Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety.


hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
69,632 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 exhaust system problems

exhaust system problem

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2003 Ford Expedition Owner Comments

problem #4

Mar 132010


  • miles


I have a 2003 Expedition 5.4L and since 2006 to present every two or three months I have to replace a coil pack and spark plug. Now since the coil packs have blown out so many times my catalytic converter on the passenger side has melted on the inside.

- Lothian, MD, USA

problem #3

Sep 052009


  • 117,000 miles
My 2003 Ford Expedition blew a spark plug out of the engine today. After reading about events leading up to this failure, my auto was acting exactly like all the others. A slight ticking sound while the engine idles. While driving 20mph, a slight loud bam occurred and the engine began to idle hard. The car was towed 70 miles to a repair center near my home and I now am to decide on a new manifold or a coil repair that is risky. How a company can operate with critical engine part that are so poorly designed is beyond my imagination. The internet is filled with complaints of spark plugs popping out of engines in F150S and Explorer/Expedition. It is a shame that such a simple thing as engineering a thread deep enough to hold a spark plug in place for the life of a car is too challenging for a car company. This repair should be the responsibility of the manufacturer. They were able to handle replacing millions of firestones and should be held to a standard close to their reputation as a tough vehicle. Without recourse, Ford will find it acceptable to cut corners and engineer sub par part.

- Chicago, IL, USA

problem #2

Jul 102008


  • 69,529 miles
I was driving at about 15 miles an hour and all of a sudden I heard a loud pop. I had to have it towed to a Ford dealership. They said that from what I was describing it was a spark plug that blew out of the engine. But since it was almost 5:00 P.M. and they were about to close they wouldn't know anything until they could look at it the next day. I didn't damage the heads but it still cost me over $400 to fix it.

- Eglin Afb, FL, USA

problem #1

Jun 112008


  • 92,000 miles
I was driving my 2003 Ford Expedition to work this morning and heard a loud "pop" noise, the vehicle began to vibrate and I smelled gas fumes. When I lifted the hood, I immediately noticed that the engine had blown a spark plug.

- Mt Airy, MD, USA

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