Which parts fail
Components named in complaints (battery, alternator, wiring, ignition, instrument cluster, infotainment).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2003 Ford Expedition owners, lightly cleaned up (personal details are redacted by NHTSA).
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.
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 [redacted] ) 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. …
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. …
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.
While driving on the highway at 70 MPH, the vehicle just suddenly lost power and shut down. I managed to get the vehicle to the side of the road. After a few minutes it started and I continued on, after a few miles the same thing happened again. I got it started again and was trying to make a rest stop a few miles away. While pulling into the rest stop the vehicle lost power again and resulted in a collision because of no steering or brakes. The loss of power happened 8 times that day. While looking for answers about the problem, I found on the nhtsb website that other vehicles of the same make, model and year also experienced this same problem that turned out to be a problem with the fuse block. I took it to a Ford dealership to have it checked out. They said it was a fuel pump issue. That would not cause a loss of power. …
I have a huge problem with my 03 Ford Expedition shutting of randomly it is very dangerous on highways you lose power steering and all power to motor almost caused accidents many times I believe many people have this problem and it all relates to the fuse box please make this a recall so many people can get hurt or even killed
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.
The brakes are burning while driving & the emergency brakes are not applied. The power windows are failing 1 by 1.
Check engine light came on while driving home and the engine shut down 4 times each time the battery would die instantly. We had to keep jump starting it to get home. 2 days later the check engine light started flashing. Scanned it came back p0304 cylinder 5 misfire. Changed spark plugs and coils. Engine light went off.ran obd2 scanner to double check codes. Code p2503 charging system low voltage . Took battery to advanced auto parts had them test it. The coca should have been 650cca and was at 11cca so bought a new battery. Next day took son to school less the 2 miles ran fine on my way home it died 3 times this time I would wait a few minutes then restart it. Check engine light never came on started searching on line and and calling mechanics. So bought new alternator. Started the truck to warm up after 5 minutes it shut down again waited a minute and started back up did it again. …
Open door sound indicator while engine is running--vehicle stopped to let passenger out. When any door is opened, the open-door high pitched steady-hum sound comes on, which is normal, however, the hum will not shut off. It continues loudly for 8-10 minutes and then reduces to a faint hum under the dash. The sound(s) continue even after the SUV is turned off, put in park, and the key is removed. We are the original owners of the 2003 eddie bauer Expedition and it's otherwise in excellent shape with just 57,000 miles. This problem has recently been verified by a local Ford/Kia repair shop whose mechanic scratched his head in confusion; however, they want to charge us to tear the dash apart to attempt to figure out why this is happening. They can't turn the indicator speaker off altogether. We want to know what Ford knows about the problem; mainly, what is causing the problem. …
Electrical complaints in other Expedition years
Frequently asked questions
How common are electrical problems on the 2003 Ford Expedition?
NHTSA has 104 complaints about the electrical system of the 2003 Ford Expedition, 17% of the model year's 615 complaints. The component named most often is wiring (6 mentions).
Is there a recall for 2003 Ford Expedition electrical problems?
No. NHTSA lists no electrical system recall for the 2003 Ford Expedition, though it has 1 recall for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2003 Ford Expedition electrical problems start?
Half of the complaints with a recorded mileage happened before about 97,000 miles, and 13% before 25,000 miles.
Is it dangerous?
Owners linked 3 crashes, 16 fires and 1 injury to electrical system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.