2003 Ford Expedition fuel system problems

Filed May 5, 2024 · Fuel system · GA

Fuel leaking from emissions vents on fuel tank. Non reparable part.

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 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 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 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 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 Apr 29, 2019 · Fuel system · 2,000 miles · FL

Fuel tank crack and leaks

Filed Nov 3, 2018 · Electrical, Fuel system · AR

"takata recall" I was driving down the interstate at 65 MPH when my truck just cut off, had to have it towed in to the shop. Had fuel pump replace, 2 weeks later same problem.had to have it towed again fuse was replace. 3 weeks later I'm now having to have the fuse box replace. Ford motor company don't think this should be a recall issue. They just came out with the latest update fuse box in 2017.

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.