2003 Ford Expedition electrical problems

Filed Mar 9, 2026 · Electrical · AR

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.

Filed Jan 19, 2024 · Electrical, Engine · NM

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)

Filed Dec 8, 2023 · Brakes, Electrical · VA · crash

The brakes are burning while driving & the emergency brakes are not applied. The power windows are failing 1 by 1.

Filed Oct 26, 2022 · Electrical, Engine · 196,000 miles · WA

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.

Filed Jun 8, 2021 · Electrical · GA

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.

Filed Nov 5, 2020 · Electrical, Engine · 156,000 miles · AZ · fire

Fuel pump relay shorted out in motion. Highway and city streets. Steering locks up engine just dies in motion. Super dangerous and scary replaced fuse box and same thing happened again. No power steering engine just dies in motion. So scary on highway 75 MPH.

Filed Jun 22, 2020 · Electrical · 186,000 miles · AZ

My fuse and relay panel has a defect and now my truck won't start.

Filed Jun 5, 2020 · Electrical · 130,989 miles · FL

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.

Filed Apr 14, 2020 · Electrical · 190,035 miles · LA

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.

Filed Dec 18, 2019 · Electrical, Lights · GA

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