2003 Ford Expedition Engine cooling Problems
- Complaints
- 127about this part
- Share
- 21%of 615 total for the year
- Median mileage
- 90,000miles
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
NHTSA recorded 127 complaints about the engine cooling of the 2003 Ford Expedition, 21% of the 615 complaints for this model year. Where a mileage was given, the median is 90,000 miles. 7 a fire, according to the filers.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“At 92,000 about miles the passenger side plug blew out. I put jb. Weld around the plug and put it back in the truck. It worked for 3 months and now its done it again. I am now out of work and my wife can't make it to here job because of the truck. So I am looking for a heli coil repair kit. But no way to go and get it I have one truck. So I don't know what to do next.”
NHTSA complaint #10246350, filed 2008-10, 100,008 miles“Recently purchased this 2003 Expedition with the 5.4l engine. Purchased on 12/20/2011. Since owning said vehicle I have had two spark plug failures. On cyl 8 and cyl 3. The first incident happened at a speed of about 25 MPH. The second and recent happened driving highway speed, cruise set to 65 MPH. The plug ejects from the cyl causing damage to the coil, and possibly creating a fire hazard. There was no recent tune up to my knowledge.”
NHTSA complaint #10456551, filed 2012-04, 104,045 miles“My 2003 Ford Expedition blew a spark plug completely out of the cylinder head without warning. This happened while driving at almost 65 MPH, and the engine stalled, causing a very dangerous condition. The vehicle had less than 59k miles at the time of the incident. It cost me over $4k to repair, and I now find out that this has happened to thousands of owners with Ford triton motors from 1999 to 2004.”
NHTSA complaint #10261632, filed 2009-03, 58,400 miles“I have a 2003 Ford Expedition with the triton 5.4l engine. I had the spark plug eject from the #7 cylinder. In my case the garage that I took it to had to remove the cylinder head to helicoil the cylinder. It took 5 weeks to get my truck back and cost over $1200 to fix. I had to replace 2 coil packs, a spark plug, the head gasket, intake and exhaust manifold gaskets, oil pan gasket, valve cover gasket and timing chain gasket.”
NHTSA complaint #10324937, filed 2010-04, 112,800 miles“On april 13, 2007 my 2003 Ford Expedition with the 5.4 liter triton engine blew out the #3 spark plug destroying the threads and requiring a total head replacement. The cost of this repair, in spite of the fact I purchased the extended warranty, was $3655.22. Upon further research I have found that apparently this is a very common occurrence affecting thousands of Ford owners.”
NHTSA complaint #10188541, filed 2007-04, 59,022 milesRelated service bulletins
- 10023943Oct 1, 2007Some 1997-2008 vehicles equipped with a 4.6l 2v, 5.4l 2v, or 6.8l 2v engine--spark plug thread repair procedure--not covered under new vehicle limited warranty. *nj this includes…
- 10018745Nov 14, 2005Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running.
- 10014685Mar 21, 2005Use of stainless steel exhaust studs in service for 5.4l 2v engine.
- 10014666Mar 7, 2005Intermittent rough idle - non-commanded egr (exhaust gas recirculation valve) flow.
- 10011162Aug 23, 2004Engine misfire or running - coil on plug (cop) ignition systems - wds cop kit diagnostic tips. To include various 2005 models. * ar this article 04161 supersedes tsb 03-14-04.
- 10011156Aug 9, 2004Misfire at idle with diagnostic trouble codes p0300-p0308, p0316.
Engine cooling: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2023 | 1 | 2% |
| 2021 | 3 | 1% |
| 2020 | 4 | 1% |
| 2019 | 31 | 6% |
| 2018 | 25 | 7% |
| 2017 | 5 | 1% |
| 2016 | 3 | 1% |
| 2015 | 1 | 1% |
| 2013 | 1 | 1% |
| 2011 | 2 | 3% |
| 2010 | 3 | 5% |
| 2008 | 3 | 2% |
| 2007 | 9 | 4% |
| 2006 | 75 | 25% |
| 2005 | 47 | 15% |
| 2004 | 26 | 9% |
| 2003 | 127 | 21% |
| 2002 | 95 | 28% |
| 2001 | 122 | 21% |
| 2000 | 116 | 13% |
| 1999 | 248 | 26% |
| 1998 | 127 | 15% |
| 1997 | 89 | 10% |
Other parts of the 2003 Ford Expedition
104 complaintsBrakes
87 complaintsAir bags
59 complaintsTires
57 complaintsTransmission and drivetrain
50 complaintsEngine
44 complaintsFuel system
38 complaintsVisibility (wipers, defrost, mirrors)
38 complaintsBody and structure
32 complaintsOther or unknown
22 complaintsSteering
20 complaintsSuspension
20 complaints
← All problems reported for the 2003 Ford Expedition
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology