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2003 Ford F-250 Recalls, Problems & Maintenance

The 2003 Ford F-250 has no open NHTSA recalls. Owners report 5 recurring issue clusters, led by “Spark plug ejection from cylinder head.” 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-250.

Reported to NHTSA

Spark plug ejection from cylinder head

ENGINE AND ENGINE COOLING

22 NHTSA complaints · 2006-07 → 2015-12

“A SPARK PLUG BLEW OUT WHILE ACELERATING FROM A STOP SIGN, THIS HAS HAPPENED 3 SEPARATE OCCASIONS. A SMELL OF UNBURNT FUEL WAS PRESENT WHILE DRIVING TO FORD DEALER FOR REPAIR”
— Owner report, NHTSA ODI #10726943
“I WAS DRIVING MY 2003 FORD F-250 WHEN A SPARK PLUG BLEW OUT OF THE CYLINDER HEAD BREAKING THE COIL, AND CAUSING THE TRUCK TO RUN ON 7 CYLINDERS. MY TRUCK HAS ONLY 72340 MILES ON IT AND THOSE ARE THE ORIGINAL SPARK PLUGS FROM THE FACTORY”
— Owner report, NHTSA ODI #10321859
“I HAVE A 2003 FORD F250 WITH THE 5.4L ENGINE WITH ABOUT 80,000 MILES. I PURCHASED THE TRUCK NEW. THE NUMBER 3 OEM SPARK PLUG BACKED OUT AND BLEW OUT OF THE HEAD. I CONTACTED FORD, THEY RECOMMENDED I COVER ALL EXPENSES AND HAVE IT TOWED AND REPAIRED AT FORD DEALERSHIP. I PAID A”
— Owner report, NHTSA ODI #10272710

Read all complaints on NHTSA →

Speed control switch failure and fire

VEHICLE SPEED CONTROL

8 NHTSA complaints · 2005-01 → 2024-02

“Speed control sensor allows brake fluid leak through the plug connector and run down the wiring harness, allowing brake fluid to splash on the exhaust manifold and cause a fire”
— Owner report, NHTSA ODI #11572268
“ON MARCH 2ND 2015, MY 2003 FORD F-250 CAUGHT FIRE ON IT'S OWN. NO ONE WAS HOME AT THE TIME AND LUCKILY MY NEIGHBORS CALLED 911. THIS TRUCK WAS RECALLED FOR A FAULTY SPEED CONTROL SWITCH. THE ENTIRE ENGINE COMPARTMENT WAS TORCHED. THIS TRUCK IS NOT REPAIRABLE”
— Owner report, NHTSA ODI #10745950
“FORD F250 DIESEL PARKED IN DRIVEWAY NEXT TO HOUSE SPONTANEOUSLY CAUGHT FIRE DURING THE NIGHT. TRUCK TOTALLY DESTROYED, (OTHER PROPERTY ALSO DAMAGED/DESTROYED). HAD ISSUES WITH CRUISE CONTROL NOT WORKING, WAS FIXED TWICE, AFTER SECOND TIME FIXED AND STOPPED WORKING, DID NOT HAVE”
— Owner report, NHTSA ODI #10363782

Read all complaints on NHTSA →

Fuel tank strap corrosion and fracture

FUEL/PROPULSION SYSTEM

8 NHTSA complaints · 2013-07 → 2022-06

“Fuel tank straps corrode causing fuel tank to fall off A recall was issued for other similar ford trucks, but this model was not included”
— Owner report, NHTSA ODI #11471677
“TL* THE CONTACT OWNS A 2003 FORD F-250 SD. WHILE THE VEHICLE WAS PARKED, THE CONTACT NOTICED THAT THE FUEL TANK WAS HANGING DOWN. THE CONTACT LOOKED UNDERNEATH THE VEHICLE AND SAW THAT THE FUEL TANK STRAP WAS FRACTURED AND THE FUEL GAUGE WAS DAMAGED. THE DEALER WAS NOT”
— Owner report, NHTSA ODI #11230742
“1 OF THE TANK STRAPS BUSTED OFF AND THE TANK BEGAN SAGGING AND ALMOST TOUCHING THE GROUND, THUS CAUSING A SEVERE FIRE HAZARD”
— Owner report, NHTSA ODI #10716410

Read all complaints on NHTSA →

Tire tread separation and blowout

TIRES

30 NHTSA complaints · 2006-04 → 2019-01

“TIRE SEPARATION, I WAS DRIVING DOWN THE FREEWAY AT APPROX 70 MPH WHEN THE RIGHT REAR TREAD SEPARATED FROM MY TIRE CAUSING EXTENSIVE DAMAGE TO MY F250 2003 FORD PICK UP TRUCK. MY TRUCK SURGED TO THE RIGHT AND I CORRECTED BACK TO MY LANE. THERE WERE NO INJURIES TO THE PASSENGERS”
— Owner report, NHTSA ODI #10354771
“ON FRIDAY, JUNE 8TH 2012, ON MY 2003 FORD F250, THE FRONT LEFT (DRIVERS SIDE) TIRE TREAD SEPARATED FROM THE REST OF THE TIRE AND CAUSED EXTENSIVE DAMAGE TO MY VEHICLE. THE TIRE IS A DICK CEPEK FUN COUNTRY 2 PURCHASED IN JULY 2007. AT THE TIME OF THE ACCIDENT, THE TIRE HAD 60,000”
— Owner report, NHTSA ODI #10461299
“DT*: THE CONTACT STATED WHILE DRIVING 55 MPH THE TREAD COMPLETELY DETACHED FROM THE TWO TIRES ON THE PASSENGER SIDE. ANOTHER TIRE HAD A VIOLENT TREAD SEPARATION AT 55 MPH. WHICH CAUSED AN ACCIDENT AND INCURRED DAMAGES TO THE WHEEL ALIGNMENTS, FENDER, BUMPER, SUSPENSION AND OTHER”
— Owner report, NHTSA ODI #10168205

Read all complaints on NHTSA →

Front-end shake over bumps at highway speed

STEERING, SUSPENSION

9 NHTSA complaints · 2004-12 → 2018-05

“DRIVING 60 MPH OR GREATER AND HIT A BUMP THE FRONT END WILL VIOLENTLY SHAKE AND YOU HAVE TO PULL OVER AND SLOW WAY DOWN TO STOP IT. THERE WAS A RECALL FOR NR 62 PARTS BUT THAT DOESN'T STOP THE DODGE DEATH WOBBLE. THIS IS GOING TO CAUSE AN ACCIDENT AND KILL SOMEONE. DODGE WILL”
— Owner report, NHTSA ODI #10593251
“I OWN A 2003 F-250 SUPERDUTY EXTENDED CAB TWO WHEEL DRIVE FORD PICK-UP, THE FRONT END WILL SHAKE VIOLENTLY AT AROUND 55 MILES AN HOUR WHEN YOU HIT A BUMP IN THE ROAD OR EVEN MAKING A SLIGHT RIGHT HAND CURVING TURN ON THE HIGHWAY. IT IS SO BAD THAT I HAVE TO PULL OF THE HIGHWAY”
— Owner report, NHTSA ODI #10333847
“I HAVE A 2003 F250 GAS ENGINE WITH 46,000 MILES AND THE FRONT END WILL SHAKE VIOLENTLY WHEN HITTING MINOR RUFF ROAD AT SPEEDS FROM 60 MPH AND ABOVE. THIS CAUSES ME TO HAVE TO SLOW DOWN VERY FAST WHICH LEAVE DRIVERS BEHIND ME SCRAMBLING TO SAFETY. I HAVE PUT NEW TIRES ON THE”
— Owner report, NHTSA ODI #10189173

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.

12

complaints mentioning a crash

18

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-250 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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