Started the car to get heater going and warmed up and started buckling my kids up in their car seats. That's when I started to smell an electrical burning smell coming through the vents. I turned the heater off and the smell got stronger. I turned the heater back on and smelled it even worse. I immediately switched it to ac instead of heat and then I started to notice smoke coming through the air vents. I immediately turned the car off. The smoke continued to bello out of the air vents. As soon and the interior lights turned off I noticed a glow under the passenger dash down by the corner of the floorboard. When I went around to look to see what was glowing I noticed there was a fire down in that corner and it was already big enough that I couldn't blow it out no matter how hard I blew. I am thankful that I keep a fire extinguisher in my garage and was able to quickly put it out. I normally strap my kids in and turn on a movie for them while I go back in the house and spend around 3 to 5 minutes getting the kids waters, making sure the diaper bag is stocked, and basic stuff like that. Had that fire started after I walked back in the house I am sure that I would have lost my kids in a blaze, strapped in to car seats, that day. It was thanksgiving eve. I found out that the blower fan for the vents is what sparked up and caught fire. There are no recalls by Ford for this and I have found out that I am not the only one this has happened to. This is an enormous safety hazard and I am shocked that it has gone ignored by Ford. Does an actual death need to take place before they set it right? because I did just buy it; the dealership replaced the fan. But the floorboard in that corner is all burnt up and am now questioning what more serious damage is in that dash that I can't see. Like the airbag or other electronic wiring that may now be at risk.

- Nampa, ID, USA

We detected a burnt rubber smell while driving on a surface street (with A/C on). The A/C suddenly quit. We pulled over to turn SUV off and back on again hoping A/C would return. A/C did not return, smoke began billowing out of A/C vents. Stopped at a gas station and turned off SUV. The smoke from the vents got thicker and large flames began coming out underneath the dash. Husband ran in to gas station and got a fire extinguisher and put out the fire. Fire kept restarting (the parking lights were on though the car was off). Husband finally had to disconnect the battery to keep fire from restarting. The A/C/heater blower then fell out onto the front passenger floor-mat burned to a crisp.

- Milledgeville, GA, USA

The vehicle blower speed controller doesn't match setting on the clement control. The blower will blow at full speed or not at all. This happens not matter the disposition to the vehicle. I took this in while under warranty, nothing was found. Second time out of warranty, stated it was a software update that was needed. Third time they found the issue with the speed control and the wire harness had melted (potential fire issues). Now that the issue was found, palm coast Ford refuses to fix it under warranty. On searching most common issues with the Ford Expedition I have found that the blower speed control is an issue for many people. From personal finding, it is a fire hazard, which makes it a safety hazard. I had mentioned it to the dealership since I bought the vehicle. When it got more common of an issue and more annoying, I took it in while still under warranty to have it documented.

- Palm Coast, FL, USA