2003 Ford Expedition: won't start

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 15, 2022 · Engine, Fuel system · TX

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....

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 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 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 Nov 5, 2015 · Electrical · 160,000 miles · PA

This specific make and model year has a defective fuse box which case a fuse called a PCM relay to melt and causes the vehicle to stall and not start. The fuse box will buzz continuously but the vehicle does not start. You can replace the relay which is about $15 but this is more than likely temporary and it will melt and cause the vehicle to stall. The only remedy is to replace the fuse panel entirely which brings me here, the panel alone is $500 and that doesn't include labor and taxes. Ford is well aware of this issue as there are thousands of forums online that refer to this specific manufacturer defect. I've spent thousands replacing parts that did not need repair. Ford needs to foot the bill for this defect because it's a manufacture's defect not a consumer (wear and tear) issue.

Filed Oct 4, 2015 · Electrical, Fuel system · 129,000 miles · TX

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.

Filed Sep 24, 2015 · 157,000 miles · MI

While driving my vehicle, several times, it stalled. It began to stall every few months. It later stalled weekly and later daily. Each time, the check engine light appeared (it did not appear each and every time), I would have it checked by a mechanic. I always got the p0231 error code. I have had my fuel pump, fuel relay, fuel filters, transmission and several other things replaced. None of the previous listed repairs fixed the issue. Recently on 09/07/2015, I was driving 35 MPH. My vehicle stalled on a train track. It did not start right away. After several attempts, I was able to get it going for a few seconds, long enough to move it. I was terrified. It has been parked ever since. My mechanic willingly did a house call and explained the real issue. He stated that the issue was a faulty fuse box located in the kick panel of the passenger side. He stated that if I get it repaired, it is just a matter of time before it happens again, due to the faulty design of the windshield and the location of the box. He also stated that if I get it replaced, I would need to get it from the dealer. Replacing it is very expensive due to the manufacturer selling the whole assembly to include fuses and relays. I am not sure how far this complaint would go, but it's worth complaining about.

Filed Sep 8, 2014 · Electrical · 141,000 miles · SC

My 03 ford expedition would not start and was making a ticking sound. Found out it was a relay switch changed it and it started but it keeps blowing about every 3-4 weeks.

Filed Mar 1, 2011 · Electrical, Transmission · 107,000 miles · NJ

2003 ford expedition would not start after long tow to mechanic it was a burnt relay switch but now it turns off while driving, change the relay switch and problem is temporarily fixed now since the relay is for the fuel pump and PCM my transmission is acting up not shifting 3rd or over drive no one can figure out the problem but we are scared to drive the truck!

Filed Jun 23, 2008 · Fuel system · 101,179 miles · TN

Car would not start on first attempt. Ford dealer (ted russell kingston pike) said defective battery which was replaced. Problem still persisted. Ford dealer (ted russell kingston pike) then said it was a defective fuel pump. Went to pep boys kingston pike - they diagnosed defective fuel pump regulator. Went to different car dealer location (ted russell parkside drive) - they observed leak of fuel from fuel rail onto exhaust manifold. Requested that they hold part for me after replacement.

Filed Mar 10, 2007 · Electrical · 47,500 miles · PA

The vehicle would randomly fail to start over a period of 2 months, usually in the morning. All lights, gauges, radio, and heater would work, but the engine would not crank. After turning the key 4-5 times, it would eventually start. One time, nothing worked and had to jump start the battery. I replaced the battery and 1 week later, it did not turn over again at all, but everything else was working. I let it sit, and tried it later in the day, of which it started right away. I took it to the dealer and they tested it. They had the problem happen twice on the first day and determined the cause to be the starter terminal wiring pigtail was corroded, and they replaced it with a new one.