Problems · by component

2003 Ford Expedition structure problems

32 owner complaints to NHTSA about the 2003 Ford Expedition cite structure, 5% of all 655 complaints for this model year. NHTSA also lists 1 recall on this component.

Complaints
32
5% of all complaints
Crashes
1
Reported by owners
Fires
0
Reported by owners
Injuries
2
Reported by owners
01 —Owner reports

What owners say about the structure

Verbatim from NHTSA complaints, newest first
“bought truck 3/2/22 from Gold cAuto In troy NY. 3/7/22 went to take kids to school 2.5 inches of water set in my weather guard mats. seats soaked console everything in front cab reversed to pull out spot and water starting pouring on my and my kids from sides in pass sides front and the front windshield area omgand the sun roof was worst.kids had to go in myslef too it was snow still out.so that dayi oh sunroof needs to be blown out i said well that right frontdoor sounds open when its shut . same night i picked it up said all was good to go and his guy didn't hear any issues with door. the next snow it was worst this was about toward end of march. i called back around 3/15 said its still leaking dude i just want my money back for real and we are good, he said no doesnt work liek that said all his winshield guy he would take a lok at it and tell hijm ihe sent me. did that talked to the guy said he woudl call me the next day week went by so i called him back long story short he said he wasnt fixing it josh the dealer never pays him , i understood. called talked joshgoldstien told him he said well u just have to bring it in and let me have it for a few days he…”
Owner complaint to NHTSAFiled Jun 28, 2022Air bags, Seat belts, StructureODI 11471391
“TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. WHILE DRIVING, THE MUFFLER DETACHED FROM THE VEHICLE. THE VEHICLE WAS TOWED TO FZ PERFECTIONS AUTO BODY AND COLLISION (191 US-9W, CONGERS, NY 10920) WHERE IT WAS DIAGNOSED THAT THE CROSSMEMBER WAS CRACKED AND THE REAR OF THE VEHICLE WAS ROTTED. THE SCHUTLZ FORD DEALER WAS CONTACTED AT 1-877-724-8589 AND CONFIRMED THAT FORD EXPEDITIONS WERE KNOWN TO ROT FROM THE REAR OF THE VEHICLE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 92,851.”
Owner complaint to NHTSAFiled Jun 16, 2017StructureODI 10995596
“TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. WHILE DRIVING 50 MPH, THE VEHICLE BEGAN TO VIBRATE. THE FAILURE RECURRED ON NUMEROUS OCCASIONS. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FRONT PASSENGER SIDE SUBFRAME CORRODED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 186,000.”
Owner complaint to NHTSAFiled May 16, 2016StructureODI 10865072
“MY PASSENGER WINDOW AND BOTH BACK WINDOWS HAVE DROPPED SEVERAL TIMES. I HAVE HAD TO HAVE THIS FIXED MORE THAN ONCE ON THE BACK PASSENGER SIDE WINDOW, WHAT HAPPENS IS ILL TRY TO PUT THE WINDOW UP AND THE WINDOW MOTOR MAKES A STRUGGLING NOISE AND I AM UNABLE TO ROLL UP THE WINDOW. AT THIS POINT I'M SURE IT MUST BE A DEFECT BECAUSE OF HOW IT HAS HAPPENED TO EACH WINDOW MORE THAN ONCE. ALSO THE BUMPER THAT GOES AROUND THE ENTIRE CAR IS EXTREMELY FADED AND I AM UNABLE TO GET FIXED I HAVE GONE TO GET ESTIMATES FOR A PAIN JOB BUT HAVE BEEN TOLD DUE TO THE MATERIAL IT IS JUST GOING TO FADE I WOULD NEED TO GET IT SANDED AND HAVE THEM DO SOME SPECIAL TREATMENT I CANT AFFORD AND THEY WILL NOT JUST PAINT OVER IT FOR ME BECAUSE THEY GUARANTEE THERE WORK AND WOULD HAVE TO REDO IT TOO OFTEN. ALL THE EXPEDITIONS I SEE HAVE THE EXACT SAME ISSUE.”
Owner complaint to NHTSAFiled Oct 26, 2015Electrical system, Structure, Electronic stability control (esc)ODI 10786046
“I OWNED THIS VEHICLE SINCE 2003. A COUPLE OF YEARS AGO I NOTICED SMALL PERFORATION/RUSTING ON THE TOP OF THE VEHICLE AND OVER TIME IT BECAME WORST. NOW THERE ARE NUMEROUS BADLY CORRODED AREAS . IT APPEARS THAT DUE TO THE DESIGN AND THE MATERIALS USED WATER REMAINS TRAPPED ESPECIALLY WHEN THE VEHICLE IS PARKED. ALSO POOR WORKMANSHIP OR POOR MATERIALS ARE CONTRIBUTING FACTORS. THIS MAY HAVE CAUSED THIS UNFORESEEN ISSUES. THERE IS A POSSIBILITY THAT THE HOOD CAN BECOME WEAK IN THE AREAS AFFECTED BY THE CORROSION, THEREFORE I AM SEEKING GUIDANCE. I DID REACH OF TO THE FORD COMPANY WITH NEGATIVE RESULTS, THEY ONLY ADVISE THAT THIS WAS NOT A WARRANTY ISSUE. ON ANOTHER NOTE I AM THE ONLY OWNER AND I HAVE NOT LIVED CLOSE TO THE BEACHES OR EVEN WHERE YOU WOULD EXPECT CORROSION OF THIS MAGNITUDE.”
Owner complaint to NHTSAFiled Oct 10, 2015StructureODI 10781257
“TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 50 MPH, DECELERATION BECAME VERY DIFFICULT. THE VEHICLE WAS EXAMINED BY AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE BRAKES LINES HAD RUSTED. THE MECHANIC ALSO DISCOVERED THAT THE ROCKER PANELS AND FRAME WAS RUSTED. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS 150,000. UPDATED 06/27/14*LJ”
Owner complaint to NHTSAFiled Apr 22, 2014Service brakes, hydraulic, StructureODI 10584189

Showing 6 of 32 reports. Read every report on NHTSA.gov.

Data from NHTSA Complaints API (owner reports, unverified) · synced Nov 11, 2026NHTSA vehicle page
02 —Related recalls

1 recall on this component

Structure

Free remedy

CERTAIN PICKUP TRUCK, VAN, AND MINI VAN CONVERSIONS EQUIPPED WITH SOUTHERN COMFORT BUILT RUNNING BOARDS THAT CONTAIN CERTAIN COURTESY LIGHTS MANUFACTURED BY AMERICAN TECHNOLOGY COMPONENTS, INC. THESE UNITS CONTAIN A COURTESY LIGHT OR LIGHTS THAT MIGHT OVERHEAT WHEN THE WIRE HARNESS IS EXPOSED TO EXCESSIVE MOISTURE AND ROAD SALT.

StructureReported Mar 7, 2003NHTSA 03V094000
Data from NHTSA Recalls API · synced Nov 11, 2026

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.