Problems · by component

2003 Ford Explorer structure problems

389 owner complaints to NHTSA about the 2003 Ford Explorer cite structure, 30% of all 1,313 complaints for this model year. NHTSA also lists 2 recalls on this component.

Complaints
389
30% of all complaints
Crashes
4
Reported by owners
Fires
1
Reported by owners
Injuries
13
Reported by owners
01 —Owner reports

What owners say about the structure

Verbatim from NHTSA complaints, newest first
“There is a crack down the middle section of the liftgate for quite some time. The liftgate has been unlocking and opening automatically by itself. On only rare occasions has the liftgate opened all the way while driving. On the morning of 7/28/2022 while the vehicle was parked in my driveway the liftgate was discovered to have again unlocked by itself and opened slightly and now with one of the two hinges holding the glass sheared leaving the liftgate glass hanging by only one hinge. With the glass now hanging without having both hinge supports functioning and the inability to close and lock the liftgate, 1) the glass could fall out while driving and 2) with the liftgate unable to now close and lock, contents of the back storage area could fall out of the vehicle while driving. On 8/1/2022 the vehicle was inspected by the foreman of the Service Dept. at Healy Ford, Goshen, N.Y. I was told to take it to a body shop for realignment repair. Apparently a recall on 9/13/2022 # 04V442000 did not include my Vin. However, In driving around I do see many 2003 explorers with the identical crack on the liftgate.”
Owner complaint to NHTSAFiled Aug 1, 2022Structure, Unknown or otherODI 11476879
“REAR WINDOW LOWER PANEL PLASTIC CRACKING UP, REPLACED THREE TIMES, STILL CRACKING DUE TO NO SUPPORT AND BENDING TOO MUCH, I CALLED FORD DOES NOT CARE IF CONTINUES CRACKING UP, IT LOOKS UGLY ALSO PANELS CAN CAUSE AN ACCIDENT TO OTHER CARS GETTING INTO THEIR WINDSHIELDS LOOSE PARTS. THEY KNOW ABOUT THE PROBLEM AND NOT FIXING IT.”
Owner complaint to NHTSAFiled Aug 2, 2018StructureODI 11115329
“TL* THE CONTACT OWNS A 2003 FORD EXPLORER. WHEN ATTEMPTING TO CLOSE THE REAR WINDOW, THE CONTACT NOTICED THAT THE REAR LIFTGATE WINDOW HINGES WERE CRACKING AND WERE TILTED ON ONE SIDE. THE CONTACT, A CERTIFIED MASTER TECHNICIAN, STATED THAT THE WINDOW NEEDED TO BE REPLACED. THE CONTACT CALLED FORT MILL FORD AT (866) 680-5276 (LOCATED AT 801 GOLD HILL RD, FORT MILL, SC 29708) AND WAS INFORMED THAT THE VIN WAS NOT INCLUDED IN ANY RECALLS. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND REFERRED THE CONTACT TO NHTSA. THE APPROXIMATE FAILURE MILEAGE WAS 133,000.”
Owner complaint to NHTSAFiled Jun 14, 2018Visibility, StructureODI 11101848
“THE CAB TO FRAME MOUNTING BOLT BUSHINGS, AND STEERING STABILIZER BUSHINGS ARE HAVE AND ARE CRUMBLING. ALL NEED TO BE REPLACED. I FEEL FORD IS AWARE OF THIS PROBLEM AND SHOULD HAVE TO FIX IT. I JUST INHERITED THIS TRUCK AND JUST FOUND OUT ABOUT THIS. THANK YOU.”
Owner complaint to NHTSAFiled Oct 16, 2017Suspension, StructureODI 11033833
“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. WE WOULD APPRECIATE SOMEONE LOOKING INTO THIS, AS IT COULD HAPPEN TO ANYONE AND PROVE TO BE VERY DANGEROUS IF THIS VEHICLE WERE BEING DRIVEN WHEN THIS EXPLOSION OCCURED. PLEASE CHECK INTO THIS ASAP.”
Owner complaint to NHTSAFiled May 10, 2017StructureODI 10984673
“THE BACK LIFT GATE HAS A CRACK. I HAVE NOTICED THIS ON PRACTICALLY EVERY OTHER EXPLOER OF THIS YEAR. I CONTACTED FORD SEVERAL YEARS AGO AND THEY SAID SINCE IT WAS A DEFECT THAT WAS NOT A DANGER THEY WOULD NOT RECALL OR REPAIR IT.”
Owner complaint to NHTSAFiled May 8, 2017StructureODI 10984158

Showing 6 of 389 reports. Read every report on NHTSA.gov.

Data from NHTSA Complaints API (owner reports, unverified) · synced Nov 5, 2026NHTSA vehicle page
02 —Related recalls

2 recalls on this component

Structure: hatchback

Free remedy

ON CERTAIN SPORT UTILITY VEHICLES, THE LIFTGATE GLASS STRUT MAY BECOME DISENGAGED OR THE HINGE MAY FRACTURE ALLOWING THE GLASS TO FALL AND POSSIBLY BREAK.

StructureReported Sep 13, 2004NHTSA 04V442000

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 5, 2026

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