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really awful
Crashes / Fires:
1 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
22,365 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2003 Ford Expedition brakes problems

brakes problem

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2003 Ford Expedition Owner Comments

problem #17

Feb 042011

Expedition 8-cyl

  • Automatic transmission
  • 18,535 miles


The contact owns a 2003 Ford Expedition. While driving approximately 45 mph, the brake pedal dropped to the floor and the contact experienced a loss of braking capability. The contact stated he crashed into a tree stump and snow on the ground and the vehicle came to a stop. The vehicle was towed to an independent mechanic. The approximate failure mileage was 18,535. Updated 3/14/11 it was determined the master cylinder was leaking fluid and ultimately failed. Updated 05/04/11

- Cresco, PA, USA

problem #16

Mar 012010

Expedition 4WD 6-cyl

  • 45,000 miles
Brake lines rusted and leaked causing sudden loss of most braking. I bought this Ford new in July of 2003. After the brake failure, the vehicle was towed. I had all brake lines replaced, and still have the piece which leaked. The shop said it is because the brake lines are routed on top of the frame rails, and salt builds up. But I've lived in this area all my life (I'm 66) and had many older or higher mileage vehicles, but never had this happen before. I understand that you are investigating Chevy brake line failure, and think you should include Ford.

- Manlius, NY, USA

problem #15

Jan 012009


  • 200,000 miles
Brakes need to be replaced constantly. Pads wear very fast. Rotors wear easily and need replacement with pads each time. When brought to have rotors turn, was told they are manufactured with very little tolerance and could not be turned even though there was minimal visible wear. Was told they did not "mic" with enough range to tolerate the cut when turning. Rotors should not need replacement with each brake change. Excessive brake dust. Brake dust has eaten away at finish on rims. After last brake repair, front end now has a clicking sound. Brake pedal has always felt spongy. On two occasions with aggressive braking conditions, brakes locked up. Told dealership who said this is normal with the Ford braking systems. Additionally, we have had an ongoing problem with the passenger side fog lamp not staying lit and the metal reflector piece in the fog lamps coming loose. We are now having problems with two (front drivers/rear passengers) door electric locks not unlocking or locking the doors.

- Oxford, MA, USA

problem #14

Oct 032005


  • miles


Consumer is having problems with air condition making noise, power windows only lower, radio volume gets louder when accelerating seat control buttons are inoperable. Water leaked from the sunroof, even though it was closed. The vehicle was taken to the dealer on 3 separate occasions due to brake and rotor noise. The consumer experienced lack of power when attempting to accelerate. The consumer was unable to hear the radio separately when the dvd was playing.

- Baltimore, MD, USA

problem #13

Jun 012005

Expedition 8-cyl

  • miles
2003 Ford Expedition developed problems with the brake equipment.** answer required***. the front brake rotors were completely worn down.

- Trinity, FL, USA

problem #12

Aug 162004

Expedition 4WD

  • Automatic transmission
  • 23,176 miles
Ford Expedition 2003 front brakes and brake system failed. The consumer stated there was visible dusting, difficulty stopping and brake chatter. The consumer was told the problem was due to incredibly high and overheating from the original brake pads, the problem was so bad that the rotors welded to the rims.

- Flanders, NJ, USA

problem #11

Apr 232004

(reported on)


  • miles


Rear brakes needed replacement. (nar)

- Lompoc, CA, USA

problem #10

Jul 012004


  • 12,000 miles
Consumer complained about front brake rotors. The front brake rotors were checked on three separate occasions but problem recurred. The dealer told the consumer the problem was due to dust. The vehicle was taken to two outside sources who concluded that the brakes were bad and that the rotors needed to be replaced. The consumer has also replaced the steering rack, seat motor and automatic door lock.

- Yacolt, WA, USA

problem #9

Nov 182003


  • 10,000 miles
Consumer was at a stop in traffic while gradually the vehicle moved up. Upon depressing the brakes the pedal went to the floor and would not stop the vehicle. This problem occurred more than ten times in the last six months. Also, while driving at any speed the engine check light and battery light came on. Sometimes, the lights blinked rapidly, and sometimes they would just stay on. Dealer examined the vehicle seven times, and was unable to resolve the problem.

- Jonesboro, LA, USA

problem #8

Mar 232004

Expedition 4WD

  • Automatic transmission
  • 21,000 miles
Front brakes had to be replaced at 20,000; worn down to zero mm. Checked three months earlier and they were at 4mm and told they "might" need to be replaced at the next service. Rotors had to be sanded. Excessive black brake dust on front wheels, dust also evident on back wheels.

- Las Vegas, NV, USA

problem #7

Feb 132004

Expedition 8-cyl

  • Automatic transmission
  • miles


Brakes, steering failed.

- Hacienda Heights, CA, USA

problem #6

Jun 302003

Expedition 4WD 8-cyl

  • Automatic transmission
  • 1 miles
Excessive brake dust.

- Salisbury, MD, USA

problem #5

Oct 142003

(reported on)


  • miles
Consumer noticed that in order to stop vehicle she would have to apply force to brake pedal.

- Dallas, TX, USA

problem #4

Sep 092003

Expedition 4WD 8-cyl

  • Automatic transmission
  • 32,000 miles
Rear brake pads were worn to the metal at 32,000 miles on my 2003 Ford Expedition. I am told that this was very unusual for the rear pads to wear out so fast. Brakes felt like they were failing at the time I heard the scraping of the metal scraping against the rotors.

- Stafford, VA, USA

problem #3

Jul 312003


  • miles
Excessive brake dust on wheels. After cleaning the wheels are completely black after one day.

- Baton Rouge, LA, USA

problem #2

Jul 152003

Expedition 8-cyl

  • Automatic transmission
  • 18,500 miles
Side mirrors do not return to original position after backing up. Too much brake dust and wear. Tires had to be replaced at 20,000 miles for sidewall degradation.

- Nokomis, FL, USA

problem #1

Oct 122002

Expedition 8-cyl

  • Automatic transmission
  • miles
There is an enormous amount of brake dust build-up on the front and back wheels. After having the truck washed, an enormous amount of break dust began to build-up after traveling 1 mile. I was told by the dealership service representative that this was the #1 complaint made by 2003 Expedition owners when they bring their vehicles in to be serviced. The service representative also said that there was no solution to the problem. I called the Ford company and they told me the solution to the problem is to wash the wheels every week. This will not fix the brake dust problem, so it is not a solution.

- Jackson, MS, USA

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