2003 Ford F-250 Problems

What owners report

Owners of the 2003 F-250 report a wide spread of problems across many systems, which fits a truck of this age: tire failures and front-end shake on 4x4 models, rusted brake and fuel-tank parts, and engine issues such as ejected spark plugs, stalling and lost power. Several reports involve rust on vehicles that were otherwise kept up, often noticed during inspection or after a tank strap or brake line let go.

1. 1
   Tires

   Tire tread separation or blowout

   • 15 complaints (13%)
   • median 80,000 mi at 4.9 yrs old (9 state mileage, few)
   • 2 mention a crash, fire or injury
   • filed 2003–2019

   Owners describe tread peeling away, sidewall splits or sudden blowouts while driving, sometimes on tires with relatively low mileage. Complaints note vibration or a hard-to-control pull beforehand in some cases, and several mention the tire maker or dealer examined the tire and pointed to road damage or impact. Tires involved come from several brands and sizes, so the reports are not tied to one tire model. Mostly reported between roughly 40,000 and 150,000 vehicle miles, often at 50-65 mph.

   What to check: Check tire date codes, look for cracking, bulging or uneven wear on all four tires, and factor replacement cost into the price.

   2 excerpts from owner complaints in NHTSA records

   “In june 2003, I purchased a new 2003 Ford f250. It had firestone steeltex r4s lt 265/75 r16 tires on it. On march 16, 2004, the rear driver's side tire went completely flat as I was sitting at a red light. I pulled over to the side of the road and found that the tire had a rip across the side wall approximately 5 inches long. The tires (and truck) have less than 12,000 miles on them. I called Ford, and they referred me to a local firestone dealer. …”

   NHTSA complaint #10062536, filed 2004-03, 11,400 miles

   “I had lt265/75r16 bf goodrich tires on my truck, with only approx. 12,000 miles on them, the truck does not get driven but once a week. Traveling on the interstate when the passenger front tire exploded. I was able to control the truck and get it off the road without hitting anyone. But my truck sustained $3800.00 in damage. I filed claim with michelin and sent them the tire, they denied the claim that I must have hit something very hard and that caused the tire to split on the inside lining which then caused the blow out. …”

   NHTSA complaint #10732485, filed 2015-07, 197,776 miles
2. 2
   Fuel system

   Rusted fuel tank straps letting the tank hang

   • 6 complaints (5%)
   • median 60,000 mi at 13.0 yrs old (5 state mileage, few)
   • filed 2013–2022

   Complaints describe the steel straps holding the fuel tank rusting through and breaking, so the tank drops or drags on the ground. Some owners heard a scraping noise while driving, and others noticed it while cleaning or fueling the truck. Several say the dealer told them the truck was not covered by a recall campaign for similar trucks, so the repair was not done. Noticed anywhere from about 23,000 to 150,000 miles, typically on older trucks in road-salt areas.

   What to check: Look under the truck at the tank straps for heavy rust or thinning, and push on the tank to see whether it moves; ask whether the straps have been replaced.

   2 excerpts from owner complaints in NHTSA records

   “The contact owns a 2003 Ford F-250. While cleaning the vehicle, the contact noticed that one of the fuel tank straps was fractured and the other one was about to fracture. The vehicle was not taken to the dealer or an independent mechanic for diagnostic testing. The manufacturer was notified of the failure. The vehicle was not repaired. The approximate failure mileage was 150,715.”

   NHTSA complaint #10787706, filed 2015-11, 150,715 miles

   “The contact owns a 2003 Ford F-250. The contact stated that there was rust associated with the fuel straps, which fractured and caused the fuel tank to hang. The dealer was not contacted. The vehicle was not diagnosed or repaired. The vehicle was not included in the manufacturer recall campaign number: 11s21, although the failure was identical. The manufacturer was notified of the failure. The approximate failure mileage was 60,000.”

   NHTSA complaint #11123050, filed 2018-08, 60,000 miles
3. 3
   Steering

   Shake or wobble after hitting a bump at highway speed

   • 5 complaints (4%)
   • median 102,000 mi at 7.0 yrs old (5 state mileage, few)
   • filed 2004–2017

   Complaints describe the front end going into a violent shake after the truck hits a pothole, expansion joint or bump, usually at highway speed. Owners say the shaking is hard to control, sometimes leads to lane drift, and stops once they slow down, so the truck then seems fine. Some reports say a steering or front-suspension part was repaired or replaced but the shake came back. Reported from about 16,000 miles up to roughly 130,000 miles, generally at 45-65 mph after a bump.

   What to check: Drive the truck at highway speed over uneven pavement and watch for any shake through the wheel, and have the front-end steering and suspension parts inspected before buying.

   2 excerpts from owner complaints in NHTSA records

   “Driving 50-60 hit a bump and the truck goes into a violent wobble, unable to control the breaks and steering. This last time I was on the interstate and it caused me to enter the lane next to me nearly causing an accident. The other driver was able to avoid me. When the shaking stops, the truck runs smooth without any sign of a problem. I am afraid of my families safety!!!”

   NHTSA complaint #11032830, filed 2017-10, 102,000 miles

   “Driving 60 MPH or greater and hit a bump the front end will violently shake and you have to pull over and slow way down to stop it. There was a recall for nr 62 parts but that doesn't stop the dodge death wobble. This is going to cause an accident and kill someone. Dodge will not reimburse me for the repairs that I paid for that included the recall nr62. The repairs were done before I received the recall. In the recall it is stated that they would pay for repairs if they were already done. Everyone one seems to know about the dodge death wobble but won't fix it.”

   NHTSA complaint #10593251, filed 2014-05, 104,000 miles
4. 4
   Brakes

   Brake rotors and lines rusted or seized

   • 7 complaints (6%)
   • median 33,309 mi at 7.5 yrs old (7 state mileage, few)
   • filed 2003–2019

   Owners report brake rotors and pads rusting up, especially on trucks that sit, leading to vibration when braking or a failed safety inspection that required replacing all four rotors. Other complaints describe rear brake lines rusting through and bursting, with the pedal going to the floor and fluid loss. Some also mention pedal or steering-wheel vibration that returned after rotors were machined or drums replaced. Reported from about 22,000 miles up to around 135,000 miles, often on trucks used only occasionally or kept in salt areas.

   What to check: Inspect the rotors and pads for rust and scoring, and have the brake lines, particularly the rear line above the tank, checked for corrosion.

   2 excerpts from owner complaints in NHTSA records

   “The rear brake lines have rusted out on my 2003 Ford f250 - we received a letter from the ntsb asking if our brake lines had rusted out - they just did last night and almost caused an accident. This is incredible that a 7 1/2 year old vehicle lost it's brakes already.”

   NHTSA complaint #10429022, filed 2011-10, 93,000 miles

   “I own a 2003 Ford f250 7.3 liter diesel pickup. On inspection, required by pa law for safety reasons, it failed because of rotor rust. I then had to replace all four brakes and rotors at a considerable cost to me. . The truck had 33,309 miles on it and was stored and used similar to three other older vehicles I owned the same thing occurred on this truck at 19,750 miles when it was 3 years old. The earlier rust issue was covered under warranty. Rusting brake pads are unacceptable in today's world. …”

   NHTSA complaint #10328142, filed 2010-04, 33,309 miles
5. 5
   Engine

   Spark plug ejected from the cylinder head

   • 5 complaints (4%)
   • median 115,000 mi at 9.0 yrs old (5 state mileage, few)
   • filed 2008–2015

   Owners describe a loud bang or pop followed by rough running, a strong fuel or exhaust smell and a loss of power, traced to a spark plug blowing out of the head. Complaints say the repair involves a thread insert and can cost several hundred dollars per cylinder, and some describe a second or third plug failing later. Owners also mention that escaping fuel fumes were a concern when a plug was out. Reported from roughly 75,000 to 158,000 miles, though a few describe it earlier.

   What to check: Ask whether any cylinders have had thread inserts or plug repairs, and listen for a ticking or popping sound at idle during a test drive.

   2 excerpts from owner complaints in NHTSA records

   “3rd spark plug on passenger side blew out without warning and also destroyed the coil. My research indicates this problem is well known to Ford, but no recalls that I could find.”

   NHTSA complaint #10715070, filed 2015-05, 115,000 miles

   “Have a 2003 Ford F-250 with the 5.4l triton engine I have owned the truck approx. 6months and in a matter of 1000 miles I have blown 2 spark plugs and inserts out, this repair has cost me $300 each time and $150 in towing fees,I am waiting to see when the other ones will blow, this problem is well known by all mechanics and make the repairs often, if this problem is so well known maybe Ford should address this issue and demand a recall of all vehicles with this well known issue, this problem also causes other issues, like engine fires due to the fuel fumes escaping from where the spark …”

   NHTSA complaint #10389975, filed 2011-03, 152,000 miles

Buying note. A 2003 F-250 is a 20-plus-year-old truck, so condition and rust matter more than mileage; have a shop inspect the front end, brake lines, fuel tank straps and spark plug areas before purchase, and budget for tires.

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.