Three problems related to tank assembly 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.
1. Event: gasoline leaking onto pavement. 2. Ford dealer inspected and found a crack in the filler neck on top of the gasoline tank. I, nor a foreign object, have access to this area. Tank will leak gas onto pavement continuously until below crack level. If an igniter such as a cigarette or match or spark is near the flame, a fire will start on ground under the gas tank leading to the gas tank coated with gas resulting in a vehicle fire or explosion. 3. Ford dealer estimated replacement cost at $1,350. Ford dealer stated this is not a recall item and would not discuss the fact that this might be a defect in the injection molded gasoline tank. I then contacted Ford motor company customer care. Ford motor company customer care would not give me the name of the local Ford motor company representative (regional manager), a superior customer care rep to take my concern to a higher level and dismissed my concern that this was a safety defect issue. I was then informed that there was no further recourse and there was nothing else Ford motor company or my Ford dealer could do for my situation. Therefore, I have no further recourse except to submit my complaint. I cannot afford a replacement gas tank (tank is still installed on my vehicle).
Fuel pump could not maintain proper fuel pressure. When it was replaced, dealership service dept. Discovered neck on fuel tank was warped where fuel pump connects to fuel tank. Evidence of fuel leak due to this problem was discovered.
Consumer complained about fuel tank leaking fuel while driving 45 mph. Vehicle was taken to the dealer, who informed consumer that the tank had a crack that was caused by the vehicle running over a rock.