Which parts fail
Components named in complaints (doors, hood, frame, rust, paint and trim).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2003 Ford Explorer Sport owners, lightly cleaned up (personal details are redacted by NHTSA).
Was driving the vehicle when I noticed smoke coming out from under the hood. I pulled over as quick as possible into a strip mall parking lot. Before I got out flames were coming out of the engine compartment. I ran into a store and got a fire extinguisher to try and put out the fire. I failed, as the whole front of the Explorer was in flames as well as the interior. The vehicle is a total loss. The fire department put it out. I had the vehicle for 7 weeks. The used dealer will not take any responsibility. Should they? I purchased the vehicle on mar. 3,2014 at oc auto expo in westminster, ca.
Tl* the contact owns a 2003 Ford Explorer Sport. While driving approximately 25 MPH, a noise emerged from the rear hatch window. The contact pulled the vehicle over to the side of the road and noticed that the piece that held the window in place was fractured. The vehicle was repaired for the same failure in March of 2015. The manufacturer was notified. The failure mileage was 159,149.
Tl* the contact owns a 2003 Ford Explorer Sport. While driving at an unknown speed, the body mount emitted an abnormal noise and was deteriorating. The failure occurred without warning. The vehicle was not taken to an independent mechanic or dealer. The manufacturer was not notified of the failure. The failure mileage was 150,000.
Tl* the contact owns a 2003 Ford Explorer Sport. While driving 50 MPH, a loud noise was heard when the sun roof exploded without warning. There were no injuries. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 130,000. The VIN was not available.
Rear liftgate window completely shattered. Vehicle was parked and been so for 3 hours. Temperature was about 60 degrees. There was no visible cracks or other defects. Was witnessed by several people. Did not just crack or break. It shattered into thousands or pieces. Was not being opened or closed. Vehicle was completely static
Severe clanking/banging noise in passenger rear. Replaced shocks. Noise worsened. Researched and found numerous complaints regarding body mounts with Ford Explorer Sport vehicles. Upon investigation - reaching up under vehicle found no "body insulator left on passenger side rear and on driver rear the insulator crumbled like dirt and fine powder. The body mounts appeared to be manufactured of a foam like material - substandard at best! Replacement parts must be purchased through Ford since no other aftermarket parts are available. Parts only (that being able to salvage the bolts and sleeves) and purchase the two pair of insulators only - $680.00. The same material that failed and should not. There are vehicles on the road with body mounts for 40 to 50 years. This is a manufacturer's responsibility and the cost for these parts is thievery. …
Tl contact owns a 2003 Ford Explorer Sport. While driving approximately 45 MPH on normal road conditions, an excessively loud rattle and wind noise was coming from the interior rear of the vehicle. The driver inspected the vehicle and observed that the liftgate hinge failed and the bolts loosened. The vehicle was taken to an authorized dealer for inspection. The technician stated the failure was due to the liftgate hinge which was a common problem with this vehicle. NHTSA campaign id number; 04V442000 (structure:bodyhatchback/liftgate;hinge and attachments) is a identical to the failure; however, the vehicle was excluded from the recall since it only applied to four door vehicles. The vehicle was temporarily repaired and resumed operation with caution. The contact is aware of the safety risk involved. The failure and current mileages were 65,000. Updated 05/18/09. …
On the morning of 1/29/14 I was at the market ,came out to load my items into the vehicle , opened the rear lift gate at about the 1/3 open point the glass exploded into a million pieces . Which in turn sent shards of glass into my face ,hands , head and eyes . They were minor injuries but I'm still extracting glass from my head and hands and there is still glass embedded in my hands . I have an apt with my dr only because there is glass in my eyes. My mother was with me but she was at the side of the vehicle so she didn't get nailed .I have never seen a window explode like this, this is a serious hazard and needs to be recalled asap before it kills someone , the power of the flying glass was unreal some of it went through 3 -12 packs of soda with ease. Also I have no resources to get a new window as they are around 700 dollars . …
2/14/2007 I noticed there is a fracture/crack between the tailgate door opener and the window. The fracture/crack becomes more/less wider depending on how hot or cold it is outside. I went to the dealer and they stated it would cause me between $400-$800 to get it fix and the whole area will need to be replaced. They stated that it should not cause much problem unless someone hits the back of my car or I close the tailgate not soft enough, which could damage the window. Since then, I have noticed that all explorers that I see have the same fracture/crack on the tailgate door on the same area location. I also have seen many many many complaints about this online. This has to be a defect that is causing the fracture on the tailgate door below the window. This could cause injury if the window breaks or there is issue with the door opener hinge.
Window feel and shattered into a million pieces. After contacting my insurance to have the glass replaced I found out the reason for the incident was due to a faulty hinge. I was told by the glass company that the hinge failed due to electrolysis (two different metals reacting with each other). I feel this is the same issue that happened with Ford recall manufacturer campaign number: 04s20, however my VIN does not pull up this issue code and therefore I am not receiving assistance from Ford with this manner. After doing research online I have found many other owners of my same make and model who have experienced the same issue. I feel this needs to be officially addressed as I was driving when my glass fell, but was fortunate that there was no one behind me when it happened. Otherwise I am 100% positive it would have caused an accident.
Body complaints in other Explorer Sport years
Frequently asked questions
How common are body problems on the 2003 Ford Explorer Sport?
NHTSA has 25 complaints about the body & structure of the 2003 Ford Explorer Sport, 38% of the model year's 65 complaints. The component named most often is body (13 mentions).
Is there a recall for 2003 Ford Explorer Sport body problems?
No. NHTSA lists no body & structure recall for the 2003 Ford Explorer Sport. 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 Explorer Sport body problems start?
Half of the complaints with a recorded mileage happened before about 106,000 miles, and 5% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 2 injuries to body & structure 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.