2003 Ford Expedition: engine stalls while driving

Filed Feb 11, 2025 · Engine · 230,000 miles · TX

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.

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 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 Jan 18, 2021 · Fuel system · 205,000 miles · CA

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.

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 Sep 8, 2019 · Electrical, Engine · 248,000 miles · MO

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.

Filed Jul 11, 2019 · Electrical, Engine · 250,000 miles · FL

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

Filed Jul 5, 2017 · Fuel system · 152,000 miles · GA

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.

Filed Apr 12, 2017 · Electrical, Engine · 120,000 miles · AZ

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.

Filed Aug 31, 2016 · Electrical · 128,500 miles · CA

Vehicle stall while driving freeway.my wife first then I experience myself stall vehicle on fast lane very dangerous.vehicle just shut off cannot steer the wheel lucky enough to glide to safety side.fuse box burning the fuel pump relay lots of complaint in internet how many lives to waste before anyone act on it.

Filed Jul 21, 2016 · Engine · 143,000 miles · MD

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.

Filed Feb 3, 2016 · Fuel system · 13,000 miles · PA

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