2003 Ford Expedition engine problems

ENGINE

The contact owns a 2003 Ford Expedition. The contact stated that while operating the vehicle, the check engine warning light illuminated and the front end of the vehicle was shaking abnormally, vibrating, and the vehicle stalled. The contact stated that while driving approximately 50 MPH, there was a loud booming sound coming from the engine compartment and the vehicle stalled. The vehicle was towed to the local mechanic who diagnosed that the spark plug had ejected from the engine cylinder. The engine cylinder was rethreaded, and the spark plug was installed; however, the failure reoccurred. The vehicle was not repaired. The manufacturer and local dealer were notified of the failure, but no assistance was offered. The failure mileage was 230,000.

NHTSA complaint #11642012 — an unverified report by a vehicle owner.

ENGINE

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.

ENGINE

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.

ENGINE

This vehicle has a faulty engine. The aluminum that Ford used to create the top end is too thin to support the pressure of the engine. As a result spark plugs explode from the engine at random with no warning. This has happened 5 times even after replacing all spark plugs, numerous coils and having kits installed by a mechanic sold by Ford to address the issue. $475 per kit from Ford. This is an enormous safety issue. The last one that blew out was on the highway with my two toddlers in the car.

NHTSA complaint #11450943 — an unverified report by a vehicle owner.

ENGINE

THIS IS THE 2ND TIME IT HAPPENED TO MY 2003 FORD EXPEDITION. WHILE DRIVING HEARD A LOUD POPPING NOISE, FOLLOWED BY CONTINUOUS POPPING LOUD POPPING NOISE LIKE A BROKEN EXHAUST MUFFLER, SOUNDED LIKE A MOTORCYCLE. AFTER INVESTIGATING, FOUND OUT THAT THE #3 SPARK PLUG POPPED OUT (EJECTED) OF THE HEAD CYLINDER, BROKE THE SPARK IGNITION COIL. WHEN THIS HAPPENED, I SMELLED FUEL, AND SAW SMOKE COMING FROM UNDER THE HOOD, SO I DID NOT DRIVE THE CAR AND TOWED THE CAR HOME. I HAD TO REPLACE THE IGNITION COIL AND SPARK PLUG AND REINSTALLED THE SPARK PLUG BUT IT SEEMED TO BE STILL LOOSE, SO I TOOK IT OUT AND PUT THREAD LOCK AND REINSTALLED IT BUT DID NOT TIGHTEN IT TO THE MAX AND DID NOT START THE CAR TILL AFTER 24 HOURS SO THE THREAD LOCK WILL HOLD IT IN PLACE. YESTERDAY THE SAME THING HAPPENED TO #8 SPARK PLUG, IT ALSO BROKE THE COIL, AND WHEN I TRIED TO INSTALL THE NEW SPARK PLUG, FOUND OUT THAT THE THREADS ON THE HEAD CYLINDER WILL NOT GRAB THE SPARK PLUG, AND NOW I AM STUCK WITHOUT A CAR. WHEN I ASKED AROUND, PEOPLE SAID THIS IS A COMMON PROBLEM ON THE FORD EXPEDTION. THIS IS DANGEROUS AND COULD KILL SOMEONE IF THE ENGINE CAUGHT ON FIRE, BECAUSE I SMELLED GAS AND SMOKE. IF THIS IS A COMMON DANGEROUS PROBLEM ON THE FORD EXPEDTION, HOW COME THERE IS NO RECALL FOR IT???? ARE WE WAITING FOR SOMEONE TO DIE DUE TO ENGINE / VEHICLE FIRE TO DO SOMETHING ABOUT IT? PLEASE LOOK INTO THIS ISSUE ASAP AND LET FORD FIX THIS DANGEROUS PROBLEM. SPARK PLUGS EJECTING OUT LIKE THIS? I NOTICED THAT THERE ARE ONLY 4 THREADS ON THE HEAD CYLINDER HOLDING THE PARK PLUG, BUT THE SPARK PLUG HAS 10 OR 11 THREADS AND OFCOURSE ONLY 4 OF THOSE THREADS ARE BEING HELD BY THE HEAD CYLINDER. THIS IS A DANGEROUS PROBLEM WAITING TO HURT OR KILL SOMEONE, PLEASE ASK FORD TO FIX THIS BIG PROBLEM, THANK YOU....

NHTSA complaint #11447639 — an unverified report by a vehicle owner.

ENGINE

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.

ENGINE

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.

ENGINE

TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. WHEN THE CONTACT STARTED THE VEHICLE, THE ENGINE MADE AN ABNORMAL POPPING SOUND. THE SOUND WAS A DISTRACTION TO THE CONTACT'S DRIVING. THE VEHICLE SHOOK FROM THE BEGINNING OF THE RIDE TO THE END AND THE MAINTENANCE REQUIRED INDICATOR ILLUMINATED. THE DEALER AND MANUFACTURER WERE NOT CONTACTED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE MILEAGE WAS 150,000.

NHTSA complaint #11221525 — an unverified report by a vehicle owner.

ENGINE

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.

ENGINE

MY MOMS 2003 FORD EXPIATION HAD IS SPRAK PLUG BLOW OUT I HAVE LOOKED ALL OVER THE INTERNET AND THINK IS SHOULD HAVE A RECALL BECAUSE IT IS A VERY COMMON PROBLEM

NHTSA complaint #11002486 — an unverified report by a vehicle owner.

ENGINE

ENGINE SUDDENLY FAILED WHILE DRIVING ALONG A MODEST SPEED SURFACE STREET WHILE ACCELERATING AWAY FROM A TRAFFIC LIGHT. SUDDENTY THERE WAS A LOUD REPEATED POPPLING SOUND ALONG WITH ROUGH ENGINE PERFORMANCE. I PULLED OVER RIGHT AWAY TO A CONVENIENT SPOT. INITIAL INSPECTION (HAVE NOT HAD IT TOWED OR REPAIRED YET, IT JUST HAPPENED TODAY) APPEARS TO BE A PLUG BLOWN OUT OF THE HEAD. APPARENTLY THIS IS A COMMON PROBLEM. THIS SHOULD BE CONSIDERED EXTREMELY DANGEROUS BECAUSE THE OPEN PLUG HOLE WILL ALLOW EXPLOSIVE GAS VAPORS INTO THE ENGINE COMPARTMENT WHERE THE DISLOCATED COIL IS STILL OPERATING.

NHTSA complaint #10984605 — an unverified report by a vehicle owner.

ENGINE

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.

ENGINE

SPARK PLUS BLOWN OUT OF THE ENGINE WHICH CAN CAUSE FIRE.

NHTSA complaint #10936298 — an unverified report by a vehicle owner.

ENGINE

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 AND TALKING WITH OTHER FORMER AND CURRENT MECHANICS, IT IS DEFINITELY A FORD DESIGN FLAW AND FORD SHOULD BE HELD LIABLE FOR REPAIR/REPLACEMENT, REIMBURSEMENT AND LIFETIME WARRANTY OR UNTIL THE VEHICLE IS JUNKED.

NHTSA complaint #10936100 — an unverified report by a vehicle owner.

ENGINE

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.

ENGINE

THE VEHICLE WILL RANDOMLY SHUT OFF AT ANY SPEED, UNDER ANY CONDITION. ENGINE DIES UNEXPECTEDLY AT HIGHWAY SPEEDS CREATING A PANIC TO GET OUT OF THE ROADWAY. POWER TO STEERING AND BRAKES ARE GONE WHEN THE ENGINE DIES. VEHICLE WILL RESTART AFTER A COUPLE MINUTES. THE FAULTY PART IS THE FUEL PUMP RELAY. IT IS INTEGRAL TO THE FUSE BOX AND CANNOT BE CHANGED WITHOUT CHANGING THE ENTIRE FUSE BOX. THE FUSE BOX IS ONLY AVAILABLE FROM A FORD DEALER FOR $485.20 PARTS ONLY.

NHTSA complaint #10898008 — an unverified report by a vehicle owner.

ENGINE

IN THE LAST MONTH AND A HALF I HAVE BEEN DRIVING DOWN THE FREEWAY AT 65MPH AND BLOWN 2 PLUGS OUT OF THE ENGIENE. THIS IS GETTING A LITTLE COSTLY.

NHTSA complaint #10893618 — an unverified report by a vehicle owner.

ENGINE

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.

NHTSA complaint #10887572 — an unverified report by a vehicle owner.

ENGINE

SPARK PLUGS BLOW OUT OF CYLINDER HEAD AT HIGHWAY SPEED.

NHTSA complaint #10884705 — an unverified report by a vehicle owner.

ENGINE

SPARK PLUG EJECTION! I JUST EXPERIENCED A PROBLEM WITH MY FORD TRITON MOTOR WHERE THE SPARK PLUG WILL EJECT FROM THE ALUMINUM CYLINDER HEAD. I HAVE A 2003 FORD EXPEDITION THAT EXPERIENCED THIS ON SATURDAY. I WAS DRIVING HOME FROM WAL-MART WITH MY FAMILY IN THE TRUCK, WE TURNED A CORNER AND MY HEART STOPPED! IT SOUNDED LIKE I WAS INVOLVED IN MACHINE GUN FIRE. I PULLED OVER IMMEDIATELY AND MY LOOKED. COULDN'T INITIALLY SEE ANYTHING. MY HUSBAND CHECKED UNDER THE TRUCK THINKING IT WAS EXHAUST RELATED. WE WERE LUCKILY 2 BLOCKS FROM HOME, SO WE WERE ABLE TO GET IT HOME AND INTO THE DRIVEWAY. MY HUSBAND BEGAN TRYING TO DIAGNOSE THE PROBLEM AND I TOOK TO THE INTERNET. HE TOOK THE ENGINE COVER OFF AND DISCOVERED THE SPARK PLUG MISSING AND THE COIL WIRE BROKEN OFF AND SPARKING. LONG STORY SHORT IT SEEMS THAT WE HAVE EXPERIENCED THE SITUATION WHERE THE CYLINDER HEAD HAS STRIPPED ON THE ONE SPARK PLUG. WE HAVE BEGUN LOOKING INTO WAYS TO FIX THE SITUATION, BUT IT SEEMS FORD HAS NOT DEEMED THIS TO BE AN ISSUE. TRULY DON'T UNDERSTAND HOW SO MANY PEOPLE CAN REPORT THE EXACT SAME HAPPENINGS AND NO ONE WILL DO ANYTHING ABOUT IT..... MERRY STINKIN CHRISTMAS!!! WE ARE REACHING OUT TO OUR LOCAL FORD DEALER BUT AM PRETTY SURE THEY ARE GOING TO TELL US WE ARE CRAP OUT OF LUCK AND WILL FALL ON US TO REPAIR IF WE CHOOSE.

NHTSA complaint #10810023 — an unverified report by a vehicle owner.

ENGINE

WE WERE DRIVING WITH THE KIDS HEADED HOME, GOING ABOUT 45MPH AND LOUD NOISE AND SMELL OF FUEL, WE PULL OVER LIFTED THE HOOD AND SAW MY COIL PACK BUSTED OFF, WE DROVE THE REST WAY HOME TO ARK IT, AND LOOKED AGAIN. THE SPARK PLUG ARCHED INSIDE THE HEAD AND BUSTED THE COIL PACK BOLT AND ALL. SHAME THAT WE TRIED AN INSERT TO REPAIR IT AND DOESNT WORK. I HAVE BEEN STRESSING THIS CONSIDERING IM A SINGLE MOM OF TWO THAT HAVE DISABILITIES AND WE HAVE THESE APPOINTMENTS LEFT AND RIGHT AND ITS HARD WALKING ACROSS TOWN ALL THE TIME. THIS PROBLEM NEEDS FIXED BY FORD. I RESEARCHED AND ITS A KNOWN PROBLEM CAUSE THE CHEAP ALUMINUM HEADS. WE REALLY NEED OUR VEHICLE...

NHTSA complaint #10715535 — an unverified report by a vehicle owner.

ENGINE

TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. WHILE DRIVING AT 60 MPH, THE ENGINE STALLED WITHOUT WARNING. THE VEHICLE FAILED TO RESTART. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE WHERE AN INDEPENDENT MECHANIC DIAGNOSED THAT THE FUSE BOX FAILED AND NEEDED TO BE REPAIRED. THE VEHICLE WAS REPAIRED, BUT THE FAILURE RECURRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 130,000.

NHTSA complaint #10700647 — an unverified report by a vehicle owner.

ENGINE

I WAS DRIVING AT 45MPH AND A SPARK PLUG BLEW OUT ON MY 2003 FORD EXPEDITION XLT WITH THE 5.4L V8.

NHTSA complaint #10692418 — an unverified report by a vehicle owner.

ENGINE

TRANSMISSION SLIPPING @ 30-50 MPH.

NHTSA complaint #10678912 — an unverified report by a vehicle owner.

ENGINE

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 MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VIN WAS UNAVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 200,000.

NHTSA complaint #10664013 — an unverified report by a vehicle owner.