2003 Ford Expedition electrical problems

ELECTRICAL SYSTEM

My truck stopped working in November 2025. I was told I needed fuel pump and filter. I replaced those and still didn't crank. I was then told I needed a circuit box. Purchased a circuit box and had it put on. Got my truck back February 2026. March 08,2026, truck went out again. I kept my truck maintenance and don't understand what's going on with it. I was told it is a recall on electrical parts and engine coils and spark plugs.

NHTSA complaint #11722874 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

My Ford Expedition started randomly stalling and it stalled in the highway. The engine just shut down in the middle of the highway and it was such a scary a life endangering experience. This total loss of power in the middle of the highway when vehicles are traveling at highway speeds can cause death very, very easily to the occupants of the Ford Expeditions suffering this defect. I have been reading in many forums ( I have included the link to one of many forums) this is a common defect [XXX] ) many have Ford Expedition owners have experienced and have been very concerned and shocked that there was not recall. The issue is that the R303 relay (non serviceable fuel pump relay) fails very commonly on Ford Expeditions. In my Ford Expedition, the relay was melted. The fuel pump relay fails and cuts all current going to the fuel pump causing the engine to stall. This is a life-threatening risk caused by a defective fuse box with a defective fuel pump relay (R303). There were no warnings, the Ford Expedition just stalled randomly. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11566561 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM:IGNITION:COIL

The contact owns a 2003 Ford Expedition. The contact stated while driving 45 MPH, the engine was misfiring, and the contact smelled a burning odor inside the vehicle. The check engine warning light was illuminated. The contact was able to drive to his residence. The contact stated that the failure had been reoccurring while driving. The vehicle was taken to an independent mechanic on five occasions where it was diagnosed that water was leaking into the ignition coil. The independent mechanic installed silicon around the boot to prevent water from leaking into the coils; however, the failure persisted. The dealer was notified of the failure and informed the contact it was not a known failure. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 196,000.

NHTSA complaint #11491056 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

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 on the panel causing the fault. Replacing the fuse/relay will correct, but for a time. Panel replacement is required. First incident at 165k. Second incident at about 205k. After the last panel replacement, the vehicle continued to stall. Another faulty fuse, for the day running lamps, caused a fault, which melted the housing between the panel and the wiring harness. The screw attachment is "crunchy" because of the melted elements. The smell is noticeable, and the panel requires replacement again. Third incident about 246k. This is a fire hazard. The wiring harness is hot to the touch. Being a KNOWN issue, having discussed on various socials and with ford dealer techs, this should have been recalled ages ago.

NHTSA complaint #11420216 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

MY FUSE AND RELAY PANEL HAS A DEFECT AND NOW MY TRUCK WON'T START.

NHTSA complaint #11330232 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

WAS DRIVING CAR HAD AT LEAST 80 MILES WHEN CAR CUT OFF AT LIGHT IN WOULD NOT COME BACK ON SO I HAD REPLACED FUEL PUMP ONLY TO FIND OUT MY FUSE BOX ISN'T READING MY FUEL RELAYS FROM THE BURNING RELAYS REPLACED.

NHTSA complaint #11327392 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

AS MY FIANCE WAS COMING FROM WORK THE CAR SUDDENLY JUST QUIT ON HIM WHILE DOING 75 MPH. HE GUIDED THE CAR TO THE SIDE OF THE ROAD TO A COMPLETE STOP. HE TRIED TO CRANK THE CAR AGAIN TO ONLY HEARING A BUZZING SOUND. THE FIRST MECHANIC THOUGHT IT WAS THE STARTER SO HE CHANGED IT OUT. THE VEHICLE STILL WOULD NOT START BUT KEPT MAKING THE BUZZING SOUND. THE MECHANIC CAME OUT AGAIN TO SEE WHAT THE ISSUE WAS TOLD ME TO CHANGE MY RELAY SWITCH I DID STILL HASN'T STARTED UP YET. MY VEHICLE HAS BEEN SITTING UP FOR THREE WEEKS NOW.

NHTSA complaint #11321046 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

SUNROOF LEAKS BADLY IT HAS FUSE BOX SHORTING OUT. WHEN IT RAINS MY WINDOWS GO UP DOWN ALONE. ALL LIGHTS SHORTED OUT AND NOTHING WORKING ANY LONGER

NHTSA complaint #11289948 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

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 UNDER THE DASHBOARD, AND PULLED THE RELAY FUSE TO STOP THE BUZZING NOISE. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE WHERE AN INDEPENDENT MECHANIC DIAGNOSED THAT THE FUEL PUMP WAS BURNED. ANOTHER MECHANIC CAME ALSO CAME TO THE CONTACT'S RESIDENCE AND INFORMED HER THAT THE FUSE RELAY AND THE FUSE BOX NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE CONTACT CALLED ANDERSON FORD (3900 CLEMSON BLVD, ANDERSON, SC 29621, (864) 225-4151) AND WAS PROVIDED WITH A QUOTE. THE CONTACT STATED THAT THE FAILURE RECURRED SEVERAL TIMES AND THE FUEL PUMP/FILTER, 402 SENSORS, AND FUSE RELAYS WERE REPLACED NUMEROUS TIMES. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURES. THE FAILURE MILEAGE WAS APPROXIMATELY 236,000. *DT

NHTSA complaint #11266998 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

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 VEHICLE RIGHT AWAY IN THE MIDDLE OF THE STREET

NHTSA complaint #11265641 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

THIS HAS HAPPENED 3 TIMES, FIRST TIME STOPPED AT A RED LIGHT, WHEN FOOT WAS PUT ONTO GAS TO GO VEHICLE INSTANTLY LOST POWER WITH NO STUTTERING OR STALLING AND HAD TO PUT IN PARK TURN KEY OVER TO GO AGAIN. SECOND TIME, GOING 65 DOWN THE HIGHWAY VEHICLE SUDDENLY ACTED LIKE IT LOST POWER AND SPEED DECREASED, PULLED OVER TO SIDE OF HIGHWAY AND PUT IN PARK AND STARTED RIGHT UP. THIRD TIME, GOING 65 DOWN HIGHWAY STARTED TO ACT LIKE IT WAS LOSING POWER AND SHOWED DASH LIGHTS AS IF ALL POWER WAS CUT SHORT AND THEN GAINED ALL POWER BACK WITHOUT HAVING TO PULL OVER AND RESTART.

NHTSA complaint #11253937 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

THE TRUCK WOULD JUST TURN OFF WHILE DRIVING AT 55 OR 60 MILES AN HOUR , NO STEERINGWAS ON HIGHWAY ,NO BRAKES PUT IN NEURAL TO GET TO SIDE OF ROAD WITH CARS ALL AROUND ME .THIS HAS HAPPENED 3 TIMES, THEN IT WOULD NOT START AT ALL WHEN FULLED UP WITH GAS, HAD TO BE TOWED, THEN WHEN I WAS DOWN TO 1/4 TANK ,WOULD NOT TURN OVER, HAD GAS IN IT TOO, BUT WOULD NOT START, HAD TO BE TOWED IN SHOP NOW AGAIN 3RD TIME ,HAD PROBLEMS WITH THE DOOR AGAR GOING OFF HAD SENOR REPLACED STILL COMES UP

NHTSA complaint #11231014 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

THE VEHICLE WAS STATIONARY, WHEN UNLOCKING THE VEHICLE WITH THE KEYLESS ENTRY, IT MOVED THE SIDEVIEW MIRRORS AND NEVER MOVWS BACK. I PUT THE MIRRORS BACK WHERE THEY BELONG AND EVERY FOLLOWING TIME WHEN I UNLOCK THE VEHICLE WITH THE KEY FOB, IT CONTINUES TO DO THE SAME. I BOUGHT THE VEHICLE THIS WAY.

NHTSA complaint #11205517 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

CHECK ENGINE LIGHT CAME ON WHILE DRIVING HOME AND THE ENGINE SHUT DOWN 4 TIMES EACH TIME THE BATTERY WOULD DIE INSTANTLY. WE HAD TO KEEP JUMP STARTING IT TO GET HOME. 2 DAYS LATER THE CHECK ENGINE LIGHT STARTED FLASHING. SCANNED IT CAME BACK P0304 CYLINDER 5 MISFIRE. CHANGED SPARK PLUGS AND COILS. ENGINE LIGHT WENT OFF.RAN OBD2 SCANNER TO DOUBLE CHECK CODES. CODE P2503 CHARGING SYSTEM LOW VOLTAGE . TOOK BATTERY TO ADVANCED AUTO PARTS HAD THEM TEST IT. THE COCA SHOULD HAVE BEEN 650CCA AND WAS AT 11CCA SO BOUGHT A NEW BATTERY. NEXT DAY TOOK SON TO SCHOOL LESS THE 2 MILES RAN FINE ON MY WAY HOME IT DIED 3 TIMES THIS TIME I WOULD WAIT A FEW MINUTES THEN RESTART IT. CHECK ENGINE LIGHT NEVER CAME ON STARTED SEARCHING ON LINE AND AND CALLING MECHANICS. SO BOUGHT NEW ALTERNATOR. STARTED THE TRUCK TO WARM UP AFTER 5 MINUTES IT SHUT DOWN AGAIN WAITED A MINUTE AND STARTED BACK UP DID IT AGAIN. THIS TIME THE BATTERY LIGHT CAME ON. SO AFTER SEARCHING MANY PEOPLE WERE SAYING THE FUSEABLE LINK WAS BAD SO WENT TO FORD HAD ONE ORDERED INSTALLED IT TO DAY. BATTERY LIGHT STILL ON STARTED IT RAN FOR 5 MIN AND DIED AGAIN. SO NOW I BOUGHT NEW SPARK PLUGS, COIL PACKS, BATTERY,ALTERNATOR, FUSIBLE LIN. NOW OBDII CODE B1676- BATTERY PACK VOLTAGE OUT OF RANGE TESTER BATTERY FULLY CHARGED TESTED ALTERNATOR IT'S AT 14.7 WHICH IT SUPPOSED TO BE.

NHTSA complaint #11156464 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

"TAKATA RECALL" I WAS DRIVING DOWN THE INTERSTATE AT 65 MPH WHEN MY TRUCK JUST CUT OFF, HAD TO HAVE IT TOWED IN TO THE SHOP. HAD FUEL PUMP REPLACE, 2 WEEKS LATER SAME PROBLEM.HAD TO HAVE IT TOWED AGAIN FUSE WAS REPLACE. 3 WEEKS LATER I'M NOW HAVING TO HAVE THE FUSE BOX REPLACE. FORD MOTOR COMPANY DON'T THINK THIS SHOULD BE A RECALL ISSUE. THEY JUST CAME OUT WITH THE LATEST UPDATE FUSE BOX IN 2017.

NHTSA complaint #11145153 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. OCCASIONALLY, THE VEHICLE WOULD NOT IMMEDIATELY START DUE TO A FAULTY FUSE BOX. THE FUSE BOX WAS REPLACED BY THE OWNER AND THE FAILURE WAS REMEDIED. EVENTUALLY, WHILE DRIVING, THE VEHICLE SHUT COMPLETELY OFF AND COULD NOT BE RESTARTED. THE CAUSE OF THE FAILURE WAS NOT DETERMINED. THE MANUFACTURER AND LOCAL DEALER (VISTA FORD IN WOODLAND HILLS, CA) WERE NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 160,000.

NHTSA complaint #11032102 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM:WIRING:FUSES AND CIRCUIT BREAKERS

TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. WHILE DRIVING 75 MPH, THE ENGINE STALLED WITHOUT WARNING. THE CONTACT PULLED THE VEHICLE OVER TO THE SIDE OF THE ROAD. THE CONTACT RESTARTED THE VEHICLE AFTER A FEW MINUTES AND IT RETURNED TO NORMAL. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE MAIN FUSE BLOCK NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 120,000.

NHTSA complaint #10972072 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

THE ENGINE STOPS RUNNING WITHOUT WARNING. I WAS DRIVING ON THE FREEWAY AT 70+ IN HEAVY TRAFFIC. ALL OF A SUDDEN THE ENGINE SHUTS DOWN. I PUT THE VEHICLE IN NEUTRAL AND ENGAGED THE FLASHERS. I TRIED TO RESTART THE VEHICLE WHILE MANEUVERING TO THE SIDE OF THE ROAD AVOIDING MULTIPLE CLOSE CALLS. ONCE STOPPED, I PUT THE VEHICLE IN PARK AND TRIED TO RESTART. AFTER A COUPLE OF MINUTES THE CAR RESTARTED. I TOOK THE VEHICLE TO THE AUTOZONE TO SEE IF THERE WERE ANY FAULT CODES. ONE CODE INDICATED THE FUEL PUMP WAS AN ISSUE. THEY ADVISED ME THAT THEY HAVE SEEN THIS BEFORE AND DIRECTED ME TO GO TO THE DEALERSHIP. THE DEALERSHIP COULD NOT LOOK AT IT IMMEDIATELY SO I HAD MY SON PICK ME UP WITH ANOTHER VEHICLE. THE FOLLOWING DAY THEY RAN A DIAGNOSTICS ($95 FEE THAT WAS TOTALLY UNNECESSARY SINCE THIS IS A WELL KNOW FAILURE) ON THE CAR AND INDICATED THAT IT WAS THE FAULTY CENTRAL JUNCTION FUSE BOX LOCATED INSIDE THE VEHICLE ON THE PASSENGER SIDE NEAR THE FEET. PN 3L1Z-14-A068-AA-A11 @$517. INSTALLATION COSTS $215. WHEN I GOT HOME I SEARCHED THE WEB AND FOUND THAT THIS IS A COMMON FAILURE FOR THIS VEHICLE. THE BLOGS AND COMMENTS ARE OF MULTIPLE NEAR MISSED COLLISIONS AMONG OTHER THINGS. THIS PART FAILURE HAPPENED ON VEHICLES THAT WERE LESS THAN ONE YEAR OLD. IT CAN HAPPEN AT ANYTIME TO ANY 2003 FORD EXPEDITION. THIS PART WAS REDESIGNED FOR LATER FORD EXPEDITIONS BECAUSE FORD KNEW OF THE PROBLEM. IF YOU CONTACT ANY PICK AND PULL SALVAGE YARD YOU WILL FIND THAT ALL OF THESE CENTRAL JUNCTION BOX (FUSE BOXES) ARE NOT AVAILABLE SINCE EVERYONE TRIES TO REPLACE THEM BY THEMSELVES BECAUSE OF THE HIGH COSTS. ALSO, THERE ARE MULTIPLE COMPANIES THAT WILL REPAIR THE FAULTY PART WITH A RE-ENGINEERED CIRCUIT. FORD HAS SINCE MADE A NEW PART WITH A DIFFERENT PN / MODEL NUMBER. THIS SHOULD HAVE BEEN A SAFETY RECALL IN THE FIRST YEAR. IT IS VERY DANGEROUS AND LIVES ARE AT STAKE.

NHTSA complaint #10972088 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

THE COMPLAINT IS IN REGARDS TO THE CIRCUIT BOARD. THE CAR MAY STOP AT RANDOM TIMES. WE HAVE BEEN IN THE VEHICLE GOING 35 MILES AN HOUR AND THE CAR SUDDENLY STOPPED. IT APPEARED THAT IT WAS A FUSE THAT BURNED OUT.... THAT SEEMED TO FIX THE PROBLEM TEMPORARILY BUT THEN IT HAPPENED AGAIN AT A HIGHER SPEED. LUCKILY THERE WERE NO INJURIES. FORD SEEMS TO BE AWARE OF THIS PROBLEM AND SHOULD ISSUE A RECALL. I WAS TOLD FROM DEALERSHIP THAT WHAT HAPPENS IS THAT THE WATER RUNS DOWN THE SIDE AND GETS INTO THE FUSE BOX. THIS IS CAUSING A SHORT. SO, THE REASON IT WORKED THE FIRST TIME WAS BECAUSE WE ADDED A NEW FUSE. BUT, THE SECOND TIME THAT IT STOPPED IT BURNED THE FUSE BOX. NOW, I HAD TO TOW THE VEHICLE AND REPLACE THE PART COSTING OVER $500. AFTER RESEARCHING THIS ISSUE IT APPEARS TO BE A NUMBER OF COMPLAINS WITH THE SAME ISSUE. FORD SHOULD ISSUE RECALL.

NHTSA complaint #10947659 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

2003 FOR EXPEDITION NOT RUNNING PROPERLY SHUTTING DOWN WHILE DRIVING PASSENGER WINDOW STUCK BRAKES NOT WORKING PROPERLY WHEN VEHICLE SHUTS DOWN.

NHTSA complaint #10905972 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

OPEN DOOR SOUND INDICATOR WHILE ENGINE IS RUNNING--VEHICLE STOPPED TO LET PASSENGER OUT. WHEN ANY DOOR IS OPENED, THE OPEN-DOOR HIGH PITCHED STEADY-HUM SOUND COMES ON, WHICH IS NORMAL, HOWEVER, THE HUM WILL NOT SHUT OFF. IT CONTINUES LOUDLY FOR 8-10 MINUTES AND THEN REDUCES TO A FAINT HUM UNDER THE DASH. THE SOUND(S) CONTINUE EVEN AFTER THE SUV IS TURNED OFF, PUT IN PARK, AND THE KEY IS REMOVED. WE ARE THE ORIGINAL OWNERS OF THE 2003 EDDIE BAUER EXPEDITION AND IT'S OTHERWISE IN EXCELLENT SHAPE WITH JUST 57,000 MILES. THIS PROBLEM HAS RECENTLY BEEN VERIFIED BY A LOCAL FORD/KIA REPAIR SHOP WHOSE MECHANIC SCRATCHED HIS HEAD IN CONFUSION; HOWEVER, THEY WANT TO CHARGE US TO TEAR THE DASH APART TO ATTEMPT TO FIGURE OUT WHY THIS IS HAPPENING. THEY CAN'T TURN THE INDICATOR SPEAKER OFF ALTOGETHER. WE WANT TO KNOW WHAT FORD KNOWS ABOUT THE PROBLEM; MAINLY, WHAT IS CAUSING THE PROBLEM. CAN IF BE FIXED VIA A SIMPLER SOLUTION (MAYBE A SIMPLE FUSE OR WIRING?), IS THIS IS A POSSIBLE FUTURE FIRE DANGER, AND HAVE ANY OTHERS HAVE EXPERIENCED THIS UNUSUAL OCCURRENCE.

NHTSA complaint #10904766 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

VEHICLE STALL WHILE DRIVING FREEWAY.MY WIFE FIRST THEN I EXPERIENCE MYSELF STALL VEHICLE ON FAST LANE VERY DANGEROUS.VEHICLE JUST SHUT OFF CANNOT STEER THE WHEEL LUCKY ENOUGH TO GLIDE TO SAFETY SIDE.FUSE BOX BURNING THE FUEL PUMP RELAY LOTS OF COMPLAINT IN INTERNET HOW MANY LIVES TO WASTE BEFORE ANYONE ACT ON IT.

NHTSA complaint #10899683 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

FUSE RELAYS KEEP BURNING OUT! I HAVE BROUGHT OVER 10 RELAYS IN 2 WEEEKS. I HAVE DONE MY RESEARCH AND THIS IS A COMMON PROBLEM WITH ALL 2003 FORDS AND IS VERY EXSPENSIVE TO FIX. I WAS SHOCKED TO FIND THAT IT HAS NOT BEEN RECALLED! THERE ARE VIDEOS ON YOU TUBE TO PROVE THAT ALL OF THESE TRUCKS HAVE THIS PROBLEM. I WAS TOLD I HAD TO REPLACE THE ENTIRE FUSE BOX BUT EVENTUALLY I WILL HAVE THE SAME PROBLEM OUT OF THAT FUSE BOX BECAUSE THUS IS A DEFECT IN ALL 2003 FORD EXPEDITIONS. THE CAR CUTS OFF WHILE DRIVING AND HAS ALMOST CAUSED ME TO BE IN 2 VERY DANGEROUS CAR ACCIDENTS! IT HAS STOPPED ON ME ON THE HIGHWAY AND STREET! WHEN I SAW THAT THIS IS A VERY COMMON PROBLEM WITH THE FUEL EMMISION RELAYS AND THE FUSE BOX I DECIDED TO FILE THIS COMPLAINT IN ORDER TO GET THIS RECALLED!

NHTSA complaint #10893675 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

CREDIT ACCEPTANCE CORPORATION 25505 W TWELVE MILE ROAD P.O. BOX 513 SOUTHFIELD,MI 48037 1-800-634-1506 INSTALLED A GPS DEVICE WHEN I PURCHSED THIS VEHICLE USED. I HAD IT REPLACED ONCE BY THE DEALER BECAUSE IT NOT ONLY DISABLED THE VEHICLE WHEN NOT MOVING,BUT IT CREATED A DANGEROUS PROBLEM WHEN I WAS DRIVING CUTTING THE VEHICLES POWER OFF. CREDIT ACCEPTANCE DENIES THEY HAD ANYTHING TO DO WITH IT . THIS STARTED TO HAPPEN WHEN I FELL BEHIND ON PAYMENTS.

NHTSA complaint #10862353 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

2003 FORD EXPEDITION XLT 4.6 FUSE BOX FAIL FUSE PUMP RELAY BURN, ON 01/14/2015 WHILE THE TRUCK WAS IN MOTION ON THE 5FWY GOING 70 MILES THE TRUCK SHOT OFF LUCKILY MY WIFE WAS ABLE TO PULL TO THE EMERGENCY LANE WITH OUT HITTING ANY OTHER CAR ON THE FWY. I REPLACE THE FUSE BOX FOR ANOTHER USED ONE THAT I BOUGHT AT A JUNK YARD,THE TRUCK RUN GOT FOR A YEAR , ON 01/05/2016 IT HAPPEN AGAIN WHILE DRIVING THE TRUCK ON THE 118 FWY GOING 75 THE TRUCK SHUT OFF AGAIN SAME PROBLEM FUSE BOX , FUSE RELAY IS BURN IN HAVE POST IT 3 VIDEOS ON YOU TUBE LOOK FOR 2003 FORD EXPEDITION XLT 4.6 CRANKS WON'T START IS UNDER JAVALOSREALESTATE

NHTSA complaint #10823522 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

THIS SPECIFIC MAKE AND MODEL YEAR HAS A DEFECTIVE FUSE BOX WHICH CASE A FUSE CALLED A PCM RELAY TO MELT AND CAUSES THE VEHICLE TO STALL AND NOT START. THE FUSE BOX WILL BUZZ CONTINUOUSLY BUT THE VEHICLE DOES NOT START. YOU CAN REPLACE THE RELAY WHICH IS ABOUT $15 BUT THIS IS MORE THAN LIKELY TEMPORARY AND IT WILL MELT AND CAUSE THE VEHICLE TO STALL. THE ONLY REMEDY IS TO REPLACE THE FUSE PANEL ENTIRELY WHICH BRINGS ME HERE, THE PANEL ALONE IS $500 AND THAT DOESN'T INCLUDE LABOR AND TAXES. FORD IS WELL AWARE OF THIS ISSUE AS THERE ARE THOUSANDS OF FORUMS ONLINE THAT REFER TO THIS SPECIFIC MANUFACTURER DEFECT. I'VE SPENT THOUSANDS REPLACING PARTS THAT DID NOT NEED REPAIR. FORD NEEDS TO FOOT THE BILL FOR THIS DEFECT BECAUSE IT'S A MANUFACTURE'S DEFECT NOT A CONSUMER (WEAR AND TEAR) ISSUE.

NHTSA complaint #10788628 — an unverified report by a vehicle owner.