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2003 Ford Expedition: problems, recalls and fuel economy
The 2003 Ford Expedition has 615 owner complaints on file with NHTSA, more than any Expedition year that came after it[1][2]. Engine and electrical reports lead the list, air bag complaints carry the most injury reports, and every version is rated at 14 mpg combined[3][4][5][6].
Most reported problems
NHTSA has 615 owner complaints for this model year[1]. Of those, 57 mention a crash, 36 a fire, 70 injuries and 3 deaths[1]. These are unverified owner reports, and one complaint can name more than one part of the car.
| Component group | Complaints | Crashes | Fires | Injuries | Median miles |
|---|---|---|---|---|---|
| Engine[3] | 171 | 0 | 13 | 0 | 100,070 |
| Electrical system[4] | 104 | 3 | 16 | 1 | 96,452 |
| Brakes[7] | 87 | 9 | 2 | 1 | 27,100 |
| Air bags[5] | 59 | 27 | 0 | 48 | 84,385 |
| Tires[8] | 57 | 5 | 0 | 11 | 34,500 |
| Power train[9] | 50 | 8 | 1 | 2 | 40,000 |
| Visibility[10] | 37 | 2 | 0 | 0 | 18,250 |
| Structure[11] | 32 | 1 | 0 | 2 | 42,000 |
Engine. This group has the most complaints, 171, and 13 of them mention a fire[3]. In a sample of complaints we read, owners describe the engine stalling or shutting off while driving, and some say the dealer could not reproduce it. Others describe heavy exhaust smoke at startup or trouble getting the engine to start[3]. These problems tend to show up later in life, at a median of 100,070 miles[3].
Electrical system. There are 104 complaints here, and 16 mention a fire, the highest fire count of any group[4]. In the sample we read, owners describe power mirrors and memory seats moving on their own, sometimes while driving, which threw off their view of the road. A few describe warning lights flashing and charging trouble linked to the alternator, and rear parking sensors that beep for no reason or stay silent[4].
Brakes. Brake complaints come early, at a median of 27,100 miles, and 9 of the 87 mention a crash[7]. Owners in our sample describe heavy brake dust on the wheels and pads or rotors wearing out quickly. A smaller number describe the pedal sinking or weak braking, sometimes with the ABS light on[7].
Air bags. This group is smaller at 59 complaints, but it has 27 crashes, 48 injuries and 1 death, the highest crash and injury counts of any group[5]. In the sample we read, owners describe air bags that did not deploy in a crash, air bags that went off with no crash, and an air bag warning light that stays on[5].
Tires (57 complaints, including 5 crashes, 11 injuries and 1 death) and power train (50 complaints, 8 crashes) round out the larger groups[8][9].
Recalls
NHTSA lists one recall for the 2003 Expedition[2].
- Running board courtesy lights (03V094). Issued March 7, 2003, it covers 3,674 potentially affected pickup truck, van and minivan conversions with Southern Comfort running boards[12]. The courtesy lights in these boards can overheat when the wiring is exposed to a lot of moisture and road salt. That can melt the running board or start a fire. Dealers replace the wiring harness on the running boards for free[12]. This applies only to conversion vehicles with these running boards, so check whether your Expedition has them.
Fuel economy
Every 2003 Expedition version is rated at 14 mpg combined by the EPA, whatever the engine or drive[6][13][14][15]. All use an Automatic 4-spd and regular fuel[6][13][14][15].
| Version | City | Highway | Combined |
|---|---|---|---|
| 2WD, 4.6L 8-cyl[6] | 13 | 18 | 14 |
| 2WD, 5.4L 8-cyl[13] | 12 | 16 | 14 |
| 4WD, 4.6L 8-cyl[14] | 12 | 17 | 14 |
| 4WD, 5.4L 8-cyl[15] | 12 | 16 | 14 |
The 2WD 4.6L does best on the highway at 18 mpg[6]. The EPA estimates an annual fuel cost of $4,800 for each version, based on current fuel prices, not the prices when the truck was new[6][13][14][15].
Safety ratings
NHTSA lists the 2003 Expedition as not rated under its 5-Star Safety Ratings program[16]. So there are no NHTSA crash test stars to compare for this model year.
Engine and size
The EPA lists two engines for 2003, a 4.6L 8-cyl and a 5.4L 8-cyl, both with an Automatic 4-spd[6][13].
The sizes below are Canadian-market specifications and can differ slightly from US models[17].
How 2003 compares with other years
Show the numbers
| Model year | Complaints | Recalls |
|---|---|---|
| 1997 | 853 | 7 |
| 1998 | 836 | 5 |
| 1999 | 946 | 5 |
| 2000 | 890 | 7 |
| 2001 | 578 | 6 |
| 2002 | 340 | 2 |
| 2003 | 615 | 1 |
| 2004 | 297 | 0 |
| 2005 | 315 | 0 |
| 2006 | 299 | 2 |
| 2007 | 215 | 2 |
| 2008 | 146 | 3 |
| 2009 | 28 | 1 |
| 2010 | 58 | 0 |
| 2011 | 71 | 0 |
| 2012 | 118 | 3 |
| 2013 | 92 | 0 |
| 2014 | 72 | 0 |
| 2015 | 164 | 3 |
| 2016 | 217 | 3 |
| 2017 | 357 | 4 |
| 2018 | 382 | 14 |
| 2019 | 518 | 11 |
| 2020 | 425 | 18 |
| 2021 | 238 | 12 |
| 2022 | 116 | 12 |
| 2023 | 65 | 8 |
| 2024 | 78 | 7 |
| 2025 | 38 | 6 |
| 2026 | 10 | 2 |
With 615 complaints, 2003 has the fifth-highest count of all Expedition years NHTSA lists[2]. Only 1999 (946), 2000 (890), 1997 (853) and 1998 (836) have more[2]. It is above 2001 (578) and every later year, and about double 2002 (340) and more than double 2004 (297), the years on each side of it[2].
On recalls the picture is different. The 2003 model has 1 recall, fewer than any year from 1997 to 2002, which have between 2 and 7 each[2].
These counts are not adjusted for how many trucks were sold.
Should you buy a used 2003 Expedition?
The 2003 Expedition has a heavy complaint record, with 615 reports, more than the 2002 or 2004 model[2]. Engine and electrical complaints lead, and both groups include fire reports[3][4]. Air bag complaints are fewer but tie to 27 crashes and 48 injuries[5]. The one recall covers only conversion vehicles with certain running boards and has a dealer fix[12]. If you are shopping, have a mechanic check the engine, the electrical system, brakes and air bag warning light, and keep the 14 mpg combined rating in mind for your fuel budget[6].
Frequently asked questions
- What are the most common problems with the 2003 Ford Expedition?
- The engine group has the most NHTSA complaints at 171, followed by the electrical system at 104 and brakes at 87[3][4][7]. Owners in a sample of complaints describe stalling, mirrors and seats moving on their own, and heavy brake dust[3][4][7].
- Does the 2003 Ford Expedition have any recalls?
- NHTSA lists one recall, 03V094, for conversion vehicles with Southern Comfort running boards whose courtesy lights can overheat. Dealers replace the wiring harness[12][2].
- What gas mileage does a 2003 Expedition get?
- The EPA rates every version at 14 mpg combined, with 12 to 13 mpg city and 16 to 18 mpg highway[6][13][14][15].
- Is the 2003 Expedition a good year?
- It has 615 complaints, more than the 2002 (340) and 2004 (297) models and every later year, but fewer recalls than 1997 to 2002[2].
Facts and sources
- NHTSA has 615 owner complaints on file for the 2003 Ford Expedition (57 mention a crash, 36 a fire, 70 injuries, 3 deaths reported). NHTSA vehicle records
- Owner complaints and recalls for every Ford Expedition model year (chart above). NHTSA recall database
- 171 complaints name the engine component group (0 crashes, 13 fires, 0 injuries, median mileage at failure 100,070). NHTSA vehicle records
- 104 complaints name the electrical system component group (3 crashes, 16 fires, 1 injuries, median mileage at failure 96,452). NHTSA vehicle records
- 59 complaints name the air bags component group (27 crashes, 0 fires, 48 injuries, median mileage at failure 84,385). NHTSA vehicle records
- EPA rating for Expedition 2WD, 4.6L 8-cyl, Automatic 4-spd, Regular, Rear-Wheel Drive: 13 city / 18 highway / 14 combined MPG; EPA estimated annual fuel cost $4,800. EPA / DOE fueleconomy.gov
- 87 complaints name the brakes component group (9 crashes, 2 fires, 1 injuries, median mileage at failure 27,100). NHTSA vehicle records
- 57 complaints name the tires component group (5 crashes, 0 fires, 11 injuries, median mileage at failure 34,500). NHTSA vehicle records
- 50 complaints name the power train component group (8 crashes, 1 fires, 2 injuries, median mileage at failure 40,000). NHTSA vehicle records
- 37 complaints name the visibility component group (2 crashes, 0 fires, 0 injuries, median mileage at failure 18,250). NHTSA vehicle records
- 32 complaints name the structure component group (1 crashes, 0 fires, 2 injuries, median mileage at failure 42,000). NHTSA vehicle records
- Recall 03V094, filed March 7, 2003: Structure. NHTSA recall database
- EPA rating for Expedition 2WD, 5.4L 8-cyl, Automatic 4-spd, Regular, Rear-Wheel Drive: 12 city / 16 highway / 14 combined MPG; EPA estimated annual fuel cost $4,800. EPA / DOE fueleconomy.gov
- EPA rating for Expedition 4WD, 4.6L 8-cyl, Automatic 4-spd, Regular, 4-Wheel or All-Wheel Drive: 12 city / 17 highway / 14 combined MPG; EPA estimated annual fuel cost $4,800. EPA / DOE fueleconomy.gov
- EPA rating for Expedition 4WD, 5.4L 8-cyl, Automatic 4-spd, Regular, 4-Wheel or All-Wheel Drive: 12 city / 16 highway / 14 combined MPG; EPA estimated annual fuel cost $4,800. EPA / DOE fueleconomy.gov
- NHTSA 5-Star Safety Ratings, 4 DR None: not rated; rollover risk 0.0%. NHTSA vehicle records
- Transport Canada specifications via NHTSA vPIC, EXPEDITION 4DR 4X4 Eddie Bauer/ Special Servi: length 204 in, width 79 in, height 78 in, wheelbase 118 in, curb weight 5,686 lb (converted from centimeters and kilograms). vpic.nhtsa.dot.gov
- Transport Canada specifications via NHTSA vPIC, EXPEDITION 4DR 4X4 XLT 4.6L: length 204 in, width 79 in, height 78 in, wheelbase 118 in, curb weight 5,564 lb (converted from centimeters and kilograms). vpic.nhtsa.dot.gov
- Transport Canada specifications via NHTSA vPIC, EXPEDITION 4DR 4X4 XLT 5.4L / XLT 5.4 L FX4: length 204 in, width 79 in, height 78 in, wheelbase 118 in, curb weight 5,686 lb (converted from centimeters and kilograms). vpic.nhtsa.dot.gov