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.

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1.6

hardly worth mentioning
Crashes / Fires:
0 / 1
Injuries / Deaths:
0 / 0
Average Mileage:
105,023 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 fuel system problems

fuel system problem

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2003 Ford Expedition Owner Comments

problem #11

Sep 272014

Expedition 8-cyl

  • 171,000 miles

A D V E R T I S E M E N T S

When driving on I-10 West at 65 mph my Ford Expedition shut down for no apparent reason. I was in the far left lane and don't like to park in the interior lanes so I placed my hazards on and drifted to the far right lane. It was hard to do because when my vehicle went dead the pwr steering and brakes became hard to use. Once I got to a safe area, I tried to start my vehicle again.....without success. I contacted my insurance company for roadside assistance and they picked my vehicle up and towed it to my residence. The next day I started the vehicle and went to a doctors appt. On the way back from the appointment I was in the left turning lane and the vehicle died again. This time I had someone behind me that almost rear ended me. At this time I took the vehicle to the Ford dealership (shamaley Ford). They indicated that the fuel pump was defective. I retrieved my vehicle and replaced the fuel pump. When driving to ensure that my vehicle was operational it died again on me in the middle of a one lane street which nearly caused an accident. Someone helped me push my vehicle around the corner so that traffic could proceed. I waited about 10 minutes and tried to start me vehicle and it started. I hurried and placed it in my parking space. As I have read, this is a recurring issue with Ford Expedition and luckily this hasn't caused a major accident or resulted in death. I did not state this but I connected my code reader and there was no indication of anything wrong. As stated previously, I took my car to the dealer and they misdiagnosed the problem. Could you address the issue?

- Horizon, TX, USA

problem #10

Jun 022014

Expedition 8-cyl

  • 107,500 miles
The engine would randomly shut off with no warning. Sometimes the engine would shut off while driving, other times would shut off at a stop light. The issue happened 10 times over a 3 day period. I was lucky to not crash as the engine died once while making a turn on a busy road. Once it died, so did the power steering and brakes - very scary. There were no engine codes that came up and no indication anything was wrong, the engine would simply shut off. While diagnosing the issue I did some internet research that indicated it could be the fuel pump relay issue. The fuel pump relay is a non-serviceable relay that is soldered to the main fuse box circuit board. I removed the fuse box and disassembled it revealing the fuel pump relay was getting hot and had melted the solder on the board. When the relay cooled, the solder made contact and the engine would start right up. When driving the solder would warm up and break contact. This would shut the fuel pump off and the engine would die. There are reports of this all over the internet. The only repair for this item was to replace the main circuit board as the relay cannot be replaced without soldering to the circuit board. Once the fuse box was replaced, the issue was resolved. I believe this could potentially be a huge problem and could lead to serious accidents. I have read this problem affects numerous years of the Ford Expedition.

- Hacienda Heights, CA, USA

problem #9

Apr 232014

Expedition 8-cyl

  • 139,000 miles
The car was running well and suddenly it die. No lights in dash board, no shakes, no any previous sign of trouble. Simply it die. I pumped the accelerator pedal and the car continue running. Next time, few days after the incident, the car does the same. This time do not continue running when I pump gas. I have to put in neutral and start it again. It start at once. Could be more than two weeks without signal of problem and then, it happen again. Some other time, it happen 4 or 5 times in a half hour trip.

- Rogers, AR, USA

problem #8

Jun 202013

Expedition

  • 137,000 miles

A D V E R T I S E M E N T S

While driving down the freeway I put my foot on the gas and did not get any response. In a few seconds I pushed on the gas again and nothing. I started to pull over and pushed on the gas again and the car had power. The same thing happened 25 minutes later getting back onto the freeway. Next incident was starting from a stop light the car just died. No warning. Engine light, battery light and service now lights come on. Again I pulled over put the car in park and it started back up. We had the coils and plugs changed. Next time driving at 35 mph out of the blue no power to the gas and the car shuts down. Changed a relay. Took it to the Ford dealership who can't figure out what the problem is. We changed the battery next time I am coming to a stop and the car stops. No battery light, no service light nothing. Again I pull over and it took a long time to get the car started again. Took it back into Ford. This time I gave them a thread of email about others having the same issue. Now they have changed another relay and we hope this solves the problem. This is a huge safety concern. For a person who is driving 55-66 mph on a highway or freeway and their car dies is a big accident waiting to happen. I did email Ford but so far have been told to talk to the service person.

- Lynnwood, WA, USA

problem #7

Jun 262010

Expedition

  • miles
Factory spark plug blew out of engine. I found numerous complaints of the same problem and was surprised to find there has been no recall.

- Springfield, MA, USA

problem #6

Jul 012010

Expedition 4WD 8-cyl

  • 138,000 miles
2003 Ford Expedition spark plug blow out from cylinder. Driving my car from portland to seattle, hear a bang. Pulled over to find the ignition coil blown out of its position. Had car towed for $100 to local shop. They said "this is one of the most common problems in any Ford (they) see" what happened was the spark plug came loose (after having the dealer tighten it less than a year ago) and blew out the ignition coil. Cost me $100 in towing and $700 in shop repairs and there is no guarantee that more damage was not done to the cylinder. Dealer in portland reported a "clean inspection". only had oil changed between.

- Aloha, OR, USA

problem #5

Aug 102009

Expedition

  • 45,000 miles

A D V E R T I S E M E N T S

1. event: Gasoline leaking onto pavement. 2. Ford dealer inspected and found a crack in the filler neck on top of the gasoline tank. I, nor a foreign object, have access to this area. Tank will leak gas onto pavement continuously until below crack level. If an igniter such as a cigarette or match or spark is near the flame, a fire will start on ground under the gas tank leading to the gas tank coated with gas resulting in a vehicle fire or explosion. 3. Ford dealer estimated replacement cost at $1,350. Ford dealer stated this is not a recall item and would not discuss the fact that this might be a defect in the injection molded gasoline tank. I then contacted Ford Motor Company customer care. Ford Motor Company customer care would not give me the name of the local Ford Motor Company representative (regional manager), a superior customer care rep to take my concern to a higher level and dismissed my concern that this was a safety defect issue. I was then informed that there was no further recourse and there was nothing else Ford Motor Company or my Ford dealer could do for my situation. Therefore, I have no further recourse except to submit my complaint. I cannot afford a replacement gas tank (tank is still installed on my vehicle).

- Waukesha, WI, USA

problem #4

Dec 062008

Expedition

  • 165,000 miles
I was driving on highway 12 West. As I turned onto a road, I noticed smoke coming from under my hood. My 8-year-old said, " what is that smell?" I told her that it is coming from under the hood of the vehicle. At this particular time, I turned the truck around and went to the nearest quick store. The man inside looked under my hood and used water to put on the "hood blanket". there was a hole in it above the brake fluid reservoir. The man kept putting water on it until it stopped smoking. At this particular time, he told me that me and little girl were lucky. I knew that it could have gotten worse. It was cold and if I were not close to the store I probably would have stayed in the vehicle to stay warm. I am so glad that I turned around and took a chance on getting to the nearest store. My insurance agent will be coming Monday (today is Saturday) to assess the damages and determine what could have caused the fire.

- Kosciusko, MS, USA

problem #3

Oct 262008

Expedition 8-cyl

  • 91,569 miles
I own a 2003 Ford Expedition 5.4 L, V8. We were on our way to church this morning and heard a loud pop coming from the engine, I pulled over and drove back to the house which is two blocks away. I checked to see what the problem is and found out that my vehicle spit out one of my spark plug and broke the coil. Noticed gas was coming out of the hole the plug should be. I checked the web today and there are thousands of complaints from different sites about this same issue. This is a serious matter that needs to be address, I hope you guys will address this matter before someone get hurt or even die due to this issue. Thank you and have a wonderful day.

- Fairfield, CA, USA

problem #2

Jun 232008

Expedition

  • 101,179 miles
Car would not start on first attempt. Ford dealer (ted russell kingston pike) said defective battery which was replaced. Problem still persisted. Ford dealer (ted russell kingston pike) then said it was a defective fuel pump. Went to pep boys kingston pike - they diagnosed defective fuel pump regulator. Went to different car dealer location (ted russell parkside drive) - they observed leak of fuel from fuel rail onto exhaust manifold. Requested that they hold part for me after replacement.

- Knoxville, TN, USA

problem #1

Nov 242007

Expedition 4WD 8-cyl

  • Automatic transmission
  • 60,000 miles
My 2003 Ford Expedition is shutting off while I am driving, nearly causing me to lose control and be rear ended. It happens when I least expect it and the dealership is baffled. All their expensive diagnostic equipment can't even track down the issue. So far they have replaced some fuel parts and my fuse box but it still shuts down unexpectedly. I am $900. In the hole already, let alone I am going to have my first grandchild within a week, and I have this tank that shuts down on the middle of the highway. It sounds electrical and I am in fear of catching fire.

- East Canton, OH, USA

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