2003 Ford Expedition fuel system problems

FUEL/PROPULSION SYSTEM

Fuel leaking from emissions vents on fuel tank. Non reparable part.

NHTSA complaint #11587033 — an unverified report by a vehicle owner.

FUEL/PROPULSION 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.

FUEL/PROPULSION SYSTEM

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.

FUEL/PROPULSION SYSTEM

THIS SUV STALLED ON THE HIGHWAY WHILE DRIVING IN TRAFFIC. IT WAS CAUSED BY A FAULT IN THE FUEL PUMP OR FUEL PUMP RELAY. PLEASE RECALL THIS VEHICLE.

NHTSA complaint #11388658 — an unverified report by a vehicle owner.

FUEL/PROPULSION 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.

FUEL/PROPULSION 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.

FUEL/PROPULSION SYSTEM

FUEL TANK CRACK AND LEAKS

NHTSA complaint #11204363 — an unverified report by a vehicle owner.

FUEL/PROPULSION 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.

FUEL/PROPULSION SYSTEM

TAKE A LOOK: HTTP://SPARKYS-ANSWERS.COM/2011/03/2003-FORD-EXPEDITION-NO-RUN-NO-FUEL.HTML MY FATHER'S CAR IS REGISTERING A P0231 CODE. MY MECHANIC WAS THINKING IT WAS THE CHARGING SYSTEM. (NO CODE WAS REGISTERED FOR A PERIOD OF 2 MONTHS.) TODAY, IT PULLED A P0231 CODE. MUCH TO MY SURPRISE THERE SEEMS TO BE FACTUAL THINGS DOCUMENTED ALL OVER THE INTERNET. I AM TAKING THE CAR TO CHEROKEE AUTO TECH. VINCENT NGUYEN IS A REGISTER SAE TECH WITH A MECHANICAL ENGINERING DEGREE. HE ALSO DISCOVERED THE IGNITION CYLINDER ON MY 2003 PONTIAC GRAND AM BEFORE IT WAS AN ISSUE... THIS CAR IS NOT ANY DIFFERENT. DURING HIGH PERIODS OF DRIVING, THE SOLDER "HEATS UP" AND STALLS THE GAS. WHEN THE CAR COOLS OFF, THE SOLDER SOLIDIFIES AND CURRENT CAPACITY TO THE FUEL PUMP RESUMES... THE FUSE IS NOT PROTECTING THE TRACE. YOU HAVE COMPLAINTS ON YOUR WEBSITE ON THIS MODEL ALSO. EVEN YOUTUBE VIDEOS.... HTTPS://WWW.YOUTUBE.COM/WATCH?V=1BRGVBETKEK IF IT IS TRUE WITH MY MODEL, I WILL GIVE YOU FACTUAL EVIDENCE THAT YOU NEED.

NHTSA complaint #11003194 — an unverified report by a vehicle owner.

FUEL/PROPULSION 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.

FUEL/PROPULSION SYSTEM

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.

FUEL/PROPULSION 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.

FUEL/PROPULSION SYSTEM

I WAS HAVING PROBLEM MY CAR OF IT LOSING POWER UNTIL ONE DAY IT JUST LOST POWER COMPLETELY AT A STOP LIGHT I WAS LUCKY I WAS WAITING FOR THE LIGHT TO TURN GREEN SO I QUICKLY PUT ON MY EMERGENCY BLINKERS AND I WAS LUCKILY NO ONE HIT ME FROM BEHIND THIS WAS AROUND 8:30 P.M. MY CAR HAD TO BE TOWED TO THE MECHANIC WELL IT WAS AT THE MECHANIC I WENT AHEAD AND GOOGLE WHAT HAPPENED WITH MY CAR AND I CAME ACROSS A WHOLE BUNCH OF COMPLAINTS FROM THE CARS DOING THE SAME THING MY CAR WAS DOING BUT I FOUND OUT A LOT OF PEOPLE ENDED UP WASTING A LOT OF MONEY TO FIGURE OUT AT THE END WHAT THE PROBLEM WAS IF YOU'RE TRAVELING ON THE FREEWAY AND THIS HAPPENS YOU CAN BE IN SERIOUS TROUBLE I THINK THIS SHOULD BE A RECALL AND INVESTIGATE ON THIS PART

NHTSA complaint #10853985 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

THE TRUCK JUST QUITS LIKE RUNNING OUT OF GAS STALL NO STEERING NOW BRAKING VERY UNSAFE IT IS BECAUSE THE FUEL PUMP RELAY IS BUILT INTO THE FUSE JUNCTION BOX NOT SERVICEABLE AND IF YOU HAVE A MOON ROOF THE DRAIN RUNS DOWN THAT SIDE THE WATER DRIPS ON FUSE BOX SHORTS OUT THE RELAY AND OFF YOUR TRUCK GOES THEY ONLY DID IT 2 YEARS AND THEY OBVIOUSLY NOW ABOUT IT AND CHANGED IT AND THE NEW PART DIFFERENT NUMBER

NHTSA complaint #10823955 — an unverified report by a vehicle owner.

FUEL/PROPULSION 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.

FUEL/PROPULSION SYSTEM

CARS STALLED WHILE TURNING LEFT AGAINST TRAFFIC. WOULD NOT START RIGHT AWAY. HAD TO WAIT A FEW MINUTES TRYING TO START IT AND FINALLY IT STARTED AND I COULD CLEAR THE INTERSECTION. VERY DANGEROUS AND FORTUNATE THAT ONCOMING TRAFFIC WAS ABLE TO STOP. HAVE CLEANED THROTTLE BODY, AIC BUT FUSE ON FUSE BOX IS MELTED CAUSING INTERMITTENT OPERATION. STARTED OUT ONCE A MONTH AND NOW FREQUENTLY TO INCLUDE THIS LAST ONE IN TRAFFIC.

NHTSA complaint #10779619 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

TRUCK SHUT OFF AT 60MPH TOWING A CAMPER BECAUSE MY FUEL PUMP RELAY BLEW BECAUSE OF A DEFECT IN THE FUSE BOX!! ALMOST KILLED US........ NOT HAPPY AT ALL. I'VE SPOKEN TO MANY MECHANICS AND BEEN ON MANY FORUMS AND THIS SEEMS TO BE A WIDE SPREAD AND DANGEROUS ISSUE FORD SHOULD TAKE CARE OF. SPOKE WITH THE LOCAL FORD PARTS DEPARTMENT AND THEY ARE AWARE OF THE ISSUE. THIS IS NOT A CHEAP PART BY ANY MEANS, BUT ON TOP OF THAT IT ALMOST KILLED MY WIFE AND FAMILY! PLEASE DO SOMETHING ABOUT THIS DEFECT. I CAN SEND YOU PICTURES OF THE FUSE BOX BOARD SO YOU CAN SEE THE BURNS.

NHTSA complaint #10732953 — an unverified report by a vehicle owner.

FUEL SYSTEM, GASOLINE

WHEN DRIVING ON I-10 WEST AT 65 MPH MY FORD EXPEDITION SHUT DOWN FOR NO APPARENT REASON. I WAS IN THE FAR LEFT LANE AND DON'T LIKE TO PARK IN THE INTERIOR LANES SO I PLACED MY HAZARDS ON AND DRIFTED TO THE FAR RIGHT LANE. IT WAS HARD TO DO BECAUSE WHEN MY VEHICLE WENT DEAD THE PWR STEERING AND BRAKES BECAME HARD TO USE. ONCE I GOT TO A SAFE AREA, I TRIED TO START MY VEHICLE AGAIN.....WITHOUT SUCCESS. I CONTACTED MY INSURANCE COMPANY FOR ROADSIDE ASSISTANCE AND THEY PICKED MY VEHICLE UP AND TOWED IT TO MY RESIDENCE. THE NEXT DAY I STARTED THE VEHICLE AND WENT TO A DOCTORS APPT. ON THE WAY BACK FROM THE APPOINTMENT I WAS IN THE LEFT TURNING LANE AND THE VEHICLE DIED AGAIN. THIS TIME I HAD SOMEONE BEHIND ME THAT ALMOST REAR ENDED ME. AT THIS TIME I TOOK THE VEHICLE TO THE FORD DEALERSHIP (SHAMALEY FORD). THEY INDICATED THAT THE FUEL PUMP WAS DEFECTIVE. I RETRIEVED MY VEHICLE AND REPLACED THE FUEL PUMP. WHEN DRIVING TO ENSURE THAT MY VEHICLE WAS OPERATIONAL IT DIED AGAIN ON ME IN THE MIDDLE OF A ONE LANE STREET WHICH NEARLY CAUSED AN ACCIDENT. SOMEONE HELPED ME PUSH MY VEHICLE AROUND THE CORNER SO THAT TRAFFIC COULD PROCEED. I WAITED ABOUT 10 MINUTES AND TRIED TO START ME VEHICLE AND IT STARTED. I HURRIED AND PLACED IT IN MY PARKING SPACE. AS I HAVE READ, THIS IS A RECURRING ISSUE WITH FORD EXPEDITIONS AND LUCKILY THIS HASN'T CAUSED A MAJOR ACCIDENT OR RESULTED IN DEATH. I DID NOT STATE THIS BUT I CONNECTED MY CODE READER AND THERE WAS NO INDICATION OF ANYTHING WRONG. AS STATED PREVIOUSLY, I TOOK MY CAR TO THE DEALER AND THEY MISDIAGNOSED THE PROBLEM. COULD YOU ADDRESS THE ISSUE?

NHTSA complaint #10641026 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. WHILE THE VEHICLE WAS UNDERGOING ROUTINE MAINTENANCE BY AN INDEPENDENT MECHANIC, IT WAS DISCOVERED THAT THE MEDAL STRAP WAS MISSING THAT SECURES THE FUEL TANK. THE DEALER STATED THAT THE MISSING PART WAS NO LONGER MANUFACTURED. THE MANUFACTURER WAS NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 80,000.

NHTSA complaint #10621502 — an unverified report by a vehicle owner.

FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. WHILE DRIVING 70 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHERE THE FUEL PUMP WAS REPLACED. THE FAILURE RECURRED AND THE VEHICLE WAS NOT REPAIRED AGAIN. THE MANUFACTURER WAS NOT NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 220,000.

NHTSA complaint #10619193 — an unverified report by a vehicle owner.

FUEL SYSTEM, GASOLINE

THE ENGINE WOULD RANDOMLY SHUT OFF WITH NO WARNING. SOMETIMES THE ENGINE WOULD SHUT OFF WHILE DRIVING, OTHER TIMES WOULD SHUT OFF AT A STOP LIGHT. THE ISSUE HAPPENED 10 TIMES OVER A 3 DAY PERIOD. I WAS LUCKY TO NOT CRASH AS THE ENGINE DIED ONCE WHILE MAKING A TURN ON A BUSY ROAD. ONCE IT DIED, SO DID THE POWER STEERING AND BRAKES - VERY SCARY. THERE WERE NO ENGINE CODES THAT CAME UP AND NO INDICATION ANYTHING WAS WRONG, THE ENGINE WOULD SIMPLY SHUT OFF. WHILE DIAGNOSING THE ISSUE I DID SOME INTERNET RESEARCH THAT INDICATED IT COULD BE THE FUEL PUMP RELAY ISSUE. THE FUEL PUMP RELAY IS A NON-SERVICEABLE RELAY THAT IS SOLDERED TO THE MAIN FUSE BOX CIRCUIT BOARD. I REMOVED THE FUSE BOX AND DISASSEMBLED IT REVEALING THE FUEL PUMP RELAY WAS GETTING HOT AND HAD MELTED THE SOLDER ON THE BOARD. WHEN THE RELAY COOLED, THE SOLDER MADE CONTACT AND THE ENGINE WOULD START RIGHT UP. WHEN DRIVING THE SOLDER WOULD WARM UP AND BREAK CONTACT. THIS WOULD SHUT THE FUEL PUMP OFF AND THE ENGINE WOULD DIE. THERE ARE REPORTS OF THIS ALL OVER THE INTERNET. THE ONLY REPAIR FOR THIS ITEM WAS TO REPLACE THE MAIN CIRCUIT BOARD AS THE RELAY CANNOT BE REPLACED WITHOUT SOLDERING TO THE CIRCUIT BOARD. ONCE THE FUSE BOX WAS REPLACED, THE ISSUE WAS RESOLVED. I BELIEVE THIS COULD POTENTIALLY BE A HUGE PROBLEM AND COULD LEAD TO SERIOUS ACCIDENTS. I HAVE READ THIS PROBLEM AFFECTS NUMEROUS YEARS OF THE FORD EXPEDITION.

NHTSA complaint #10607024 — an unverified report by a vehicle owner.

FUEL SYSTEM, GASOLINE

THE CAR WAS RUNNING WELL AND SUDDENLY IT DIE. NO LIGHTS IN DASH BOARD, NO SHAKES, NO ANY PREVIOUS SIGN OF TROUBLE. SIMPLY IT DIE. I PUMPED THE ACCELERATOR PEDAL AND THE CAR CONTINUE RUNNING. NEXT TIME, FEW DAYS AFTER THE INCIDENT, THE CAR DOES THE SAME. THIS TIME DO NOT CONTINUE RUNNING WHEN I PUMP GAS. I HAVE TO PUT IN NEUTRAL AND START IT AGAIN. IT START AT ONCE. COULD BE MORE THAN TWO WEEKS WITHOUT SIGNAL OF PROBLEM AND THEN, IT HAPPEN AGAIN. SOME OTHER TIME, IT HAPPEN 4 OR 5 TIMES IN A HALF HOUR TRIP.

NHTSA complaint #10595537 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

WAS DRIVING THE 2003 EXPEDITION ON INTERSTATE 10 NEAR PENSACOLA, WHEN THE VEHICLE SHUT OFF. THE CAR COASTED TO A STOP, LUCKILY I DID NOT CAUSE A WRECK AND MY FAMILY AND I WAS SAFE. IT HAS HAPPENED SEVERAL TIMES, AT LEAST 10 SO FAR. WE HAVE REPLACED THE FUEL PUMP, FUEL PUMP RELAY SWITCH, THE FUEL FILTER, HAD THE INJECTORS INSPECTED AND IT STILL DOES IT. I DID SOME RESEARCH INTO THE PROBLEM AND IT TURNS OUT THE RIGHT SIDE FRONT PASSENGER WINDOW LEAKS DOWN ONTO THE INTERIOR FUSE PANEL AND IS CAUSING THE ELECTRICAL SYSTEM TO SHORT OUT. IN ALL CASES ONCE THE VEHICLE COOLS DOWN, THE CAR STARTS RIGHT BACK UP AGAIN. I HAVE TAKEN IT TO 4 GARAGES AND NOW I HAVE IT AT THE FORD DEALERSHIP IN PENSACOLA. WHERE THEY ARE LOOKING AT IT. IT TURNS OUT THAT THE P0231 CODE KEEPS RE-APPEARING IN THE SYSTEM (FUEL PUMP RELAY CIRCUITRY) WHICH SHOWS THE PROBLEM COULD BE THE FUSE PANEL SINCE THE FUSES ARE SOLDERED TO THE BOARD AND NOT PLUGGED IN. HOPEFULLY FORD RECOGNIZES THIS PROBLEM AND WILL ORDER A RECALL SOON.

NHTSA complaint #10550793 — an unverified report by a vehicle owner.

FUEL SYSTEM, GASOLINE

WHILE DRIVING DOWN THE FREEWAY I PUT MY FOOT ON THE GAS AND DID NOT GET ANY RESPONSE. IN A FEW SECONDS I PUSHED ON THE GAS AGAIN AND NOTHING. I STARTED TO PULL OVER AND PUSHED ON THE GAS AGAIN AND THE CAR HAD POWER. THE SAME THING HAPPENED 25 MINUTES LATER GETTING BACK ONTO THE FREEWAY. NEXT INCIDENT WAS STARTING FROM A STOP LIGHT THE CAR JUST DIED. NO WARNING. ENGINE LIGHT, BATTERY LIGHT AND SERVICE NOW LIGHTS COME ON. AGAIN I PULLED OVER PUT THE CAR IN PARK AND IT STARTED BACK UP. WE HAD THE COILS AND PLUGS CHANGED. NEXT TIME DRIVING AT 35 MPH OUT OF THE BLUE NO POWER TO THE GAS AND THE CAR SHUTS DOWN. CHANGED A RELAY. TOOK IT TO THE FORD DEALERSHIP WHO CAN'T FIGURE OUT WHAT THE PROBLEM IS. WE CHANGED THE BATTERY NEXT TIME I AM COMING TO A STOP AND THE CAR STOPS. NO BATTERY LIGHT, NO SERVICE LIGHT NOTHING. AGAIN I PULL OVER AND IT TOOK A LONG TIME TO GET THE CAR STARTED AGAIN. TOOK IT BACK INTO FORD. THIS TIME I GAVE THEM A THREAD OF EMAIL ABOUT OTHERS HAVING THE SAME ISSUE. NOW THEY HAVE CHANGED ANOTHER RELAY AND WE HOPE THIS SOLVES THE PROBLEM. THIS IS A HUGE SAFETY CONCERN. FOR A PERSON WHO IS DRIVING 55-66 MPH ON A HIGHWAY OR FREEWAY AND THEIR CAR DIES IS A BIG ACCIDENT WAITING TO HAPPEN. I DID EMAIL FORD BUT SO FAR HAVE BEEN TOLD TO TALK TO THE SERVICE PERSON.

NHTSA complaint #10536798 — an unverified report by a vehicle owner.

FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

WHY IS THERE NO WARNING LIGHT,OR SIGNAL OF ANY KIND WHEN THE PCM FAILS? OUR PCM FAILED, WHICH CAUSED OUR CATALYTIC CONVERTERS, 02 SENSORS, & FUEL PUMP TO FAIL. OUR IGNITION COILS HAD TO BE REPLACED. WOULD HAVE BEEN NICE IF A WARNING LIGHT CAME ON THE DASH. THIS HAS CAUSED OUR EXPEDITION ENGINE TO RANDOMLY SHUT OFF WHILE DRIVING COUNTLESS TIMES! I HAVE MIRACULOUSLY BEEN ABLE TO MANEUVER MY EXPEDITION TO THE SIDE OF THE FREEWAY &HAVE IT TOWED EIGHT TIMES WITHOUT KILLING MYSELF, MY FAMILY OR ANY ONE ELSE! WE HAVE HAD ODD ELECTRICAL AND PERFORMANCE PROBLEMS SINCE AUGUST OF 2002 WHEN WE PURCHASED IT. NOT ONE FORD MECHANIC (3 DIFFERENT DEALERSHIPS) COULD EVER DIAGNOSE OR REPAIR ISSUES. BECAUSE THERE IS NO WARNING LIGHT/CODE WHEN THE PCM IS OUT, THE DAMAGE SNOWBALLS. THERE ARE NO COMPUTER CODES, OR WARNING LIGHTS TO SHOW UP ON THE DASH BOARD WHEN THE PCM IS OUT, WHICH BEFUDDLES THE MECHANICS. WE ARE LITERALLY $5,000 IN THE HOLE SO FAR! FORD DEALERSHIP "REPAIRED" OUR EXPEDITION BY REPLACING THE PCM ($1,300.00). 48 HOURS AFTER THEY REPLACED THE PCM, AND 18 MILES AFTER WE DROVE EXPEDITION OFF THE FORD LOT, THE "SERVICE ENGINE SOON" LIGHT CAME UP ON THE DASHBOARD -FOR THE FIRST TIME EVER! WE DROVE BACK TO THE FORD DEALERSHIP, AND HE SAID FOR $3,400 PLUS TAX HE COULD REPLACE OUR NEW CATALYTIC CONVERTERS IN "BANK ONE" THAT WERE DESTROYED AGAIN, & THE "BANK TWO" CONVERTERS WHICH ARE NOW VERY WEAK, NOT UP TO SPEC. THE DRIVER'S SEAT MOTOR THAT HAS BEEN FICKLE SINCE AUG OF 2002, STOPPED WORKING WHEN WE WENT TO PICK IT UP, SO I CAN'T DRIVE IT, BECAUSE I CAN'T REACH THE GAS OR BRAKE PEDALS. $800 WILL FIX THAT, FORD SAYS. IF YOU GOOGLE "2003 FORD EXPEDITION EDDIE BAUER ENGINE SHUTS OFF RANDOMLY", THOUSANDS OF PEOPLE ARE REPORTING THE SAME ISSUES. UNTIL SOMEONE CRASHES AND DIES, I DON'T THINK FORD CARES. THE CONSUMER ALSO STATED THE VEHICLE HAD ELECTRICAL PROBLEMS. THE CONSUMER STATED THE DRIVER'S SEAT MOTOR STOPPED WORKING WHILE BEING SERVICED AT THE DEALER, THERE WERE PROBLEMS WITH THE WINDOWS AS WELL.

NHTSA complaint #10458864 — an unverified report by a vehicle owner.

FUEL SYSTEM, GASOLINE

FACTORY SPARK PLUG BLEW OUT OF ENGINE. I FOUND NUMEROUS COMPLAINTS OF THE SAME PROBLEM AND WAS SURPRISED TO FIND THERE HAS BEEN NO RECALL.

NHTSA complaint #10409193 — an unverified report by a vehicle owner.

FUEL SYSTEM, OTHER

2003 FORD EXPEDITION SPARK PLUG BLEW OUT OF HEAD AT 85K MILES. FORD DEALERSHIP ACKNOWLEDGED THAT IT SEES 2 SPARK PLUG BLOW OUTS A MONTH AND FORD IS AWARE OF THE PROBLEM IN 2003 EXPEDITIONS. REPAIRED WITH A FORD FIX - HELIACOIL OR LINER INSTALLED INTO HEAD FOR DAMAGED SPARK PLUG. FOR TRUE FIX, FORD NEEDS TO REPLACE THE HEAD AND SPARK PLUGS TO ENSURE THAT OTHER SPARK PLUGS DON'T COME UNTHREADED AS MILEAGE INCREASES.

NHTSA complaint #10355727 — an unverified report by a vehicle owner.

FUEL SYSTEM, GASOLINE

2003 FORD EXPEDITION SPARK PLUG BLOW OUT FROM CYLINDER. DRIVING MY CAR FROM PORTLAND TO SEATTLE, HEAR A BANG. PULLED OVER TO FIND THE IGNITION COIL BLOWN OUT OF ITS POSITION. HAD CAR TOWED FOR $100 TO LOCAL SHOP. THEY SAID "THIS IS ONE OF THE MOST COMMON PROBLEMS IN ANY FORD (THEY) SEE" WHAT HAPPENED WAS THE SPARK PLUG CAME LOOSE (AFTER HAVING THE DEALER TIGHTEN IT LESS THAN A YEAR AGO) AND BLEW OUT THE IGNITION COIL. COST ME $100 IN TOWING AND $700 IN SHOP REPAIRS AND THERE IS NO GUARANTEE THAT MORE DAMAGE WAS NOT DONE TO THE CYLINDER. DEALER IN PORTLAND REPORTED A "CLEAN INSPECTION". ONLY HAD OIL CHANGED BETWEEN.

NHTSA complaint #10341316 — an unverified report by a vehicle owner.

FUEL SYSTEM, GASOLINE

1. EVENT: GASOLINE LEAKING ONTO PAVEMENT. 2. FORD DEALER INSPECTED AND FOUND A CRACK IN THE FILLER NECK ON TOP OF THE GASOLINE TANK. I, NOR A FOREIGN OBJECT, HAVE ACCESS TO THIS AREA. TANK WILL LEAK GAS ONTO PAVEMENT CONTINUOUSLY UNTIL BELOW CRACK LEVEL. IF AN IGNITER SUCH AS A CIGARETTE OR MATCH OR SPARK IS NEAR THE FLAME, A FIRE WILL START ON GROUND UNDER THE GAS TANK LEADING TO THE GAS TANK COATED WITH GAS RESULTING IN A VEHICLE FIRE OR EXPLOSION. 3. FORD DEALER ESTIMATED REPLACEMENT COST AT $1,350. FORD DEALER STATED THIS IS NOT A RECALL ITEM AND WOULD NOT DISCUSS THE FACT THAT THIS MIGHT BE A DEFECT IN THE INJECTION MOLDED GASOLINE TANK. I THEN CONTACTED FORD MOTOR COMPANY CUSTOMER CARE. FORD MOTOR COMPANY CUSTOMER CARE WOULD NOT GIVE ME THE NAME OF THE LOCAL FORD MOTOR COMPANY REPRESENTATIVE (REGIONAL MANAGER), A SUPERIOR CUSTOMER CARE REP TO TAKE MY CONCERN TO A HIGHER LEVEL AND DISMISSED MY CONCERN THAT THIS WAS A SAFETY DEFECT ISSUE. I WAS THEN INFORMED THAT THERE WAS NO FURTHER RECOURSE AND THERE WAS NOTHING ELSE FORD MOTOR COMPANY OR MY FORD DEALER COULD DO FOR MY SITUATION. THEREFORE, I HAVE NO FURTHER RECOURSE EXCEPT TO SUBMIT MY COMPLAINT. I CANNOT AFFORD A REPLACEMENT GAS TANK (TANK IS STILL INSTALLED ON MY VEHICLE).

NHTSA complaint #10282653 — an unverified report by a vehicle owner.