Eight problems related to manifold/header/muffler/tail pipe have been reported for the 2003 Ford F-150. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2003 Ford F-150 based on all problems reported for the 2003 F-150.
Requestng Ford be made to issue a recall for exhaust manifold holes and cracking issues. This issue is known and the are multiple forums online where people are talking about having this issue. When the manifold leaks, the risk is there that exhaust fumes can get into the driving compartment and asphyxiate the people in the car. It is an expensive repair for an issue for should have resolved long ago.
The contact owns a 2003 Ford F-150. The contact stated that exhaust fumes were present inside the vehicle. The vehicle was taken to an independent mechanic for diagnostic testing. The technician stated that the manifold was leaking. The vehicle was not repaired and the manufacturer was notified of the failure. The approximate failure mileage was 80,000.
2003 Ford f150. Consumer writes in regards to vehicle brake issues. The consumer stated when he came to a stop, with his foot on the brake, the vehicle rolled forward. The dealer replaced the hydraulic control unit. Also, the exhaust manifold was cracked.
The contact owns a 2003 Ford F-150. The contact stated that while driving at various speeds, he heard a vibrating noise from beneath the vehicle. Upon further inspection, he noticed that a clamp holding the exhaust system had rusted and had became partially detached. The contact personally replaced the clamp. The failure and current mileage was 135,000.
Spark plug blew out of the engine, stripping all the threads in the cylinder head.
Truck was parked overnight (no problems). Next morning, I started the truck. It sounded like a lawnmower trying to start with a loud "popping" noise. Smelt raw gas vapors coming from the top of the engine. Took to Ford to fix. They quoted me $3200 repair job by replacing a cylinder head. I refused and took to a (farther away) trustworthy mechanic to put a thread insert into spark plug hole and use a helicoi for approx $400. Ford refused to do thread insert repair, and wanted to sell me same part that broke in the first place.
2003 F-150 with 5. 4l triton engine. 54k miles, experiencing right cylinder head gasket leak. Ford has TSB 02227 concerning this issue. Truck had 36k warranty. The costly repairs are not covered by Ford. I believe there should be a recall on this defect in which the parts and labor is covered. I have researched with other owners on the internet who have had the same problems with their vehicles. I also believe there maybe a safety issue since the leaking oil drips onto the exhaust manifolds and catalytic converters which may cause a fire. Please look into this issue. Thanks.
Own a 2003 Ford f150 with 11,000 miles. There is a heat shield over the muffler that was falling down. Took vehicle to the dealer, and as instructed by Ford, was to remove the heat shield entirely. Feels this is dangerous without the heat shield which is not on the vehicle right now. Dealer ordered a new heat shield because the old one was deteriorating. Ford ordered not to replace the heat shield as per engineering since it was no longer needed. Leaking rear seal, pan and gasket were also replaced.