Ford Recalls 41,000 Super Duty Trucks and Expeditions for Potential Headlight Failure

Ford Motor Company has issued a recall for 41,748 of its largest vehicles due to a manufacturing defect that could cause headlights to fail unexpectedly. The recall affects several high-profile models, including the 2025–2027 Ford Expedition and 2026 models of the F-Series Super Duty line (F-250, F-350, F-450, and F-550).

The safety risk involves contaminated LED chips within the headlight assemblies. According to documentation filed with federal regulators, this contamination occurred at a supplier facility and can lead to the total failure of various lighting functions, including daytime running lights, parking lights, and both high and low beams. While a total failure is possible, Ford estimates that only approximately 1% of the recalled vehicle population actually contains the defective chips.

The recall stems from LED chip contamination at a supplier facility.

Affected Models and Production Dates

The recall targets specific manufacturing windows for vehicles produced over the last year. Owners of the following models should check their production dates to determine if their vehicle is included:

Ford F-Series Super Duty (F-250 to F-550): Vehicles manufactured between August 4, 2025, and August 4, 2026. Ford Expedition: SUVs manufactured between June 24, 2025, and July 2, 2026.

Owners can identify this specific action through NHTSA campaign number 26V606 or Ford’s internal recall reference, 26C43. Ford has reported six warranty claims related to the headlight issue but is not aware of any accidents or injuries resulting from the defect.

Official notification letters are scheduled to be mailed to owners starting October 26, 2026. On that same date, vehicle identification numbers (VINs) for the affected units are expected to become searchable in the National Highway Traffic Safety Administration database. Dealers will inspect the headlight assemblies and replace them as necessary at no cost to the owner.

Ford continues to monitor supplier-side defects as part of its 2026 quality initiatives.

Context of Ford’s 2026 Quality Initiatives

This latest action adds to a significant year for Ford regarding vehicle reliability and safety compliance. The headlight recall follows a massive software-related recall in February 2026 that affected 4 million vehicles, as well as an April 2026 recall involving 1.4 million F-150 trucks.

According to Car and Driver, the company has been focusing on streamlining its recall process and identifying supplier-side defects earlier in the production cycle. Despite the high volume of recalled units this year, the narrow 1% estimated defect rate for the headlight assemblies suggests a targeted approach to this specific hardware failure.

Owners who notice flickering or non-functional lights before the official notification date are encouraged to contact their local dealership. Because the defect can disable all forward-facing illumination, a failure while driving at night presents an immediate safety hazard.

The post Ford Recalls 41,000 Super Duty Trucks and Expeditions for Potential Headlight Failure appeared first on World Weekly News.