2003 Ford Expedition
Here’s a breakdown of common issues and complaints for the 2003 Ford Expedition, categorized by system. This information is based on owner reports, repair data, and common failure points for this model year.
The 2003 Ford Expedition is a full-size SUV known for its spacious interior, towing capacity, and comfortable ride. Engine options included a 4.6L Triton V8 producing around 232 horsepower and 291 lb-ft of torque and a 5.4L Triton V8 producing around 260 horsepower and 350 lb-ft of torque. Both engines were paired with a 4R70W 4-speed automatic transmission. Many owners appreciate the vehicle’s versatility and ability to haul large families and cargo. Common complaints often revolve around fuel economy, age-related repairs, and some specific component failures.
Engine
4.6L Triton V8
- Spark Plug Ejection
- Description/Symptoms: Spark plugs can eject from the cylinder head, often due to stripped threads in the aluminum head. This results in a loud popping noise, misfire, and loss of power.
- Solution: Repairing the threads using a thread repair kit (e.g., Time-Sert) or replacing the cylinder head.
- Estimated Cost to Fix: $300 - $1500+ depending on the severity and repair method.
- Recalls: None Found
- Intake Manifold Cracking
- Description/Symptoms: The intake manifold can crack, leading to coolant leaks. This may be indicated by a low coolant level, overheating, or a sweet coolant smell.
- Solution: Replacing the intake manifold.
- Estimated Cost to Fix: $300 - $600+
- Recalls: None Found
5.4L Triton V8
- Spark Plug Ejection
- Description/Symptoms: Similar to the 4.6L, spark plugs can eject from the cylinder head due to stripped threads.
- Solution: Repairing the threads using a thread repair kit or replacing the cylinder head.
- Estimated Cost to Fix: $300 - $1500+
- Recalls: None Found
- Camshaft Phaser Noise
- Description/Symptoms: A ticking or rattling noise, especially at idle or low RPMs, that may indicate a failing cam phaser. This is more common in later Triton engines but can occur in the 2003 5.4L.
- Solution: Replacing the cam phasers and related components.
- Estimated Cost to Fix: $800 - $2000+
- Recalls: None Found
- Exhaust Manifold Leaks
- Description/Symptoms: Cracking or warping of the exhaust manifolds, leading to exhaust leaks. Symptoms include a ticking noise that gets louder when the engine is cold.
- Solution: Replacing the exhaust manifold.
- Estimated Cost to Fix: $300 - $800+
- Recalls: None Found
Transmission
4R70W 4-Speed Automatic
- Slipping/Harsh Shifting
- Description/Symptoms: The transmission may slip between gears or shift harshly. This can be caused by worn clutches, valve body issues, or low fluid.
- Solution: Transmission fluid flush, valve body replacement, or transmission rebuild/replacement.
- Estimated Cost to Fix: $150 (flush) - $3000+ (rebuild/replacement)
- Recalls: None Found
- Torque Converter Failure
- Description/Symptoms: Shuddering at highway speeds, stalling at stops, or abnormal noises.
- Solution: Torque converter replacement.
- Estimated Cost to Fix: $500-$1500+
- Recalls: None Found
Suspension
- Air Suspension Issues (If Equipped)
- Description/Symptoms: Sagging rear end, compressor failure, or error messages on the dashboard related to the air suspension.
- Solution: Replacing the air springs, compressor, or sensors. Conversion to coil springs is also a common option.
- Estimated Cost to Fix: $300 - $1500+ per component. Coil spring conversion kits can range from $500-$1000+.
- Recalls: None Found
- Ball Joint Failure
- Description/Symptoms: Clunking noises from the front suspension, uneven tire wear, and loose steering.
- Solution: Replacing the worn ball joints.
- Estimated Cost to Fix: $200 - $500+ per ball joint.
- Recalls: None Found
Electrical
- Blend Door Actuator Failure
- Description/Symptoms: Inability to control the temperature of the air coming from the vents, or clicking noises behind the dashboard.
- Solution: Replacing the blend door actuator.
- Estimated Cost to Fix: $150 - $400+
- Recalls: None Found
- Window Regulator Failure
- Description/Symptoms: Windows not going up or down properly, or making grinding noises.
- Solution: Replacing the window regulator.
- Estimated Cost to Fix: $200 - $500+ per window
- Recalls: None Found
- Instrument Cluster Issues
- Description/Symptoms: Gauges not working correctly, flickering lights, or complete failure of the cluster.
- Solution: Repair or replacement of the instrument cluster.
- Estimated Cost to Fix: $200 - $800+
- Recalls: None Found
Exterior
- Running Board Motor Failure (If Equipped)
- Description/Symptoms: Running boards failing to extend or retract, or making grinding noises.
- Solution: Replacing the running board motor or the entire running board assembly.
- Estimated Cost to Fix: $300 - $1000+ per side.
- Recalls: None Found
- Rust
- Description/Symptoms: Rust formation, particularly on the undercarriage, rocker panels, and wheel wells.
- Solution: Rust repair or panel replacement.
- Estimated Cost to Fix: Highly variable, depending on the severity of the rust.
Interior
- Broken Door Handles
- Description/Symptoms: Interior or exterior door handles breaking, making it difficult to open the doors.
- Solution: Replacing the broken door handle.
- Estimated Cost to Fix: $50-$200+
- Recalls: None Found
- Sunroof Issues (If Equipped)
- Description/Symptoms: Sunroof getting stuck, leaking, or making grinding noises.
- Solution: Sunroof repair or replacement.
- Estimated Cost to Fix: $200 - $1000+
- Recalls: None Found
Summary
The 2003 Ford Expedition, while generally reliable, is prone to certain age-related issues. The spark plug ejection problem in the Triton engines can be a significant concern, and the air suspension (if equipped) often requires maintenance or replacement. Electrical problems, like blend door actuator failure, are also common. Costs can range from relatively minor repairs like door handles to more substantial expenses for engine or transmission work. The severity and cost of these issues emphasize the importance of a thorough pre-purchase inspection and ongoing maintenance.