Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2003 Ford Explorer owners, lightly cleaned up (personal details are redacted by NHTSA).
Hello my name is [redacted] just writing you cause my neighbors have program my vehicle meaning they hack my 2003 explore pretty much they want to take over my driving they trying to dominate me in this matter when in reality is not going to be possible that's why I come to your people's corporate plus they have invade my family privacy they have a gang organization watching me every where I go had few confrontation they just want me to confront them so they could put me in jail this is not going to happen i apologize for the inconvenience I told police regards this matter they didn't do nothing about it .
Tl* the contact owns a 2003 Ford Explorer. While driving 65 MPH, the temperature gauge increased to high and the vehicle caught fire under the hood without warning. The air bags did not deploy. There were no injuries due to the fire. A police report was filed. The vehicle was towed to an independent mechanic. The local dealer and manufacturer were not contacted. The vehicle was not diagnosed or repaired. The failure mileage was approximately 160,000.
As I have been driving like I normally do the o/d light came on blinking. Then I pressed the button for it nothing happened. I continued with my daily routine and the light came on and off. And continued to blink. Then all of the sudden I would step on the gas but it would not give me anymore than 15mph. When I came to a traffic light my car did not want to go anymore so I had to pull over on the side of the road. It didn't want to continue going. Then after the third try it gave me more gas to drive normal not even a minute after it did it again. I was afraid yo get hit by traffic and since I had my three toddlers I was scared. I pulled into a shopping center and called my dad. And also a mechanic. It needs a new transmission when that vehicle has had all its needs. …
1 history of engine surge, very fast idle upon starting since vehicle acquired.-all reported to dealer.---------------------------------------------------------------- 2.car stopped, motor off. Started, placed in reverse-touched accelerator and car jumped back full speed. Very narrow parking area (have pictures). Had to turn car rapidly to avoid large hill and trees -too short a distance to turn completely and hit front left fender and bumper glancing blow off two trees. Was able to shift into neutral and got stopped after going in a semicircular and backing over concrete parking barrier.-motor still racing--unable to turn off with key until fourth or fifth try and than motor bucked several time trying to stop. 3.no corrections to date. Reported to Ford! !
Dt*: the contact stated the vehicle experienced a problem with hesitation when the speed was kept constant. The dealership replaced the mass air flow sensor. The hesitation problem continued, the vehicle was returned to the dealership which was unable to duplicate the problem. While backing into the driveway the vehicle suddenly accelerated. Although the brakes were applied the vehicle did not stop. The vehicle hit the contact's home resulting in a neck sprain injury. The acceleration continued until the shifter was moved into drive. The dealership was unable to determine the cause of the acceleration. Also, contact complained that ABS light was on and pedal felt stiff. Vehicle ran rough. In addition, removed and installed automatic transmission main control valve body.
Tl* the contact owns a 2003 Ford Explorer. While driving on an incline at an unknown speed, the vehicle failed to accelerate and the overdrive warning light illuminated. The vehicle was taken to an independent mechanic where it was diagnosed that the transmission needed to be replaced. The vehicle was repaired, but the failure recurred. The vehicle was taken to another independent mechanic where it was diagnosed that the solenoid pack and the oxygen sensors needed to be replaced. The vehicle was repaired, but the failure recurred. The contact also mentioned that the check transmission and check engine warning lights illuminated. The manufacturer was not notified of the failure. The failure mileage was 80,000. The VIN was not available.
Dt*: the contact stated while driving at 70 MPH smoke emitted from the rear of the vehicle. The vehicle was pulled off the road and towed to the dealership. The radiator, fuel filter, air filter, and steering gear assembly was replaced, the front end was aligned as well. Two days later while driving at 70 MPH smoke was noticed in the rearview mirror. The vehicle was pulled off the road and less than one minute later the entire vehicle was engulfed in flames. The fire department responded and extinguished the fire. The fire marshal determined this fire was caused by a mechanical failure malfunction. There was a police and fire report filed.
I was driving home from work when I noticed my vehicle started to make this taping noise. I pulled over to the side of the road to see what it could be then noticed it was coming from under the hood. I didn'ttt feel safe continuing to drive on the highway so drove to the next exit and got off. The noise started to get louder so I pulled into a gas station and waited for someone to come pick me up because I didn't feel the vehicle was safe to drive. As I was sitting there with the car turned off, something on the driver side under the hood burst into flames. Fire department had to come out and put vehicle fire out.
Vehicle died upon turning once again. This is becoming more frequent, as it has happened twice now in the last week. Seems to occur after highway speed, then slowing for a turn (tipically a right hand turn). I consider myself quite mechanically inclined and I am baffled. I also own an obdii scanner and no codes come up!! This is the second time I have filed a complaint, and would like some answers. Very dangerous issue in my opinion!! I will also be posting this on other websites to raise awareness, and hopefully get some results!! This is unacceptable.
2003 Ford Explorer, while driving through town I started to slow down for a group of kids waiting to use a cross walk when the Explorer shut down & lost all power to control brakes and steering almost hitting the kids.. I have taken to a shop & was told they could not duplicate the issues I have been having for 5 years. The reason I am now reporting this is because the close call I just had with the cross walk. This problem starts after about 5 or 10 minutes of run time then clears up not returning until next run or some time later...
NHTSA investigations
Spark plug ejection from cylinder head
On September 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 Ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or…
Engine complaints in other Explorer years
Frequently asked questions
How common are engine problems on the 2003 Ford Explorer?
NHTSA has 91 complaints about the engine & cooling of the 2003 Ford Explorer, 8% of the model year's 1,131 complaints. The component named most often is engine (24 mentions).
Is there a recall for 2003 Ford Explorer engine problems?
No. NHTSA lists no engine & cooling recall for the 2003 Ford Explorer, though it has 2 recalls 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 Explorer engine problems start?
Half of the complaints with a recorded mileage happened before about 65,000 miles, and 24% before 25,000 miles.
Is it dangerous?
Owners linked 4 crashes, 4 fires and 1 injury to engine & cooling 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.