The 2003 Ford Expedition has no open NHTSA recalls. Owners report 7 recurring issue clusters, led by “Frame and body rust or corrosion.” Ford uses the Intelligent Oil-Life Monitor (IOLM) to determine when oil changes are due based on actual driving load — not just mileage. Ford's published cap is 10,000 miles or 1 year, whichever comes first. The schedule below reflects Ford's Normal service intervals; F-Series trucks and Super Duty have additional towing-specific items.
No open recalls on file. NHTSA lists no unrepaired safety recalls for this year, make and model. A recall can be issued at any time, and a specific car can still have one open — check yours by VIN at nhtsa.gov/recalls.
What drivers and federal regulators have officially reported about the 2003 Ford Expedition.
STRUCTURE
7 NHTSA complaints · 2013-05 → 2022-06
“FRAME ROT IN MULTIPLE LOCATIONS, FRONT AND REAR”
“I OWNED THIS VEHICLE SINCE 2003. A COUPLE OF YEARS AGO I NOTICED SMALL PERFORATION/RUSTING ON THE TOP OF THE VEHICLE AND OVER TIME IT BECAME WORST. NOW THERE ARE NUMEROUS BADLY CORRODED AREAS . IT APPEARS THAT DUE TO THE DESIGN AND THE MATERIALS USED WATER REMAINS TRAPPED”
ENGINE
34 NHTSA complaints · 2010-08 → 2025-02
“SPARK PLUGS BLOW OUT OF CYLINDER HEAD AT HIGHWAY SPEED”
“MY FORD EXPEDITION IS EQUIPPED WITH A 5.4L TRITON ENGINE AND LIKE MANY OTHER ENGINES OF THE SAME FAMILY, IT BLEW A SPARK PLUG OUT OF THE HEAD WHILE DRIVING DOWN THE INTERSTATE. THIS ALLOWED FUEL TO ESCAPE AND ALMOST CREATED A FIRE UNDER THE HOOD. LUCKILY, I WAS ABLE TO CONTAIN”
“ALL 3 HAPPENED WHILE DRIVING ON HIGHWAYS AND IN COLD WEATHER PUTTING OCCUPANTS AT RISK. #1, #3 AND #7 SPARK PLUGS HAVE BLOWN OUT OVER A PERIOD OF 15 MONTHS, DESTROYING THE COIL IN THE PROCESS. ALL WERE THE ORIGINALLY INSTALLED SPARK PLUGS FROM THE FORD ASSEMBLY PLANT. READING”
ELECTRICAL SYSTEM
30 NHTSA complaints · 2011-03 → 2024-01
“Faulty fuse panel. This is a known issue. It is ALL over the internet. There has never been a recall. The vehicle will stall while driving. On attempting restart or crank, there is a buzzing noise from the fuse panel. The pcm #203 I believe, corrodes or melts through the board”
“TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. THE CONTACT STATED THAT THE FUSE BOX FAILED. WHILE DRIVING 85 MPH, THE VEHICLE STALLED WITHOUT WARNING, THE STEERING WHEEL SEIZED, AND THE FUSE BOX MADE A BUZZING SOUND. THE CONTACT COASTED THE VEHICLE TO THE SIDE OF THE ROAD, REACHED”
“KEEPS BLOWING THE FUEL PUMP REPLY. WE HAVE HAD TO REPLACE THE REPLY 4 TIMES IN THE LAST FEW DAYS. AFTER REMOVING THE REPLY FROM THE FUSE PANEL AND LOOKING AT THE PORT IT IS BURNING BOTH FUSE AND FUSE PANEL.THIS HAPPEN WHEN WE ARE RUNNING AND WHEN THE FUSE BLOWS IT KILLS THE”
ENGINE
25 NHTSA complaints · 2010-08 → 2024-01
“TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING VARIOUS SPEEDS THE ENGINE STALLED WITHOUT ANY WARNING. THE CONTACT WAS ABLE TO RESTART THE VEHICLE EACH TIME HOWEVER, THE FAILURE RECURRED INTERMITTENTLY. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE”
“TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. WHILE DRIVING 56 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO BE DIAGNOSED, BUT THE DEALER COULD NOT DUPLICATE THE FAILURE. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE FAILURE MILEAGE WAS 143,000”
“TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 60 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE CONTACT WAS ABLE TO RESTART THE VEHICLE AFTER WAITING FOR SEVERAL MINUTES. THE DEALER WAS UNABLE TO DIAGNOSE THE FAILURE. THE”
AIR BAGS
4 NHTSA complaints · 2010-08 → 2017-09
“TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. WHILE DRIVING 35 MPH, THE TWO SIDE AIR BAGS DEPLOYED WITHOUT WARNING OR IMPACT. THERE WERE NO INJURIES. THE LOCAL DEALER WAS NOT CONTACTED. THE MANUFACTURER WAS NOT NOTIFIED OF THE ISSUE. THE FAILURE MILEAGE WAS 144,943”
“SIDE AIRBAGS SPONTANEOUSLY DEPLOYED WHILE DRIVING DOWN THE HIGHWAY. I STOPPED THE VEHICLE SAFELY AND NO APPARENT INJURY TO MYSELF OR PASSENGER EXCEPT FOR POSSIBLE HEARING LOSS DUE TO THE LOUD BANG ON DEPLOYMENT. I USED A KNIFE TO CUT THE BAGS AWAY FROM THE FRONT SIDE WINDOWS”
“TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 5 MPH THE SIDE AIR BAGS DEPLOYED WITHOUT ANY WARNINGS. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO DID NOT OFFER ANY ASSISTANCE. THE VEHICLE WAS NOT”
AIR BAGS
6 NHTSA complaints · 2011-05 → 2013-08
“WAS INVOLVED IN A HEAD ON COLLISION DOING AROUND 20-30 MPH AND NOT ONE OF THE AIRBAGS DEPLOYS I NEED TO KNOW Y AND WHAT INFO I COULD GET ON IT. *TR”
“TL* THE CONTACT OWNS A 2003 FORD EXPEDITION . THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 35 MPH, THE CONTACT CRASHED THE VEHICLE INTO A BUILDING AND THE AIR BAGS FAILED TO DEPLOY. THERE WERE NO INJURIES REPORTED. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE MANUFACTURER”
“HEAD ON COLLISION, BOTH VEHICLES TRAVELING APPROXIMATELY 40 MPH. 2003 EXPEDITION AIR BAGS DID NOT DEPLOY. BOTH VEHICLES WERE TOTALED BECAUSE OF THE SEVERE IMPACT, HOWEVER THE EXPEDITION AIR BAGS DID NOT DEPLOY. AS A RESULT THE EXPEDITION DRIVER HIT HIS HEAD ON THE STEERING”
SERVICE BRAKES
10 NHTSA complaints · 2010-09 → 2017-02
“THE BRAKE LINE THAT IS ROUTED TO THE REAR BRAKES RUSTED COMPLETELY THROUGH, CAUSING ME TO LOSE ALL BRAKING FUNCTION HENCE, CONTROL OF MY VEHICLE. I HAD TO RUN OFF INTO A DITCH TO MISS A SLOWING VEHICLE. AFTER I HAD COME TO REST IN THE DITCH THERE WAS AN ENGINE FIRE CAUSED BY”
“MY VEHICLE EXPERIENCED TOTAL BRAKE FAILURE AS I APPROACHED A FOUR-WAY STOP INTERSECTION ON A RURAL COUNTY HIGHWAY. INSPECTION BY AUTO REPAIR TECHNICIANS REVEALED MY BRAKE LINES HAD RUSTED AND HAD EXPERIENCED SEVERAL RUPTURES. THE TECHNICIANS SAID THE RUST WAS THE RESULT OF”
“I PREVIOUSLY REPORTED 3 FAILURES OF THE BRAKE SYSTEM ON THIS VEHICLE DUE TO CORRODED BRAKE LINES UNDER NHTSA ID# 10491754. THIS PAST WEEKEND I JUST HAD A FOURTH BRAKE FAILURE DUE TO A CORRODED BRAKE LINE IN 11 MONTHS. THIS BRAKE LINE RUNS ALONG THE LEFT FRONT BELOW THE ENGINE”
Issues on other model years
Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 20, 2026. Investigation data refreshed Sep 20, 2026.
We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.
Critical for safety and preventing major damage
Replace synthetic-blend or full-synthetic Motorcraft oil per the IOLM, or every 7,500-10,000 miles. EcoBoost engines require full synthetic; Coyote 5.0L V8 specifies SAE 5W-30.
Estimated cost — typical U.S. ranges
Dealer
~$120–$160
Shop
~$85–$115
DIY
~$25–$55
Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.
Rotate tires every 10,000 miles, or with every other oil change. F-150 4x4 owners should rotate every 5,000-7,500 miles to even out drivetrain bias wear.
Estimated cost — typical U.S. ranges
Dealer
~$85
Shop
~$60
DIY
Free
Often free at the shop where you bought the tires — worth asking before paying.
Inspect brake pads, rotors, and brake fluid level every 10,000 miles. Front pads on F-150 and Explorer typically last 40,000-60,000 miles.
Estimated cost — typical U.S. ranges
Dealer
~$85
Shop
~$60
DIY
Free
Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.
Ford specifies brake fluid replacement on an inspection basis, but moisture testing every 3 years is recommended. Replace if reading exceeds 3% water content.
Estimated cost — typical U.S. ranges
Dealer
~$180–$200
Shop
~$125–$140
DIY
~$10–$25
DOT 3 or 4 — match the cap. Vacuum bleeders make this a one-person DIY.
Keeps your vehicle running smoothly and efficiently
Replace the engine air filter every 30,000 miles. EcoBoost turbocharged engines are sensitive to airflow restriction — don't extend.
Estimated cost — typical U.S. ranges
Dealer
~$60–$95
Shop
~$45–$70
DIY
~$15–$40
5-minute job on most cars; the airbox lid usually has clips, no tools needed.
Ford 6R80, 10R80, and 8F transmissions use Mercon LV fluid rated 150,000 miles under normal service. Severe service (towing, plowing) drops this to 60,000 miles.
Estimated cost — typical U.S. ranges
Dealer
~$330–$500
Shop
~$235–$355
DIY
~$60–$180
Some sealed transmissions have no dipstick — fill is precise and best left to a shop. Many drivers can still DIY drain-and-fill.
On 4x4 models, replace transfer case fluid every 60,000 miles. Use Motorcraft XL-12 — do not substitute generic transfer case fluid.
Estimated cost — typical U.S. ranges
Dealer
~$105–$140
Shop
~$75–$100
DIY
~$15–$40
AWD/4WD vehicles only. Easy drain-and-fill on most platforms.
F-Series and Expedition: replace rear axle fluid every 100,000 miles, or 50,000 miles if towing. Limited-slip rear ends require friction-modifier additive.
Estimated cost — typical U.S. ranges
Dealer
~$150–$195
Shop
~$105–$135
DIY
~$20–$50
Drain plug + fill plug — straightforward DIY. AWD vehicles have two; budget for both.
Iridium spark plugs on Coyote 5.0L, EcoBoost 2.7L/3.5L, and 2.3L are rated 100,000 miles. EcoBoost engines: never exceed the interval — gap erosion causes coil failure.
Estimated cost — typical U.S. ranges
Dealer
~$285–$390
Shop
~$200–$275
DIY
~$25–$100
Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.
Motorcraft Orange (Dex-Cool compatible) coolant: first change at 100,000 miles, then every 50,000. Older trucks with Yellow Motorcraft coolant: 50,000 miles throughout.
Estimated cost — typical U.S. ranges
Dealer
~$285–$330
Shop
~$200–$235
DIY
~$25–$60
Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.
Extends the life of your vehicle and improves comfort
Replace the cabin air filter every 20,000 miles. On F-150, located behind the glove box; on Escape and Explorer, accessed from the passenger footwell.
Estimated cost — typical U.S. ranges
Dealer
~$60–$95
Shop
~$45–$70
DIY
~$15–$40
Usually behind the glovebox. Shops charge labor for a 10-minute job — easy DIY win.
Occupant deaths in fatal crashes (FARS)
432 crashes 1990–2024
How the 432 occupant deaths break down
223
driver deaths
209
passenger deaths
432
occupant deaths
Crash years covered: 1990–2024 This model year first appears in 2002 crashes. Older models have had more years on the road to appear in these crashes, so a higher count here does not by itself mean a vehicle is less safe.
FARS counts every occupant death in a fatal crash, whatever the cause — it does not mean the vehicle was at fault or defective. Counts are not adjusted for how many of each vehicle are on the road. How to read this number
FARS 2024 data is an annual report file. NHTSA revises these records when the final file is published, so this count can change.
Every vehicle has exactly one driver seat, so driver deaths line up fairly when you compare one model to another. Occupant deaths include passengers, so a three row SUV can show a higher number than a two seat car simply because it carries more people.
Both figures are plain counts, not rates. A rate would need to know how many of each vehicle are on the road, and that registration data is not public, so we do not publish rates or scores of any kind.
IIHS publishes driver death rates using this same driver only idea, paired with a registered vehicle years denominator we do not have. Their rates and these counts answer different questions, so do not read either number here as a safety rating.
Owner-reported problem signals
Separate from the federal fatality data above: complaints owners filed with NHTSA about this year and model. These are reports of problems, unverified, and are counted here only as signals.
58
complaints mentioning a crash
38
complaints mentioning a fire
Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.
How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.
This maintenance schedule for the 2003 Ford Expedition reflects Ford's published service intervals and the Intelligent Oil-Life Monitor system. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.