2003 Ford Expedition Ford Expedition 2003

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2003 Ford Expedition repairs by problem area

Engine (35%)

Transmission and Drivetrain (10%)

Brakes and Traction Control (8%)

Suspension and Steering (8%)

Electrical and Air Conditioning (32%)

Paint, Rust, Leaks, Rattles, and Trim (5%)

Other (3%)

Chart based on 171 repairs.
See TSBs and recalls for the 2003 Ford Expedition.

2003 Ford Expedition engine repair cost distribution

$2500+ (7%)

$1000 - $2499 (5%)

$500 - $999 (21%)

$100 - $499 (36%)

< $100 (31%)

Worried about potential repair costs? An extended warranty can provide peace of mind.

Chart based on 58 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

2003 Ford Expedition

Engine not specified

95000 mi

US $1500
Radiator Leak - replaced Other maintenance was routine. 

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2003 Ford Expedition 4dr SUV

260-horsepower 5.4L V8 4-speed automatic RWD

50000 mi

US $200
Replace bad speed sensor on transmission 
60000 mi

US $400
Replace bad coil on plug 
67000 mi

US $900
Replace bad coil on plug, new coil on plug insulators, replace spark plugs 
104000 mi

US $700
Misfire due to two individual ignition coils malfunctioning - two ignition coils replaced 
123000 mi

US $675
Failed ignition coils 
137000 mi

US $550
Fuel tank, corrosion at relief valve. Was repaired as a new tank is dealer only and $1,700 
137200 mi The head gasket blew 
141000 mi

US $3400
Head gasket leaking, replaced all internal engine gaskets, timing chain, and machined valves.  
143000 mi

US $2800
Oil pump failed and caused pieces of metal to appear in the oil. Engine crankshaft damaged, replaced by dealer after they had repaired head gasket and oil pump. 
143000 mi leaking oil from gaskets, dealer replaced headgasket under warranty from previous work 
148000 mi

US $200
Auxiliary heater hose came loose from fitting. Freak problem. previously re-attached auxiliary heater hose came loose again, seemingly due to not being reattached properly the first time. 
165000 mi

US $300
replaced 2 more coils 
283000 mi

US $1049
Replaced fuel pump and filter 
126000 mi

US $300
coolant valve looked. It's sitting over the top of cylinder coil which had to be replaced as well. 

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2003 Ford Expedition 4dr SUV

260-horsepower 5.4L V8 4-speed automatic 4WD w/low range

102000 mi

US $800
Intake manifold cracked 
130000 mi

US $150
Coil pack on cylinder #3 failed and needed replacement 
153000 mi

US $210
valve cover gasket leaking and needed to be replaced 
114100 mi

US $355
Spark plug ejected from head and required that a helicoil be installed. 
115900 mi

US $355
Another Spark plug ejected from head and required that a helicoil be installed. 
34200 mi engine will not start on first try during the hot weather. 
39600 mi

US $706
Fuel pump lost prime. Small hole in the pump return hose. 
47000 mi

US $200
idle pulley 
125000 mi Ignition coil number 4 replaced Engine Knocking,oil leak, need to replace oil pan/oil filter housing-gasket 
154000 mi

US $61
Water in spark plug well had to replace number 1 cylinder ignition coil pack. 
174820 mi

US $420
Also replaced the engine idle air control valve  
150000 mi

US $100
Replaced thermostat 
138000 mi

US $974
Replace Intake Manifold and heater diverter valve 
138000 mi

US $1100
Replaced shorted wire harness and O2 sensor 
184800 mi

US $800
Both catalytic converters were bad. I bought the 2003 Expedition new in California. I now live in South Carolina so I replaced the CAT's with 49 State Original Equiptment ones since my Expedition doesn't have to pass CA emissions test. 
183000 mi

US $200
My truck is burning coils right now one about every two weeks or so. Have replaced 4 already in two months. Not sure if we are done with coils yet on this one. 
104000 mi

US $248
Oil pressure gauge on the dash dropped to nothing. Mechanic replaced the oil pressure sensor and verified with that pressure was there. 
111000 mi

US $3750
Symptoms: No oil pressure and timing chain rattle. Mechanic recommended an engine rebuild. New timing chain (guides had broken and chain was flapping away unchecked), oil pump, and water pump, cylinders were bored, new bearings. 
114000 mi Previous engine rebuild was faulty. Mechanic installed piston with cracked head. Rod bearing at crankshaft failed and engine started making large banging sound. Engine was rebuilt, yet again. 
138500 mi Throttle would stick on. Likely due to sub zero temperature. 
112900 mi

US $430
Ejected no. 3 sparkplug. Drilled out hole and tapped for new insert. Installed insert. Replaced spark plugs and new no. 3 coil. 
112000 mi

US $80
replaced coil-on-plug #6 
147300 mi

US $160
check engine 313 - replaced COP3 
145000 mi

US $270
check engine light - p303/p316 - replaced COP3 
104000 mi

US $600
hard starting after warm engine. Replaced fuel pump. problem solved 
116000 mi

US $3800
Blown head gasket 
176460 mi

C $750
Installed vacuum lines and reservoir. Bill included actuator installed earlier. 
189000 mi The car was "missing" at idle or acceleration. My mechanic stated that some moisture got down in one of the spark plugs. Spark plug removed,dried then put back in. No further problems at this time. 6 wks later. 
97000 mi

US $400
Car quit 7 times on trip home from vacation. Replaced crank sensor, but problem occurred 1 week later 
97000 mi Sold car because could not get stalling problem fixed. 
81000 mi

US $350
Vacuum system hose had a leak, plus replaced fuel filter. 

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2003 Ford Expedition 4dr SUV

232-horsepower 4.6L V8 4-speed automatic RWD

154000 mi

US $84
Coil number 7 failed. Replaced coil but when I unplugged connector, wires pulled from harness. No NEW part available, went to salvage and cut and spliced no harness. Replaced Fuel Filter 

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2003 Ford Expedition 4dr SUV

232-horsepower 4.6L V8 4-speed automatic 4WD w/low range

87300 mi

US $45
Truck was misfiring and running rough. Ran OBD test, said #2 cylinder was the problem. Replaced coil pack on that cylinder. 
107000 mi

US $50
Truck was misfiring and running rough. Ran OBD test, said #3 cylinder was the problem. Replaced coil pack on that cylinder. 
111000 mi

US $60
Truck was hesitating and running rough, replaced ignition coil #3. 
121000 mi

US $98
Another lean code came up, this time Mass Airflow sensor was dirty even though it was cleaned a few months ago. 
139200 mi

US $400
Check engine was on because of the gas cap & something else in the engine. 
144000 mi

US $87
Had to replace coil pack and spark plug, third one. Probably end up having to do all eight. 
145000 mi

US $80
Replace coil pack. 
146000 mi

US $87
Replace another coil pack. 
89000 mi

US $800
Check engine light is on due to failure of small part that helps mix the gasoline/regulate emissions. Part was estimated at $50 with repair labor at $750! 
85000 mi

US $800
emissions sensor broke. Small part to fix but entails taking engine apart to reach it... 

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2003 Ford Expedition Engine Problems

See our lemon odds and nada odds page to see vehicles with no repairs or vehicles with more than three repairs. To see how frequently 2003 Ford Expedition problems occur, check out our car reliability stats.