Seven problems related to structure have 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.
I own a 2003 Ford Expedition. While washing my SUV, I recently discovered that the front of the slots on the roof between the luggage racks have rust bubbling up through the paint. There is no apparent damage in this area and 3 of the tracks have the same problem at varying stages of progression. I was informed by Ford that this was not covered under my warranty and there was nothing they could (would) do for me. I called the Ford customer service hot line and was told the same.
My 2003 Expedition had a crack in the overhead console when I purchased it used in 2004. I didn't see it at the time of purchase and didn't think that much of it when I did discover the crack. In the past year and a half the console has simply cracked apart and the plastic is very brittle. I've glued it a number of times but it keeps cracking apart in different places. I've called the parts department at my local Ford dealer and they tell me that I cannot purchase the housing for the overhead console separately. Therefore, I must purchase an entire new console package including the lights, switch, etc. According to the dealer, this part will cost me approximately $450. 00 not including any installation labor. I don't need the lights, switch, mirror, etc. , because those parts are all functional and fine. All I need is the housing. The part cant be worth more than $10. 00, especially when you consider how easily it broke into pieces. I don't know if this problem is prevalent in other Expeditions, but I should not be forced to pay over $500. 00 (parts and labor) for a small, cheap piece of plastic.
2003 Expedition headlight failed four different times due to water leakage. Heat brackets rusted due to water leakage. The consumer stated that Ford was aware of the body seal problem with the vehicle, but didn't issue a recall. The dealer tried to fix the problem six times with no success. The drivers side door rattled.
We just bought a new 2003 Expedition eddie bauer 4x4. The same night we drove it home it started to rain and we noticed a leak at the driver's grab handle. We took it back to the dealer and they replaced the front windshield stating it was not sealed correctly to the car's body. The next night it rained again and there was a puddle of water in the driver's seat. I took it back to the dealership and now they are saying the internal and external metal was not sealed at the left top corner on the driver's side. They are keeping it overnight to see if it's still leaking and will notify me tomorrow.
2003 Expedition has been vibrating since new. Purchased in sept 2002 it has been back to the dealer numerous times to no avail. They changed the differential fluids, the tires , worked on the rear changed tire pressures. Last time Ford factory rep came to sayville Ford. Said there is a vibration, but an acceptable one. To who I do not know. This vehicle is used as an emergency vehicle. What a lemon.
2003 Expedition leaked water into headlights causing it to fail. Seat brackets rusted caused by water leaks and door rattled. The dealer was aware that there was body seal problem.
While traveling windshield strip/molding blew off. The cause of the problem was not identified but the dealership replaced the strip/molding.