2003 Ford Expedition: engine failure

Filed Oct 8, 2019 · Electrical · 236,000 miles · SC

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

Filed Jun 30, 2014 · Electrical, Fuel system · 107,500 miles · CA

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.

Filed Mar 6, 2014 · Electrical, Steering · 120,000 miles · AL

Driving on interstate 70 mpg vehicle stalls then proceeds, this happened several times over a course of 1 year. One later incident engine died but restarted. Several months later completely dies. After several hrs vehicle restarts. Ford mechanics claim they cannot make a diagnosis. It will never stall or quit when it's in the shop. I'm afraid this vehicle will be someone's death trap.

Filed Dec 7, 2013 · Electrical, Lights · TX

Bulbs melting third brake light assembly internally. This happened to original and recently replaced unit. Bulbs were seized to the plastic mounting and melted/deformed both bulb mounts and reflector. Unit is now defective.

Filed Aug 12, 2010 · Engine · 88,546 miles · CA · fire

Tl*the contact owns a 2003 ford expedition. The contact stated that while driving approximately 55 MPH the vehicle began to smoke inside of the engine compartment and vehicle. The vehicle also made a loud noise and would stall. The vehicle was towed to a ford dealer who stated that a spark plug melted into the engine and that the vehicle needed a new engine. The dealer stated that the contact would be responsible for the repair cost. Ford motor company stated that there was nothing they could do. The vehicle was not repaired. The failure and current mileages were 88,546.

Filed Aug 2, 2010 · Engine · 94,000 miles · PA

Tl* the contact owns a 2003 ford expedition. While the contact's wife was driving at 60mph the engine failed. The engine over heated. She was able to pull over on the side of the road. The vehicle was towed to the contact's home. The contact diagnosed the vehicle himself, he located the failure at the number seven factory plug it ejected causing the vehicle to overheat. The manufacturer was contacted, but he didn't't received a response. The vehicle was serviced. The failure mileage was 94,000 and the current mileage was 94, 2000.

Filed Jan 4, 2010 · Engine · 113,000 miles · NC

2003 ford expedition 5.4l v-8 engine blew a sparkplug out of the cylinder head.

Filed Nov 18, 2009 · Engine · 95,786 miles · NM

My 2003 expedition, with the v8 5.4 trition engine, is being declined to be fixed by local ford dealerships, due to the fact of the "known" issue, with the spark plug, they want me to pay for the fix of the heli coil which isn't a guarantee and then hope it works, if not it will be a rebuilt engine, the first time the spark plug blew it was at night, upon starting, sounded like gun fire, had vehicle towed and then researched it on the internet for solutions, found out what it was and then replaced the spark plug and ignition coil and then hoped it would stay, upon starting it , it did it again, bought more spark plugs and ignition coils, and got it to seat better, and then 4 weeks to the day while driving is when it made the same sound like gun fire and we knew then what it was, pulled over on a highway and proceeded to look and see what damage had been done, once again a spark plug and a new ignition coil, however this time the spark plug was vastly discolored and burnt in appearance, 1 week and 1 day later upon starting it does it again, and this time no spark plug can be put in, there are no more threads is what I was told by my mechanic, they told be they will have to remove the engine to put the heli coil in, and that isn't a guaranteed fix, also that I should just replace the engine, since it can and probably will continue to happen again, I had the auto towed to my residence and I began to research my options, I called all the ford dealerships in which they said they could do the heli and there is not a guarantee for this to work, so at what cost is a human life to ford? Per the info and research it does say that it can catch fire, and explode.....or pay a fortune for a car that can't be fixed. We do have some of 6 the spark plugs that have "shot" out, I am told because it is the 3rd plug near the firewall that the angle is not approachable....help now!

Filed Jan 2, 2009 · Engine · 89,000 miles · AL

In less than seven days, two spark plugs blew out of my 2003 ford expedition engine. It is a 5.4l triton engine. Both occurrences were while driving normally down the interstate. The consequences were sudden loss of power while driving on the highway both times. I went from driving 70 MPH to 45 MPH in a matter of seconds with my wife and 9 month old baby in the vehicle! Ford knows about the problem and has issued a repair report, but not a factory recall. The issue is a flaw in the engine design or manufacture; thousands of others have reported the same issue (a quick google search of "ford 5.4l spark plug blowout" demonstrates this). Had there been traffic behind or beside me, we would have caused an accident or worse. Since ford knows of the issue, they ought to pay for the repairs or replace the engine at their expense. I no longer trust my vehicle. The repairs for this one issue have cost me approximately $1,000 to date, and there is no guarantee it will not happen again.

Filed Nov 17, 2008 · Engine · 53,000 miles · MD

I have experienced the 'blown spark plug' problem with ford's triton 5.4 liter engine for a second time. My 2003 ford expedition blew the # 3 spark plug on november 15, 2008. I am the original owner of this vehicle. The original engine was replaced august 22, 2006 with 86k miles because of the same problem at a cost to me of $5,400. This engine has 53k miles and was installed by koons ford of annapolis. Although ford accepts no responsibility for this failure, the dealer assured me that ford's redesigned v8 engine had resolved this issue. It is time for the ford motor company to take ownership of this problem and at least take care of their customers that have experienced this defect.

Filed Aug 14, 2008 · Engine · 112,000 miles · TN

Original and 2nd ford engine blew. 1st threw a rod, 2nd block cracked and ruined engine due to rapid coolant loss. Dealers offered no warranty as both engines blew at 112,000 and 120,000 respectively. This car was very well maintained and received routine recommended service for oil and fluid changes.

Filed Apr 22, 2007 · Engine · 59,022 miles · NV

On april 13, 2007 my 2003 ford expedition with the 5.4 liter triton engine blew out the #3 spark plug destroying the threads and requiring a total head replacement. The cost of this repair, in spite of the fact I purchased the extended warranty, was $3655.22. Upon further research I have found that apparently this is a very common occurrence affecting thousands of ford owners.