Buy Ford Expedition Bumper Covers

Summary
The Ford Expedition's bumper cover-also called the bumper fascia, shell, or skin-is a light polypropylene cap that clips over the steel reinforcement bar, hides sensors, and shapes airflow. Its design varies by model year groups, and modern versions tuck in adaptive-cruise radar and parking sensors that raise both convenience and repair bills. Replacing a damaged cover can cost a few hundred dollars for the part but well over a thousand once painting, sensors, and calibration are added. Polypropylene's toughness lets many covers survive low-speed taps, and scrapped covers can now be recycled into new auto plastics. Certified replacement parts that meet CAPA 501 testing provide fit and safety assurance.

Overview

Overview

The Expedition has had five main body styles (1997-2002, 2003-2006, 2007-2014, 2015-2017, and 2018-2024), and each uses its own front and rear bumper skin with different clip patterns and sensor holes. (Wikipedia, Ford Expedition Forum)
All trims share a plastic cover over a hidden steel beam; the cover adds looks and guides air but is not a crash bar. (NHTSA)

Materials

Materials

Expedition covers are injection-molded from polypropylene (PP) or PP-blend thermoplastic, prized for impact toughness and low weight. (ScienceDirect, Plastics Industry Association)
PP bends instead of shattering, making scuffs and small dents fixable with heat or filler. (ScienceDirect)

Fitment & Generations

Fitment & Generations

Because grille, headlamp, and sensor shapes changed, a 2014 bumper cover will not bolt onto a 2018 truck without custom brackets. (Ford Expedition Forum)
Upper trims may need extra holes for front park-assist or auto-park sensors shown in 2018-2024 parts diagrams. (Tasca Parts)

Sensors & Tech

Sensors & Tech

Current Expeditions hide four to six ultrasonic parking sensors and a forward-looking radar puck behind the plastic near the passenger-side lower grille. (Ford Expedition Forum, MOTOR)
Ford's ADAS job-aid lists the cruise-control module "in the front of the vehicle typically behind the front bumper cover," confirming why recalibration follows any cover swap. (fordcrashparts.com)

Removal Basics

Removal Basics

DIY removal starts by unclipping fender liners, unscrewing under-tray bolts, and releasing the top radiator-support tabs; a video walk-through on a 2022 model shows the full process takes under 30 minutes with trim tools. (YouTube)

Paint & Finish

Paint & Finish

Many Expeditions use "paint-to-match" primed covers, but some lower rear caps are molded-in-color silver or black. Owners report Ford does not sell touch-up for molded pieces; body shops mix custom paint instead. (Ford Expedition Forum)
Always verify your exterior code on the door jamb before ordering a painted fascia.

Cost Factors

Cost Factors

Blog data show bumper repairs range $100-$600; full replacement with paint and sensor calibration can top $1,000 on SUVs. (carwise)
AAA notes that forward-radar or camera components can add $900-$1,300 to a minor front-end repair bill. (WIRED)

Quality Standards

Quality Standards

CAPA 501 sets test rules for aftermarket bumper parts, checking material strength, corrosion, fit, and a live vehicle test-fit before granting its yellow seal. (capacertified.org, capacertified.org)
Choosing a CAPA-certified Expedition cover helps ensure clip positions and sensor bezels line up correctly. (capacertified.org)

Maintenance Tips

Maintenance Tips

* Keep sensor bezels clean; road grime can block park-aid signals. (Ford Expedition Forum)
* Rinse salt off the fascia in winter to slow plastic fade. (carwise)
* Inspect clips after any parking-lot bump; loose edges let water reach steel brackets. (YouTube)

Environment

Environment

A 2021 pilot program shows scrapped PP/TPO bumper skins can be shredded and re-compounded, retaining up to 90 % of original flexibility-diverting roughly 500 tons of plastic from landfills each year. (Recycling Today)

Frequently Asked Questions

Q: What is the bumper cover made of?
A: It is molded from polypropylene plastic, which is light and resists cracking. (ScienceDirect)

Q: Does the cover protect me in a crash?
A: The plastic shell is cosmetic; the steel or aluminum beam underneath absorbs impact. (NHTSA)

Q: Are 2007-2014 and 2015-2017 covers interchangeable?
A: No. A mid-cycle facelift changed the grille and sensor layout, so mounting tabs differ. (Ford Expedition Forum)

Q: How do I know if I need sensor holes?
A: Count the round parking sensors in your current bumper and check if you have adaptive cruise; those features need pre-formed holes in the new fascia. (Ford Expedition Forum)

Q: Do I have to repaint a primed cover?
A: Yes-primed parts ship in grey. A body shop must spray your paint code for a color match. (Ford Expedition Forum)

Q: What does CAPA certification mean?
A: It confirms an aftermarket part met CAPA 501 tests for material, fit, and durability. (capacertified.org)

Q: How much will replacement cost?
A: Parts typically run $250-$800; paint, labor, and sensor calibration bring totals to $1,000+ on recent Expeditions. (carwise, WIRED)

Q: Can I recycle my broken bumper skin?
A: Yes-programs collect PP skins from body shops for re-processing into fresh auto plastics. (Recycling Today)

Q: Are aftermarket covers legal?
A: As long as they fit properly and do not interfere with safety equipment, they are legal; SUVs like the Expedition are exempt from federal bumper-height rules that apply only to passenger cars. (NHTSA)