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When did Ford Expedition go to aluminum body?

The Ford Expedition, a full-size SUV, made the switch to an aluminum body in 2015. This change was part of Ford's broader effort to reduce the weight of its vehicles and improve fuel efficiency across its lineup.


The Transition to Aluminum


The 2015 Ford Expedition was the first model year to feature an aluminum body, a significant departure from the previous steel construction. This shift to an aluminum body helped the Expedition shed around 300 pounds compared to the previous steel-bodied model. The use of aluminum, a lighter and more corrosion-resistant material, was a strategic move by Ford to improve the Expedition's fuel economy and performance.


The decision to use aluminum was part of Ford's broader "lightweighting" initiative, which aimed to reduce the overall weight of its vehicles. This approach was driven by increasingly stringent fuel efficiency standards and consumer demand for more fuel-efficient SUVs and trucks.


Benefits of the Aluminum Body


The switch to an aluminum body provided several key benefits for the Ford Expedition:



  • Improved Fuel Efficiency: The weight reduction from the aluminum body helped the Expedition achieve better fuel economy, with the 2015 model boasting an EPA-estimated 16 mpg city and 22 mpg highway.

  • Enhanced Performance: The lighter weight of the aluminum body improved the Expedition's acceleration, handling, and overall driving dynamics.

  • Increased Durability: Aluminum is more resistant to corrosion and dents than steel, making the Expedition's body more durable and long-lasting.


These advantages have helped the Ford Expedition remain a popular choice in the full-size SUV segment, offering a compelling combination of capability, efficiency, and longevity.


Conclusion


The Ford Expedition's transition to an aluminum body in 2015 was a significant milestone for the full-size SUV. By leveraging the benefits of this lighter and more durable material, Ford was able to improve the Expedition's fuel efficiency, performance, and overall appeal to consumers. This strategic move has helped the Expedition maintain its position as a leading player in the highly competitive full-size SUV market.

What years of Expedition to avoid?


Years of Ford Expedition to avoid include 2003-2006 for numerous complaints and repair costs, and 2011 and 2017 due to issues like cruise control malfunctions, paint deterioration, and power loss. While the 2018-2020 models have a high price and poor fuel economy, the 2018 in particular also had significant transmission problems. 
Second Generation (2003-2006)

  • Overall: This generation is generally not recommended due to a high number of complaints and expensive repairs, notes Jarrett Automotive Group. 
  • 2005 and 2006: Interior accessory issues were common. 

Third Generation (2007-2017) 
  • 2011: Was known for long-term reliability issues, despite being spacious and comfortable.
  • 2017: Had notable problems, including sudden power loss, transmission glitches, and infotainment system glitches. 

Fourth Generation (2018-2024) 
  • 2018: Owners have reported transmission failures at relatively low mileage. 
  • 2018-2020: These models have high prices and poor fuel economy, especially when towing. 
  • 2024: Has been subject to several recalls, according to Consumer Reports. 



When did Ford Expedition get an aluminum body?


2018
The aluminum body on the 2018 Expedition follows in the footsteps of Ford's 2015 F-150 pickup platform, which saved up to 700 lbs over the previous steel body. The F-150 platform was retooled in 2016 for the Super Duty truck (saving up to 350 pounds from previous Super Duty models).



When did Expedition change their body style?


Ford redesigned the Expedition for 2007. Aside from a new chassis and body, there is also a brand new model, the Expedition EL, which has a wheelbase 12 inches longer than the standard Expedition.



Which 2018 Ford Expedition has an aluminum body and steel frame?


All-new Ford Expedition is the smartest, most capable, most adaptable Expedition ever. It features a lightweight, high-strength all-aluminum-alloy body that rides atop a high-strength steel frame.


Kevin's Auto

Kevin Bennett

Company Owner

Kevin Bennet is the founder and owner of Kevin's Autos, a leading automotive service provider in Australia. With a deep commitment to customer satisfaction and years of industry expertise, Kevin uses his blog to answer the most common questions posed by his customers. From maintenance tips to troubleshooting advice, Kevin's articles are designed to empower drivers with the knowledge they need to keep their vehicles running smoothly and safely.