Navigating the Complex Landscape of American-Made Vehicles: The Case of the 2025 Ford Expedition

The 2025 Ford Expedition has made headlines recently, not just for its robust features but also for what its assembly reveals about the intricacies of American manufacturing. As the shiny SUV rolled off the assembly line at Ford’s Kentucky Truck Plant, it symbolized both the pride of American craftsmanship and a sobering reality: a significant majority of its components are sourced from outside the U.S.

A Closer Look at the Ford Expedition’s Origins

As it stands, the 2025 Ford Expedition comes with a window sticker proclaiming that approximately 58% of its main parts are made outside the United States, with a significant 22% sourced from Mexico. This includes its powerful 3.5-liter twin-turbocharged V-6 Ecoboost engine — a core component that underscores the complexity of the global automotive supply chain. Even vehicles assembled by quintessentially American brands like Ford often depend on a web of international suppliers, challenging the notion of what it truly means to be “Made in the USA.”

Ford’s Kentucky Truck Plant employs over 9,000 workers who build not only the Expedition but also F-Series pickup trucks and Lincoln Navigators. It’s precisely this kind of facility that former President Donald Trump urged automakers to favor through aggressive tariffs on imports. The tariffs, which increased costs for vehicle imports, pushed automakers to localize their supply chains and emphasize U.S. investments.

However, the reality remains stark: the logistics and economics involved in fully Americanizing supply chains are daunting. As Martin French, a partner at Berylls Strategy Advisors, noted, certain parts are simply cheaper to manufacture abroad. He stated, “Some parts that have been offshored will still be cheaper to manufacture in those locations rather than the USA at scale even with some of the imposed tariffs.”

The Challenges of Achieving a 100% U.S.-Made Vehicle

Efforts to create 100% U.S.-made vehicles face numerous obstacles. There simply aren’t enough processing plants for essential materials like steel, aluminum, and semiconductors in the U.S. Currently, the automotive industry imports many of these materials, which would require substantial investments and time to establish domestic sources.

Ford CEO Jim Farley highlighted this delicate balance during a recent interview, saying, “We can move everything to the U.S., but if every Ford is $50,000, we’re not going to win as a company.” The cost of an entirely American-made vehicle could potentially alienate consumers, leading to decreased demand and ultimately, less production.

As per estimates, transitioning to a higher percentage of U.S. components could increase manufacturing costs significantly — possibly by thousands of dollars per vehicle. With the average vehicle price in the U.S. nearing $48,000, such increases could push the costs beyond what many consumers are willing to pay.

What About the Future of U.S. Auto Manufacturing?

Experts suggest that while achieving near-total reliance on U.S.-made parts is uncertain, a goal of 75% U.S. and Canadian parts content is considerably more realistic. Strategies could include sizable investments in localizing production, which would require time and financial resources. Cars like the Kia EV6, Tesla Model 3, and Honda Ridgeline already meet this threshold, demonstrating that some manufacturers are gearing towards a more domestically-focused future.

Mark Wakefield, a partner at AlixPartners, emphasized this potential, stating, “Getting toward 75% doesn’t really force you to do uneconomic things.” The shift towards increasing U.S. parts content could ultimately reflect a broader trend driven by changing consumer preferences and national policies aimed at boosting domestic manufacturing.

The Bottom Line

As the 2025 Ford Expedition rolls out, it serves as a microcosm for the challenges facing the American automotive industry. While the desire for fully American-made vehicles is both admirable and patriotic, the looming question remains: Is it feasible? With a complex global supply chain and ever-evolving consumer expectations, a more pragmatic approach may be necessary—aiming for substantial domestic content without sacrificing affordability.

Navigating these complexities will require collaborative efforts from automakers, suppliers, and policymakers. Whether we see significant changes in the automotive landscape in the coming years remains to be seen, but for now, understanding the dynamics at play could help shape more informed consumer choices.

For more insights into the automotive industry’s evolving landscape, check out our deep dives into the American-Made Index and the trends in electric vehicles. Want to explore how tariffs affect other industries? Learn more about trade policies and their implications.