Problems owners report
Complaints filed with NHTSA about the 2003 Ford Expedition, by the system named in each complaint. One complaint can name several.
- Engine and engine cooling127
- Electrical system104
- Service brakes, hydraulic61
- Air bags59
- Tires57
- Power train50
- Engine44
- Visibility37
- Structure32
- Unknown or other21
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 70 injuries and 3 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Fatal crashes in the US
From 2020 to 2023, 104 2003 Expedition vehicles were involved in crashes on US public roads in which someone died; 52 people died inside them, and 31 of the vehicles rolled over. This is a count, not a crash rate: it grows with the number of cars on the road.
NHTSA Fatality Analysis Reporting System (FARS), crash years 2020–2023 (public domain)
New York safety inspections
At its first New York inspection the 2003 Ford Expedition failed the safety check 2.29% of the time — 9% more often than the average 2003 passenger car (2.11%). Median odometer at inspection: 170,937 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
In New Zealand
2 2003 cars are on the New Zealand register; 100% arrived as used imports, 0% were sold new in New Zealand.
NZ Transport Agency Waka Kotahi, Motor Vehicle Register (March 2026) · CC BY 4.0
Fuel consumption
Official Canadian test results for 2 variants: combined 16.8–17.4 L/100 km (about 14 mpg US), CO₂ 386–400 g/km.
| Variant | City | Highway | Combined |
|---|---|---|---|
| Expedition 4X4 · Sport utility vehicle · Regular gasoline | 19.3 | 13.8 | 16.8 |
| Expedition 4X4 · Sport utility vehicle · Regular gasoline | 19.8 | 14.5 | 17.4 |
Litres per 100 km. Natural Resources Canada, Fuel consumption ratings (open.canada.ca) · Open Government Licence – Canada
Recalls
CERTAIN PICKUP TRUCK, VAN, AND MINI VAN CONVERSIONS EQUIPPED WITH SOUTHERN COMFORT BUILT RUNNING BOARDS THAT CONTAIN CERTAIN COURTESY LIGHTS MANUFACTURED BY AMERICAN TECHNOLOGY COMPONENTS, INC. THESE UNITS CONTAIN A COURTESY LIGHT OR LIGHTS THAT MIGHT OVERHEAT WHEN THE WIRE HARNESS IS EXPOSED TO EXCESSIVE MOISTURE AND ROAD SALT.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Ford told its dealers about the 2003 Ford Expedition: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 637850 | SUBJECT REGARDING ROOF RACK WIND NOISE. *TT |
| 637846 | INFORMATION USED WHEN REPLACING THE DRIVERS SEAT MODULE. *TT |
| 637535 | INFORMATION ON USING NSG DIAGNOSTIC CARD VERSION 20.1 AND SERVICE CARD VERSION 10.2 WHEN SERVICING. *TT |
| 637432 | THIS SERVICE REMINDER IS IN REFERENCE TO LIFT (JACKING) POINTS. *TT |
| 636291 | SOME 4X2 VEHICLES MAY EXHIBIT A REAR AXLE WHINE AT 50 AND 62 MPH IN COAST OR DRIVE. *TT |
| 636286 | SERVICE TIPS ON ON CHECKING FUSES 32, 33 AND 34. *TT |
| 636281 | SOME VEHICLES MAY EXHIBIT A CHECK TIRE PRESSURE OR A TIRE LOSING PRESSURE MESSAGE IN THE MESSAGE CENTER. *TT |
| 636279 | SOME VEHICLES MAY EXHIBIT A NO-START CONDITION WITH NO FUEL PRESSURE PRESENT AND / OR FUEL PUMP CIRCUIT DIAGNOSTIC TROUBLE CODES P0231 OR P0232. *TT |
| 636273 | DIAGNOSTICS PROVIDED FOR DIAGNOSTIC TROUBLE CODES C2777 / C2778 (SENSOR CLUSTER CAN BUS FAILURE / SENSOR CLUSTER POWER SUPPLY FAILURE). *TT |
| 636271 | DIAGNOSTIC PROCEDURES FOR DIAGNOSTIC TROUBLE CODE C1991 (MODULE CALIBRATION FAILURE) OMITTED FROM THE WORSHOP MANUAL. *TT |
| 636267 | SOME 4X4S MAY EXHIBIT A FRONT AXLE GROAN OR HUM, AND / OR A SLIGHT VIBRATION WHEN OPERATED IN 2 HIGH MODE. *TT |
| 636247 | INTERACTIVE VEHICLE DYNBAMICS (IVD) DIAGNOSTIC TROUBLE CODE C1998. *TT |
| 636231 | SOME VEHICLES BUILT BEFORE MAY 20, 2002 MAY EXHIBIT A CLICK NOISE WHEN THE BRAKE PEDAL IS DEPRESSED OR RELEASED. *TT |
| 636216 | SOME VEHICLES MAY EXHIBIT A FEATHERING OF THE TREAD EDGES ON NEW TIRES AS RECEIVED FROM THE FACTORY. *TT |
| 636182 | DIAGNOSTICS FOR DIAGNOSTIC TROUBLE CODE C1440 OMITTED FROM WORKSHOP MANUAL. *TT |
| 636109 | SOME VEHICLES MAY EXHIBIT POWER STEERING NOISE / VIBRATION FROM THE AREA OF THE POWER STEERING PUMP ACCOMPANIED BY BLUID LEAKAGE FROM THE POWER STEERING RESERVOIR CAP. *TT |
| 11005305 | 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 area. This may be due to partial engagement of the integrated wheel ends (IWE). To correct this condition, follow the Service Procedure to remove and cap the vacuum supply line or to reprogram the transfer case control module (TCCM) and replace any worn vacuum and/or IWE components. |
| 10235153 | 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 affected vehicles are VIN/vehicle specific and hardware variations between modules do exist. Swapping a module from a vehicle or ordering a module using a different vehicle/VIN can cause ineffective repairs and additional vehicle down time. Make sure all appropriate Workshop Manual (WSM) procedures are |
| 10214754 | 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 to remove and cap the vacuum supply line or to reprogram the transfer case control module (TCCM) and replace any worn vacuum and/or IWE components. |
| 10181917 | 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 Procedure steps to remove and cap the vacuum supply line. |
| 10177863 | 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 recommended. |
| 10156863 | 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 |
| 10155551 | 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 |
| 10028736 | FORD: SOME VEHICLES MAY EXHIBIT OIL SEPARATION FROM THE INTERNAL LUBE FOUND IN THE UNITIZED CARTRIDGE SEAL. OIL SEPARATION APPEARS TO BE AND IS OFTEN MISDIAGNOSED, AS AN AXLE LUBE LEAK. *PE |
| 10023943 | SOME 1997-2008 VEHICLES EQUIPPED WITH A 4.6L 2V, 5.4L 2V, OR 6.8L 2V ENGINE--SPARK PLUG THREAD REPAIR PROCEDURE--NOT COVERED UNDER NEW VEHICLE LIMITED WARRANTY. *NJ THIS INCLUDES F-53 MOTORHOME CHASSIS. UPDATED 2/23/10. *PE |
NHTSA manufacturer communications (public domain)
NHTSA investigations
SPARK PLUG EJECTION FROM CYLINDER HEAD
NHTSA Office of Defects Investigation