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2003 Ford F-150 Recalls, Problems & Maintenance

The 2003 Ford F-150 has no open NHTSA recalls. Owners report 8 recurring issue clusters, led by “Fuel tank strap corrosion and tank separation.” 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.

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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.

Known issues & problems for this vehicle

What drivers and federal regulators have officially reported about the 2003 Ford F-150.

Reported to NHTSA

Fuel tank strap corrosion and tank separation

FUEL/PROPULSION SYSTEM

32 NHTSA complaints · 2011-05 → 2022-10

“FORD F150 GAS TANK STRAPS FAILED CAUSING FULL TANK OF GAS TO FALL FROM UNDER TRUCK WHILE DRIVING DOWN HIGHWAY. *TR”
— Owner report, NHTSA ODI #10416361
“THE CONTACT STATED THAT WHILE DRIVING AT AN UNKNOWN SPEED, THE FUEL TANK STRAP FRACTURED AND THE FUEL TANK DROP TO THE GROUND”
— Owner report, NHTSA ODI #10851897
“THE CONTACT STATED THAT THE FUEL TANK STARTED LEAKING FUEL WHILE HE WAS DRIVING APPROXIMATELY 55 MPH. THE CONTACT NOTICED THE STRAPS WERE RUSTED AND CAUSED A HOLE TO OPEN IN THE FUEL TANK”
— Owner report, NHTSA ODI #10399820

Read all complaints on NHTSA →

Rear doors failing to open

STRUCTURE

9 NHTSA complaints · 2012-04 → 2024-06

“THE CONTACT STATED THAT THE REAR DRIVER SIDE AND PASSENGER SIDE DOORS FAILED TO OPEN FROM INSIDE AND OUTSIDE THE VEHICLE”
— Owner report, NHTSA ODI #10920268
“BOTH REAR DOOR LATCHES HAVE FAILED TO OPERATE. CANNOT OPEN EITHER REAR DOOR”
— Owner report, NHTSA ODI #10981410
“THE CONTACT STATED THAT BOTH REAR DOORS LOCKED AND WOULD NOT OPEN”
— Owner report, NHTSA ODI #10474497

Read all complaints on NHTSA →

Windshield water leak affecting GEM and fuse box

ELECTRICAL SYSTEM

6 NHTSA complaints · 2011-04 → 2023-10

“THE CONTACT STATED THAT WATER WAS LEAKING INTO THE VEHICLE FROM THE WINDSHIELD, CAUSING DAMAGE TO THE GEM MODULAR”
— Owner report, NHTSA ODI #10428255
“MY 2003 F-150 V8, 4.6L 2WD TRUCK RECEIVED WATER DAMAGE TO THE GEM (GENERIC ELECTRONIC MODULE) CAUSING THE WINDSHIELD WIPERS TO STOP WORKING WHILE DRIVING TO WORK ON A FOGGY/DEW MORNING AFTER A RAINSTORM”
— Owner report, NHTSA ODI #10643313
“It is leaking water when it rains. Getting front floor carpet wet and now it is getting the fuse box wet and causing electrical systems to not work”
— Owner report, NHTSA ODI #11550463

Read all complaints on NHTSA →

Spark plug ejection from cylinder head

ENGINE

27 NHTSA complaints · 2011-02 → 2025-08

“WAS DRIVING ALONG AT 35 MPH GOING STRAIGHT ON A CITY STREET. A SPARK PLUG WAS EJECTED FROM THE ENGINE HEAD. THIS COULD CREATE A FIRE HAZARD”
— Owner report, NHTSA ODI #10910692
“WHILE DRIVING AT 65 - 70 MPH ON I-95, THE SPARK PLUG ON THE #2 CYLINDER BLEW OUT. #2 CYLINDER IS 2ND PLUG FROM FRONT OF ENGINE ON THE PASSENGER SIDE. LOUD NOISE AND LOST POWER. *TR”
— Owner report, NHTSA ODI #10614523
“SECOND TIME SAME SPARK PLUG HOUSING HAS FAILED TO HOLD SPARK PLUG AND EJECTED IT FROM ENGINE ALONG WITH RAW FUEL ALMOST IGNITING ENGINE COMPARTMENT”
— Owner report, NHTSA ODI #10734656

Read all complaints on NHTSA →

Unintended acceleration

VEHICLE SPEED CONTROL

11 NHTSA complaints · 2011-03 → 2019-02

“GAS PEDAL IS STICKING. TRUCK SPEEDS UP, ONLY WAY TO STOP IS SHIFT TO NEUTRAL.HAPPENED ON HIGHWAY AND I SHIFTED TO NEUTRAL AND HIT PEDAL SEVERAL TIMES TO GET BACK TO IDLE”
— Owner report, NHTSA ODI #11180820
“WHILE ATTEMPTING TO SLOW THE VEHICLE DOWN, IT SUDDENLY ACCELERATED WITHOUT WARNING”
— Owner report, NHTSA ODI #10630068
“THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 65 MPH WITH THE CRUISE CONTROL ACTIVATED, THE VEHICLE ACCELERATED WITHOUT WARNING”
— Owner report, NHTSA ODI #10587737

Read all complaints on NHTSA →

Air bags not deploying in collision

AIR BAGS

5 NHTSA complaints · 2011-10 → 2020-11

“WHILE DRIVING APPROXIMATELY 70 MPH, ANOTHER VEHICLE CRASHED INTO THE CONTACT'S VEHICLE. AS A RESULT, THE CONTACT CRASHED INTO A TREE. THE AIR BAGS FAILED TO DEPLOY”
— Owner report, NHTSA ODI #10892820
“TRAVELING ON HIGHWAY 57 NORTH IN EAGLE PASS TEXAS MAVERICK COUNTY AROUND 10PM STRUCK A BULL THAT CROSSING THE HIGHWAY WITH MY FORD F150 SUPER CREW AIR BAGS DID NOT DEPLOY. *TT”
— Owner report, NHTSA ODI #10432836
“ON NOVEMBER 01,2020 I WAS INVOLVED IN A VEHICLE ROLLOVER IN MY FORD F150 2003 WHICH THE AIRBAGS DID NOT DEPLOY”
— Owner report, NHTSA ODI #11372877

Read all complaints on NHTSA →

Air bags deploying without a collision

AIR BAGS

4 NHTSA complaints · 2011-10 → 2019-03

“MY SON WAS DRIVING DOWN THE MAIN STREET IN OUR TOWN GOING THE SPEED LIMIT, CROSSED OVER THE RAILROAD CROSSING AND BOTH AIRBAGS DEPLOYED EVEN THOUGH THERE HAD BEEN NO COLLISION OR IMPACT OTHER THAN THE SMALL BUMP OF THE RAILROAD CROSSING”
— Owner report, NHTSA ODI #11187422
“ON MONDAY EVENING, JUNE 17TH, HE WAS GOING AROUND A CURVE, AT APPROXIMATELY 35 MPH WHEN BOTH AIR BAGS DEPLOYED FOR NO REASON”
— Owner report, NHTSA ODI #10520824
“WHILE DRIVING APPROXIMATELY 10 MPH, THE AIR BAGS INADVERTENTLY DEPLOYED AND THE HORN BEGAN TO CONTINUOUSLY SOUND”
— Owner report, NHTSA ODI #10661569

Read all complaints on NHTSA →

Brake pedal travel to floor

SERVICE BRAKES

6 NHTSA complaints · 2012-06 → 2019-10

“WHILE DRIVING APPROXIMATELY 20 MPH, THE CONTACT DEPRESSED THE BRAKE PEDAL AND IT TRAVELED TO THE FLOORBOARD”
— Owner report, NHTSA ODI #11207740
“WHILE DRIVING APPROXIMATELY 20 MPH, THE BRAKE PEDAL TRAVELED TO THE FLOOR WHEN IT WAS DEPRESSED AND FAILED TO STOP THE VEHICLE”
— Owner report, NHTSA ODI #10822203
“WITHOUT WARNING, THE BRAKE PEDAL WENT TO THE FLOOR WHILE TOWING A 6000LB TRAILER”
— Owner report, NHTSA ODI #10525177

Read all complaints on NHTSA →

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.

Raw data + downloads for this vehicle →

Essential maintenance

Critical for safety and preventing major damage

Engine Oil & Filter

Every 7,500 mi

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.

Tire Rotation

Every 10,000 mi

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.

Brake Inspection

Every 10,000 mi

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.

Brake Fluid

Every 45,000 mi

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.

Important maintenance

Keeps your vehicle running smoothly and efficiently

Engine Air Filter

Every 30,000 mi

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.

Automatic Transmission Fluid

Every 150,000 mi

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.

Transfer Case Fluid (4WD models)

Every 60,000 mi

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.

Rear Differential Fluid

Every 100,000 mi

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.

Spark Plugs

Every 100,000 mi

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.

Engine Coolant

Every 50,000 mi

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.

Recommended maintenance

Extends the life of your vehicle and improves comfort

Cabin Air Filter

Every 20,000 mi

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.

Fatal crash history & reported problems

Occupant deaths in fatal crashes (FARS)

1,662 crashes 1990–2024

How the 1,662 occupant deaths break down

1,260

driver deaths

397

passenger deaths

5

not recorded by seat

1,662

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.

Why we show driver deaths too

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.

45

complaints mentioning a crash

39

complaints mentioning a fire

Reviewed known issues for this vehicle

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 F-150 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.

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