2003 Ford Expedition problems, complaints & recalls
Most-reported problem areas: Engine And Engine Cooling (62) · Engine And Engine Cooling:engine (40) · Electrical System (38)
🧭 Reliability snapshot
Compared against other Ford Expedition model years — complaint volume vs the model's median year, recalls and severity. How we score →
🛣️ Complaints by mileage
463 NHTSA complaints that reported an odometer reading.
Safety recalls (0)
No recalls on record for this model year (campaigns announced since 2010).
Service bulletins (152)
Technical service bulletins are repair instructions manufacturers send dealers for known issues. Unlike recalls, the fix is not automatically free — but naming the bulletin at the service desk can save diagnosis time and support goodwill repairs.
Wheels 2024-07-24 · TSB 24-2188 · Service Bulletin/Repair Instructions
this article supersedes tsb 22-2219 to update the parts list and service procedure to clarify applicable steps by vehicle application. some 2003-2020 expedition/navigator and 2006-2020 f-150 (non-raptor) vehicles equipped with 4wd may exhibit grinding/clicking/ratcheting noise from the front wheel a
Structure 2023-04-04 · SSM 51536 · Service Bulletin/Repair Instructions
for 2000-2024 ford and lincoln vehicles, swapping a module from a vehicle for diagnosis purposes is likely to cause errors and is not recommended. it is also not recommended to order a replacement module using a vehicle identification number (vin) from a different vehicle. most modules on these affe
Power Train 2022-06-21 · TSB 22-2219 · Service Bulletin/Repair Instructions
some 2003-2020 expedition/navigator and 2006-2020 f-150 (non-raptor) vehicles equipped with 4wd may exhibit grinding/clicking/ratcheting noise from the front wheel area. this may be due to partial engagement of the integrated wheel ends (iwe). to correct this condition, follow the service procedure
Wheels 2020-10-16 · TSB 20-2307 · Service Bulletin/Repair Instructions
some 2003-2020 expedition/navigator and 2006-2020 f-150 vehicles equipped with tod transfer cases may exhibit grinding/clicking/ratcheting noise from the front wheel area. this may be due to partial engagement of the integrated wheel ends (iwe). to correct this condition, follow the service procedur
Structure 2020-07-13 · TSB 20-2233 · Service Bulletin/Repair Instructions
this article supersedes tsb 19-2026 to update the vehicle model years affected. some 2000 and newer ford/lincoln/mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. panel replacement is
Structure 2019-02-07 · TSB 19-2026 · Service Bulletin/Repair Instructions
some 2000 and newer ford, lincoln and mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. panel replacement is recommended. follow the service procedure steps to correct the condition
Showing the 6 most recent of 152 bulletins. Search all of them free at nhtsa.gov.
What owners report
2026-03-09 · Electrical System“my truck stopped working in november 2025. i was told i needed fuel pump and filter. i replaced those and still didn't crank. i was then told i needed a circuit box. purchased a circuit box and had it put on. got my truck back february 2026. march 08,2026, truck went out again. i kept my truck maintenance and don't understand what's going on wit…”
2025-02-11 · Engine · 230,000 mi“the contact owns a 2003 ford expedition. the contact stated that while operating the vehicle, the check engine warning light illuminated and the front end of the vehicle was shaking abnormally, vibrating, and the vehicle stalled. the contact stated that while driving approximately 50 mph, there was a loud booming sound coming from the engine compar…”
2024-05-05 · Fuel/Propulsion System“fuel leaking from emissions vents on fuel tank. non reparable part.…”
2024-01-19 · Fuel/Propulsion System“my ford expedition started randomly stalling and it stalled in the highway. the engine just shut down in the middle of the highway and it was such a scary a life endangering experience. this total loss of power in the middle of the highway when vehicles are traveling at highway speeds can cause death very, very easily to the occupants of the ford e…”
2023-12-08 · Steering · 💥 crash“the brakes are burning while driving & the emergency brakes are not applied. the power windows are failing 1 by 1.…”
2022-10-26 · Engine · 196,000 mi“the contact owns a 2003 ford expedition. the contact stated while driving 45 mph, the engine was misfiring, and the contact smelled a burning odor inside the vehicle. the check engine warning light was illuminated. the contact was able to drive to his residence. the contact stated that the failure had been reoccurring while driving. the vehicle was…”
2022-06-28 · Structure:body“bought truck 3/2/22 from gold cauto in troy ny. 3/7/22 went to take kids to school 2.5 inches of water set in my weather guard mats. seats soaked console everything in front cab reversed to pull out spot and water starting pouring on my and my kids from sides in pass sides front and the front windshield area omgand the sun roof was worst.kids had…”
2022-02-08 · Engine“this vehicle has a faulty engine. the aluminum that ford used to create the top end is too thin to support the pressure of the engine. as a result spark plugs explode from the engine at random with no warning. this has happened 5 times even after replacing all spark plugs, numerous coils and having kits installed by a mechanic sold by ford to addre…”
2022-01-15 · Fuel/Propulsion System“this is the 2nd time it happened to my 2003 ford expedition. while driving heard a loud popping noise, followed by continuous popping loud popping noise like a broken exhaust muffler, sounded like a motorcycle. after investigating, found out that the #3 spark plug popped out (ejected) of the head cylinder, broke the spark ignition coil. when this h…”
2021-06-08 · Electrical System“faulty fuse panel. this is a known issue. it is all over the internet. there has never been a recall. the vehicle will stall while driving. on attempting restart or crank, there is a buzzing noise from the fuse panel. the pcm #203 i believe, corrodes or melts through the board on the panel causing the fault. replacing the fuse/relay will correct,…”
Excerpts of consumer complaints filed with NHTSA, lightly truncated. They are owner statements, not verified findings.