One problem related to blower has been reported for the 2003 Ford Expedition. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2003 Ford Expedition based on all problems reported for the 2003 Expedition.
Rear heating/ac air blend door actuator has failed. A drive gear inside the actuator has stripped and is missing two teeth. Upon further investigation it appears that the manual temperature control causes the actuator to reach one end of it's internal travel limit prematurely, straining the internal gear drive. Also, the air blend door travel limits are reached before the actuator limits, straining the internal gear drive further at both ends of travel. The two issues cause the effective rotation range of the manual temperature control to be reduced from 300 degrees of rotation to 135 degrees of rotation, and any positioning of the control outside the effective range strains and strips the gears of the blend door actuator.