrate some owners.
For now, affected customers are being advised to monitor the center console trim for signs of bubbling or peeling and avoid direct contact with damaged surfaces until replacement parts become available.