2003 Ford F-150 Problems

What owners report

Owners of the 2003 F-150 most often describe spark plugs being ejected from the aluminum cylinder heads, a problem reported across a wide mileage range, followed by electrical faults tied to water entering through the windshield, rear door latches that stop opening, and speed-control or unexpected-acceleration behavior. Other recurring themes are fuel tank straps rusting through and a 4x4 system that fails to engage or drops out while driving. Many complaints note the dealer could not duplicate the fault or declined assistance once the vehicle was out of warranty.

1. 1
   Engine cooling

   Spark plug blows out of cylinder head

   • 57 complaints (13%)
   • median 110,500 mi at 7.7 yrs old (52 state mileage)
   • 1 mention a crash, fire or injury
   • owner-quoted repair $1,000 (median of 19 quotes)
   • filed 2005–2021

   Owners describe a loud pop followed by rough running, a strong fuel smell, and a spark plug found ejected from the head, sometimes with raw fuel in the engine bay. Complaints often mention this happening on a plug that had never been touched since the factory, and some report it recurring on a second or third cylinder. Repair quotes range from a thread insert to full head replacement, and owners describe dealers declining goodwill help because the vehicle was past warranty. A service bulletin for 4.6L and 5.4L 2V engines describes a spark plug thread repair procedure not covered by the new vehicle warranty. Reported across a wide range, from roughly 40,000 to over 250,000 miles, with the 5.4L V8 mentioned most often.

   3 related service bulletins

   What to check: Ask whether any plug has ever been ejected or repaired with a thread insert, and inspect the cylinder heads for insert work. A compression or leak-down check before purchase is a reasonable request.

   2 excerpts from owner complaints in NHTSA records

   “The spark plug in me Ford F-150 5.4ltr engine blew out of the #2 cylinder. All engine rebuilding shops and repair centers say this is common in fords. They finished my sentence when describing the problem. Please enact a recall on this problem. As I read this is an issue. Cost me 500.00 dollars to fix and I worry about the other 7 plugs...$3,500 to repair.”

   NHTSA complaint #10282258, filed 2009-08, 178,000 miles

   “Just had my 2003 f150 5.4l fixed after the #3 spark plug blew out. New plugs and heads cost me $4000.00. The heads are the updated version Ford now has. The original were 3 threads, allowing for the plugs to blow out before the 100,000 plug replacement. They now have 7 threads. Ford needs to recall and repay us.”

   NHTSA complaint #10166477, filed 2006-08, 95,600 miles
2. 2
   Vehicle speed control

   Speed control and unintended acceleration

   • 82 complaints (19%)
   • median 61,946 mi at 6.9 yrs old (68 state mileage)
   • 18 mention a crash, fire or injury
   • filed 2003–2025

   Complaints describe the truck speeding up on its own, sometimes after shifting out of park, sometimes with the cruise control engaging without the set button being pressed. Several owners mention the brake pedal only pausing the acceleration, so they shifted to neutral or used the off switch to stop it. Separate reports describe fires originating at the cruise control mechanism or engine-compartment wiring while the truck was parked and off. Mostly reported between 25,000 and 100,000 miles, often on trucks that were several years old at the time.

   Recall 07V336000Recall 07V078000

   What to check: Ask whether the speed control deactivation switch recall work was completed, and have a shop confirm the switch and its harness are intact and dry. Note any history of engine-bay wiring repairs.

   2 excerpts from owner complaints in NHTSA records

   “Faulty cruise control on 2003 Ford f150. Situation: driving at steady state; press cruise-control 'on' switch; horn chirps; cruise control engages with-out pressing the 'set' button and begins to accelerate vehicle. Brake pedal de-activation switch dis-engages cruise control only temporarily. Cruise control re-activates on it's own when foot is removed from brake pedal, and begins to accelerate again. The 'off' switch on the steering wheel successfully disengages the cruise control. This problem first occurred ~march 2007, but was unable to duplicate at the dealer. …”

   NHTSA complaint #10198560, filed 2007-08, 41,600 miles

   “The contact owns a 2003 Ford F-150. While attempting to slow the vehicle down, it suddenly accelerated without warning. The contact depressed the brake pedal and was able to stop the vehicle. The vehicle was towed to the dealer where it was pending diagnostic testing. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was 26,381.”

   NHTSA complaint #10630068, filed 2014-09, 26,381 miles
3. 3
   Body and structure

   Rear door latches will not release

   • 24 complaints (6%)
   • median 58,000 mi at 7.9 yrs old (17 state mileage)
   • 3 mention a crash, fire or injury
   • filed 2003–2024

   Owners report that one or both rear doors, including the small rear-hinged door on extended-cab trucks, stop opening from either the inside or outside handle. Some describe a latch replaced only to fail again a few years later, with the dealer attributing it to lack of use. Complaints also mention rust bubbling along the bottom inside edges of the doors. Reported from roughly 20,000 to 140,000 miles, often on trucks that are several years old.

   1 related service bulletin

   What to check: Open and close every door, including the rear half doors, from both handles, and look at the lower inside door seams for bubbling or rust.

   2 excerpts from owner complaints in NHTSA records

   “Both rear door latches have failed to operate. Cannot open either rear door. This happened in the parking lot where I live. I am handy caped and cannot get access to my rolater which in the back seat area. I need this equipment to help me walk. Has there been other reports of this malfunction? Is this a recall item? Will Ford mfg repair this defect?”

   NHTSA complaint #10981410, filed 2017-04, 94,000 miles

   “Purchased vehicle in7/2003. Rear small door (so called suicide door ) on passenger side broke in 11/2012. Would not open or close from inside or outside. Had two latches replaced at walker Ford in clearwater, fl also in 11/2012 at a cost of $615.59. Same door broke again in 9/2015. Took truck back to walker Ford . They offered to repair it again for about $500 and stated the latches they replaced in 11/2012 had deteriorated from non-use !. I declined the repair offer as it is clear to me that the latches are inadequate and/or of defected manufacture. …”

   NHTSA complaint #10785127, filed 2015-10, 79,280 miles
4. 4
   Fuel system

   Fuel tank straps rust and tank drops

   • 73 complaints (17%)
   • median 96,077 mi at 8.6 yrs old (60 state mileage)
   • 4 mention a crash, fire or injury
   • owner-quoted repair $807 (median of 8 quotes)
   • filed 2002–2024

   Complaints describe fuel tank straps rusted through so the tank hangs or separates from the frame, sometimes puncturing the tank and leaving fuel on the ground. Owners also report gasoline smells and drips from a cracked fuel line or fuel rail while parked. Some note the truck was not covered by the fuel tank strap campaign or that the repair had been closed without the work being done. Mostly reported above 100,000 miles, on trucks in areas with road salt and long-term exposure.

   Recall 11V3850004 related service bulletins

   What to check: Look under the truck at both fuel tank straps for heavy scale or thinning, and ask whether recall 11V385000 was performed. Have any fuel smell at the tank or lines checked before driving.

   2 excerpts from owner complaints in NHTSA records

   “Used 2003 Ford f150 I ordered a $100. Ny inspection, the service advisor informed me that this truck had a problem, the fuel tank straps recall his records showed on paper that it was done, but upon a physical inspection it was not done, only some make shift wires to hold up the gas tank the service advisor gave the wires to me to show you he contacted the Ford dealer in massachusetts they said it was not their responsibility since they had closed the case my service advisor then informed me that he would call 'Ford special assistance he said they denied the assistance after the call he …”

   NHTSA complaint #10487916, filed 2012-12, 183,043 miles

   “Odor of gasoline, caught on fire. An investigator determined that the fire originated in the engine compartment and had ignited from gasoline vapors. It was determined that the fuel rail had cracked, causing the fuel leak.”

   NHTSA complaint #10068298, filed 2004-05, 10,000 miles
5. 5
   Electrical system

   Water leak shorts out GEM module and electrics

   • 32 complaints (8%)
   • median 88,454 mi at 9.0 yrs old (29 state mileage)
   • 7 mention a crash, fire or injury
   • filed 2004–2023

   After rain, owners describe wipers quitting, the radio cycling on and off, dimming lights, clicking under the dash, and a dead battery. Several complaints trace this to water entering through the windshield seal and reaching the GEM module and fuse box, with mechanics recommending the module and windshield be replaced or resealed. Others report underhood or dashboard fires of electrical origin. Reported mostly between 60,000 and 130,000 miles, typically after a rainstorm.

   What to check: Check the driver-side floor and kick panel for dampness or water stains, confirm the windshield has not been replaced or resealed poorly, and test wipers, radio and interior lights.

   2 excerpts from owner complaints in NHTSA records

   “After a rainstorm and while driving, my windshield wipers stopped working, my radio/cd player started turning off and on, my panel light dimmed, and I heard a clicking noise under my driver side dash board. There was also a clicking noise coming from the engine. While stationary and key out of the ignition, I noticed water on the driver side floor, and when I looked under I could see drops of water sliding off I believe my emergency bake and brake pedal, and an ongoing clicking sound under the steering wheel. I left my truck in driveway overnight, and the next morning my battery was dead. …”

   NHTSA complaint #11191148, filed 2019-03, 95,000 miles

   “Water leaked into the cab trough the windshield and shorted out the gem module and corroded the fuse box. No leak was evident before the short out of various electrical systems.”

   NHTSA complaint #10225949, filed 2008-04, 130,000 miles

Buying note. A 2003 F-150 can be a sound used truck, but these are older vehicles, so check the spark plug and cylinder head history, the fuel tank straps, and the rear door latches before buying. Confirming that open recalls were completed and having an independent mechanic inspect the electricals and 4x4 system will tell you more than mileage alone.

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.