2003 Ford Explorer Problems

What owners report

Owners of this model year most often report two things: a cracked plastic applique on the liftgate below the rear glass, and transmission problems where the overdrive light flashes and shifting becomes harsh or delayed. The panel cracks tend to show up on parked vehicles and often in cold weather, while transmission complaints cluster on higher-mileage examples, though some appear well under 100,000 miles. Scattered reports also cover wheel bearings, liftgate hinges and glass struts, and occasional stalling.

1. 1
   Body and structure

   Cracked rear liftgate panel below the back glass

   • 241 complaints (21%)
   • median 70,000 mi at 6.2 yrs old (190 state mileage)
   • 4 mention a crash, fire or injury
   • owner-quoted repair $475 (median of 18 quotes)
   • filed 2003–2022

   Owners describe a vertical crack in the plastic applique panel under the rear window, often noticed on a parked vehicle with no impact or damage. Cracks are sometimes said to open wider in cold weather and close up in heat. Dealers reportedly replaced the panel in some cases under warranty, but owners say later replacements were declined as out of warranty, with repair estimates ranging from a few hundred dollars upward; several owners mention the same part cracking more than once. Reported from a few thousand miles up past 150,000, with many cases between roughly 40,000 and 120,000 miles; several owners link the crack to cold weather.

   3 related service bulletins

   What to check: Inspect the plastic panel directly beneath the rear glass for cracks or a split running beside or below the emblem, and check both in cold and warm conditions. Ask whether the panel has ever been replaced and whether any assistance was offered for it.

   2 excerpts from owner complaints in NHTSA records

   “My 2003 Ford Explorer has a cracked rear panel. This is the second time it has happened. The first time it was covered by warranty and Ford repaired it at no charge. This time they will not. I was told it will cost approximately $300.00 and it would happen again. The crack develops right in the middle of the panel under the rear window.”

   NHTSA complaint #10426902, filed 2011-09, 50,000 miles

   “The panel below the glass on the rear hatch of my wife's 2003 Ford Explorer cracked forno apparent reason. The dealer tells me it will cost $800 dollars to repair plus a body shop expense (paint). I've noticed on many forums on the internet that this is a very common problem and Ford should address it!”

   NHTSA complaint #10264304, filed 2009-04, 43,800 miles
2. 2
   Transmission and drivetrain

   Overdrive light flashing, harsh or slipping shifts

   • 231 complaints (20%)
   • median 89,583 mi at 7.5 yrs old (215 state mileage)
   • 8 mention a crash, fire or injury
   • owner-quoted repair $2,500 (median of 41 quotes)
   • filed 2003–2019

   Complaints describe the overdrive-off light flashing, the transmission holding high rpm, delaying or jerking into gear, sometimes refusing to shift or to engage reverse. Some owners report the vehicle slowing on its own or losing power at speed, and several note the transmission fluid cannot be checked with a dipstick. Dealers and shops are said to have replaced torque converters, servos and valve body parts, or recommended a full transmission replacement, with the warning light sometimes returning afterward. Often reported between about 60,000 and 140,000 miles, though some complaints involve vehicles under 30,000 miles or well past 150,000.

   3 related service bulletins

   What to check: Test drive long enough to reach highway speed and watch for a flashing overdrive light, delayed or hard shifts, and slipping; ask for transmission service records and have a transmission shop scan for stored codes.

   2 excerpts from owner complaints in NHTSA records

   “My 2003 Ford Explorer xls is having issues with the automatic transmission. When I accelerate from a stopped position, the transmission stalls, slips and delays when it shifts into the next gear. As I searched for issues with the transmission I found 100's of complaints regarding this matter. From what I have found, the transmission is a design flaw”

   NHTSA complaint #10788981, filed 2015-11, 115,000 miles

   “While driving the o/d light began flashing on my dashboard, the vehicle slowed down to about 15 miles as if the transmission was pulling/slipping, the car made a hard jerk and began to pick-up speed. This cycle repeated until I reached my destination. The light came on again the next day and the same events occurred.”

   NHTSA complaint #10525391, filed 2013-07, 117,000 miles
3. 3
   Body and structure

   Fractured liftgate hinges and rear glass struts

   • 283 complaints (25%)
   • median 75,000 mi at 6.5 yrs old (219 state mileage)
   • 15 mention a crash, fire or injury
   • owner-quoted repair $750 (median of 16 quotes)
   • filed 2002–2022

   Owners report liftgate hinges cracking or breaking away from the body when the gate is closed, sometimes leaving the door hanging, and struts that let the glass drop or appear to push it out. Some state the hinge or glass was repaired under a prior campaign but the problem returned later, while others say their vehicle was not covered and no assistance was offered. At least one owner describes the rear glass shattering when the partially open hatch was closed. Reported from low mileage up to around 165,000 miles, in some cases years after an earlier hinge repair.

   Recall 04V4420001 related service bulletin

   What to check: Open and close the liftgate slowly and watch the hinges for movement or cracking, and check that the glass struts hold the window up firmly. Ask whether the hinge campaign work was ever performed on the vehicle.

   2 excerpts from owner complaints in NHTSA records

   “On three separate occasions the gate lift of my Explorer opened on it's own. This happened when the vehicle was quite new. I reported it to Ford and they could not find the problem. They said that unless it malfunctioned while they were in possession of it, they could not remedy the problem. I now tie down the gate when carrying precious cargo, my dogs.”

   NHTSA complaint #10170457, filed 2006-10, 5,000 miles

   “Awoke the morning of may 10, 2017 to find the entire back liftgate and window exploded outwards and inwards of our Ford Explorer. The vehicle was parked in front of our home, we are rural, so no evidence of someone purposely breaking it. Our sheriff in cascade county, montana, stated it appears to be something internal probably the lift struts exploding. This seems to be a problem as stated on many online sites, and many Ford explorers have this problem. This particlar model VIN number did not show up as recalled, although we sit here looking at the damage caused by this problem. …”

   NHTSA complaint #10984673, filed 2017-05, 118,018 miles
4. 4
   Transmission and drivetrain

   Rear end noise, whine or vibration from the axle

   • 208 complaints (18%)
   • median 55,000 mi at 4.5 yrs old (169 state mileage)
   • 10 mention a crash, fire or injury
   • owner-quoted repair $1,131 (median of 30 quotes)
   • filed 2003–2017

   Complaints describe a roaring, whining or howling noise from the rear of the vehicle that grows with speed, sometimes with noticeable vibration at 40 to 70 mph or a shudder when turning at low speed. Owners say dealers replaced differential carrier assemblies, axle bearings and clutch packs, in some cases more than once, and a few report being told no fix was available at the time. Often noted from very low mileage up to about 100,000 miles, with some repairs repeated within about 12,000 miles.

   5 related service bulletins

   What to check: Listen for a whine or roar from the rear at highway speed and for chatter when turning slowly in a parking lot, and ask for records of any differential or axle bearing work.

   2 excerpts from owner complaints in NHTSA records

   “Whining noise coming from rear became louder 41,000 mile on odo dealer advised rear wheel bearings seals and strut inserts, we had the repairs made $1000.00 one year later we noticed more noise and chatter when turning,dealer advised rear differential needs rebuild, and new clutch packs. We are having the repairs made at this time. These are expensive problems Ford should be held responsible.”

   NHTSA complaint #10147225, filed 2006-01, 41,000 miles

   “I bought a 2003 Ford Explorer 4wd v8 june 4, 2003. About 1 month later,and less then 2,000 miles on the vehicle, I started to notice a vibration when driving between 60 and 70 MPH. The vibration became more noticeable and I took the vehicle in for service at star Ford in glendale in early august. The service department believes the vibration is coming from the drive train, probably the rear axle assembly. …”

   NHTSA complaint #10039059, filed 2003-09, 1,500 miles
5. 5
   Suspension

   Wheel bearing noise and wheel stud failure

   • 92 complaints (8%)
   • median 78,010 mi at 6.8 yrs old (82 state mileage)
   • 3 mention a crash, fire or injury
   • owner-quoted repair $572 (median of 13 quotes)
   • filed 2004–2021

   Owners describe grinding or roaring from the front or rear wheel area that gets louder with speed, with shops replacing wheel hub and bearing assemblies, sometimes on both sides and more than once. A few complaints state that worn bearings damaged rotors and studs, and one owner reports several wheel studs shearing off on a rear wheel. Mostly reported between about 40,000 and 120,000 miles, with some repeat repairs.

   1 related service bulletin

   What to check: During the test drive, listen for grinding or humming that changes when turning, and have a mechanic check wheel bearings and studs for play or wear before purchase.

   2 excerpts from owner complaints in NHTSA records

   “2003 Ford Explorer ext with less than 85,000 miles. After having my ABS (antilock brakes) lights come on several times, I had the ABS module completely replaced. The light continued to come on afterwards, so I had sears complete a front end inspection. Found out that the vehicle needs both front end wheel bearing hub assemblies replaced. This is apparently affecting the tires and the brakes as well. Had I not found out when I did, the bearing could have went out completely, and caused a crash and possible injuries and death. …”

   NHTSA complaint #10342655, filed 2010-07, 83,000 miles

   “2003 Ford Explorer front wheel bearings make a loud grinding sound. Common problem in all 2003 Ford explorers. It ground down the wheel lugs from the inside and the tire came off on the freeway doing 60mph. The rotors got eaten up on the inside too. Ford needs to address this issue before someone gets killed.”

   NHTSA complaint #10384052, filed 2011-02, 81,020 miles

Buying note. These are older vehicles where the liftgate panel and transmission condition matter most, so inspect both carefully and ask for service records. A pre-purchase inspection by an independent shop is worthwhile given the reports of axle and wheel bearing wear.

Summary written with AI from a sample of 80 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.