2003 Ford Expedition Electrical System

Faulty fuse panel. This is a known issue. It is ALL over the internet. There has never been a recall. The vehicle will stall while driving. On attempting restart or crank, there is a buzzing noise from the fuse panel. The pcm #203 I believe, corrodes or melts through the board on the panel causing the fault. Replacing the fuse/relay will correct, but for a time. Panel replacement is required. First incident at 165k. Second incident at about 205k. After the last panel replacement, the vehicle continued to stall. Another faulty fuse, for the day running lamps, caused a fault, which melted the housing between the panel and the wiring harness. The screw attachment is "crunchy" because of the melted elements. The smell is noticeable, and the panel requires replacement again. Third incident about 246k. This is a fire hazard. The wiring harness is hot to the touch. Being a KNOWN issue, having discussed on various socials and with ford dealer techs, this should have been recalled ages ago.

WAS DRIVING CAR HAD AT LEAST 80 MILES WHEN CAR CUT OFF AT LIGHT IN WOULD NOT COME BACK ON SO I HAD REPLACED FUEL PUMP ONLY TO FIND OUT MY FUSE BOX ISN'T READING MY FUEL RELAYS FROM THE BURNING RELAYS REPLACED. *TR

AS MY FIANCE WAS COMING FROM WORK THE CAR SUDDENLY JUST QUIT ON HIM WHILE DOING 75 MPH. HE GUIDED THE CAR TO THE SIDE OF THE ROAD TO A COMPLETE STOP. HE TRIED TO CRANK THE CAR AGAIN TO ONLY HEARING A BUZZING SOUND. THE FIRST MECHANIC THOUGHT IT WAS THE STARTER SO HE CHANGED IT OUT. THE VEHICLE STILL WOULD NOT START BUT KEPT MAKING THE BUZZING SOUND. THE MECHANIC CAME OUT AGAIN TO SEE WHAT THE ISSUE WAS TOLD ME TO CHANGE MY RELAY SWITCH I DID STILL HASN'T STARTED UP YET. MY VEHICLE HAS BEEN SITTING UP FOR THREE WEEKS NOW. *TR

TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. THE CONTACT STATED THAT THE FUSE BOX FAILED. WHILE DRIVING 85 MPH, THE VEHICLE STALLED WITHOUT WARNING, THE STEERING WHEEL SEIZED, AND THE FUSE BOX MADE A BUZZING SOUND. THE CONTACT COASTED THE VEHICLE TO THE SIDE OF THE ROAD, REACHED UNDER THE DASHBOARD, AND PULLED THE RELAY FUSE TO STOP THE BUZZING NOISE. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE WHERE AN INDEPENDENT MECHANIC DIAGNOSED THAT THE FUEL PUMP WAS BURNED. ANOTHER MECHANIC CAME ALSO CAME TO THE CONTACT'S RESIDENCE AND INFORMED HER THAT THE FUSE RELAY AND THE FUSE BOX NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE CONTACT CALLED ANDERSON FORD (3900 CLEMSON BLVD, ANDERSON, SC 29621, (864) 225-4151) AND WAS PROVIDED WITH A QUOTE. THE CONTACT STATED THAT THE FAILURE RECURRED SEVERAL TIMES AND THE FUEL PUMP/FILTER, 402 SENSORS, AND FUSE RELAYS WERE REPLACED NUMEROUS TIMES. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURES. THE FAILURE MILEAGE WAS APPROXIMATELY 236,000. *DT *TR

KEEPS BLOWING THE FUEL PUMP REPLY. WE HAVE HAD TO REPLACE THE REPLY 4 TIMES IN THE LAST FEW DAYS. AFTER REMOVING THE REPLY FROM THE FUSE PANEL AND LOOKING AT THE PORT IT IS BURNING BOTH FUSE AND FUSE PANEL.THIS HAPPEN WHEN WE ARE RUNNING AND WHEN THE FUSE BLOWS IT KILLS THE VEHICLE RIGHT AWAY IN THE MIDDLE OF THE STREET

TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. OCCASIONALLY, THE VEHICLE WOULD NOT IMMEDIATELY START DUE TO A FAULTY FUSE BOX. THE FUSE BOX WAS REPLACED BY THE OWNER AND THE FAILURE WAS REMEDIED. EVENTUALLY, WHILE DRIVING, THE VEHICLE SHUT COMPLETELY OFF AND COULD NOT BE RESTARTED. THE CAUSE OF THE FAILURE WAS NOT DETERMINED. THE MANUFACTURER AND LOCAL DEALER (VISTA FORD IN WOODLAND HILLS, CA) WERE NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 160,000.

THE COMPLAINT IS IN REGARDS TO THE CIRCUIT BOARD. THE CAR MAY STOP AT RANDOM TIMES. WE HAVE BEEN IN THE VEHICLE GOING 35 MILES AN HOUR AND THE CAR SUDDENLY STOPPED. IT APPEARED THAT IT WAS A FUSE THAT BURNED OUT.... THAT SEEMED TO FIX THE PROBLEM TEMPORARILY BUT THEN IT HAPPENED AGAIN AT A HIGHER SPEED. LUCKILY THERE WERE NO INJURIES. FORD SEEMS TO BE AWARE OF THIS PROBLEM AND SHOULD ISSUE A RECALL. I WAS TOLD FROM DEALERSHIP THAT WHAT HAPPENS IS THAT THE WATER RUNS DOWN THE SIDE AND GETS INTO THE FUSE BOX. THIS IS CAUSING A SHORT. SO, THE REASON IT WORKED THE FIRST TIME WAS BECAUSE WE ADDED A NEW FUSE. BUT, THE SECOND TIME THAT IT STOPPED IT BURNED THE FUSE BOX. NOW, I HAD TO TOW THE VEHICLE AND REPLACE THE PART COSTING OVER $500. AFTER RESEARCHING THIS ISSUE IT APPEARS TO BE A NUMBER OF COMPLAINS WITH THE SAME ISSUE. FORD SHOULD ISSUE RECALL.

VEHICLE STALL WHILE DRIVING FREEWAY.MY WIFE FIRST THEN I EXPERIENCE MYSELF STALL VEHICLE ON FAST LANE VERY DANGEROUS.VEHICLE JUST SHUT OFF CANNOT STEER THE WHEEL LUCKY ENOUGH TO GLIDE TO SAFETY SIDE.FUSE BOX BURNING THE FUEL PUMP RELAY LOTS OF COMPLAINT IN INTERNET HOW MANY LIVES TO WASTE BEFORE ANYONE ACT ON IT.

OPEN DOOR SOUND INDICATOR WHILE ENGINE IS RUNNING--VEHICLE STOPPED TO LET PASSENGER OUT. WHEN ANY DOOR IS OPENED, THE OPEN-DOOR HIGH PITCHED STEADY-HUM SOUND COMES ON, WHICH IS NORMAL, HOWEVER, THE HUM WILL NOT SHUT OFF. IT CONTINUES LOUDLY FOR 8-10 MINUTES AND THEN REDUCES TO A FAINT HUM UNDER THE DASH. THE SOUND(S) CONTINUE EVEN AFTER THE SUV IS TURNED OFF, PUT IN PARK, AND THE KEY IS REMOVED. WE ARE THE ORIGINAL OWNERS OF THE 2003 EDDIE BAUER EXPEDITION AND IT'S OTHERWISE IN EXCELLENT SHAPE WITH JUST 57,000 MILES. THIS PROBLEM HAS RECENTLY BEEN VERIFIED BY A LOCAL FORD/KIA REPAIR SHOP WHOSE MECHANIC SCRATCHED HIS HEAD IN CONFUSION; HOWEVER, THEY WANT TO CHARGE US TO TEAR THE DASH APART TO ATTEMPT TO FIGURE OUT WHY THIS IS HAPPENING. THEY CAN'T TURN THE INDICATOR SPEAKER OFF ALTOGETHER. WE WANT TO KNOW WHAT FORD KNOWS ABOUT THE PROBLEM; MAINLY, WHAT IS CAUSING THE PROBLEM. CAN IF BE FIXED VIA A SIMPLER SOLUTION (MAYBE A SIMPLE FUSE OR WIRING?), IS THIS IS A POSSIBLE FUTURE FIRE DANGER, AND HAVE ANY OTHERS HAVE EXPERIENCED THIS UNUSUAL OCCURRENCE.

CREDIT ACCEPTANCE CORPORATION 25505 W TWELVE MILE ROAD P.O. BOX 513 SOUTHFIELD,MI 48037 1-800-634-1506 INSTALLED A GPS DEVICE WHEN I PURCHSED THIS VEHICLE USED. I HAD IT REPLACED ONCE BY THE DEALER BECAUSE IT NOT ONLY DISABLED THE VEHICLE WHEN NOT MOVING,BUT IT CREATED A DANGEROUS PROBLEM WHEN I WAS DRIVING CUTTING THE VEHICLES POWER OFF. CREDIT ACCEPTANCE DENIES THEY HAD ANYTHING TO DO WITH IT . THIS STARTED TO HAPPEN WHEN I FELL BEHIND ON PAYMENTS.

TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. THE CONTACT STATED THAT THE FUSE BOX IN THE VEHICLE SMELLED LIKE SMOKE AND WAS OVERHEATING. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE FUSE BOX NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 185,000.

THERE ARE MANY ISSUES AND CONCERNS ABOUT MY 2003 FORD EXPEDITION. FROM REVERSE BACK UP SENSOR BLINKERS WINDOWS, FOUR WAY FLASHERS, CD PLAYER, FOUR WHEEL DRIVE, WIPERS, BACK UP LIGHTS, POWER MIRRORS, POWER SEATS, DASH BOARD GAGES, POWER LOCKS, ALL WILL STOP WORKING SUDDENLY AT DIFFERENT PERIODS OF TIMES. FORD HAS STAITEF THERE ARE NO RECALLS FOR THIS YEARS MAKE AND MODEL WHEN ALL OWNERS OF THIS VEHICLE HAVE COMPLAINED ABOUT ALL OF THESE ISSUES. I AM FIANCING THIS VEHICLE FOR $10 THOUSAND AND DEMAND A RECALL FOR ELECTRICAL ISSUES FOR THIS VEHICLE. THE INTERNET IS PASTED WITH SIMILAR ISSUES AND FORD IS TAKING PEOPLE'S MONEY TO TRY AND FIX ALL THE ISSUES AND NEVER COMPLETELY FIXING THE ISSUE. I NEED AN ANSWER TO MY PROBLEM AND I WANT FORD TO BUY BACK MY VEHICLE.

THIS SPECIFIC MAKE AND MODEL YEAR HAS A DEFECTIVE FUSE BOX WHICH CASE A FUSE CALLED A PCM RELAY TO MELT AND CAUSES THE VEHICLE TO STALL AND NOT START. THE FUSE BOX WILL BUZZ CONTINUOUSLY BUT THE VEHICLE DOES NOT START. YOU CAN REPLACE THE RELAY WHICH IS ABOUT $15 BUT THIS IS MORE THAN LIKELY TEMPORARY AND IT WILL MELT AND CAUSE THE VEHICLE TO STALL. THE ONLY REMEDY IS TO REPLACE THE FUSE PANEL ENTIRELY WHICH BRINGS ME HERE, THE PANEL ALONE IS $500 AND THAT DOESN'T INCLUDE LABOR AND TAXES. FORD IS WELL AWARE OF THIS ISSUE AS THERE ARE THOUSANDS OF FORUMS ONLINE THAT REFER TO THIS SPECIFIC MANUFACTURER DEFECT. I'VE SPENT THOUSANDS REPLACING PARTS THAT DID NOT NEED REPAIR. FORD NEEDS TO FOOT THE BILL FOR THIS DEFECT BECAUSE IT'S A MANUFACTURE'S DEFECT NOT A CONSUMER (WEAR AND TEAR) ISSUE.

ON FEB 13, 14 THE DOOR LOCKS ON THE RIGHT HAND SIDE OF THE EXPEDITION FAILED TO LOCK WHEN THE CAR WAS PLACED INTO MOTION - WHICH MADE THE CAR VENERABLE TO ENTRY OR EXIT WITH OR WITHOUT STOPPING. TOOK THE CAR TO THE DEALER, WE WERE TOLD NEEDED TO REPLACE BOTH RIGHT SIDE DOOR LOCKS BECAUSE THEY ARE A MATCHED SET - COST $500. TWO WEEKS A GO THE SAME THING HAS HAPPENED TO THE LEFT SIDE OF THE CAR HAVE AN APPOINTMENT FOR MONDAY FEB 23 TO INVESTIGATE THE DOOR LOCKING PROBLEM. TWO SETS OF LOCKS FAILING (RIGHTHAND SIDE & LEFTHAND SIDES) WITHIN A YEAR SHOULD BE INVESTIGATED FOR DEFECTIVE PARTS AND POSSIBLE INJURY IF SOMEONE WERE TO OPEN THE DOOR WHILE THE CAR WAS IN MOTION. *TR

TL* THE CONTACT OWNED A 2003 FORD EXPEDITION. WHILE PARKED IN A RESIDENTIAL DRIVEWAY, THE VEHICLE CAUGHT FIRE AND BURNED DOWN TO THE FRAME. A FIRE REPORT WAS FILED. THE VEHICLE WAS DESTROYED. THE CAUSE OF THE FIRE WAS UNKNOWN. THE MANUFACTURER WAS NOT NOTIFIED. THE VIN WAS UNAVAILABLE. THE FAILURE MILEAGE WAS 220,000.

MY 03 FORD EXPEDITION WOULD NOT START AND WAS MAKING A TICKING SOUND. FOUND OUT IT WAS A RELAY SWITCH CHANGED IT AND IT STARTED BUT IT KEEPS BLOWING ABOUT EVERY 3-4 WEEKS. *TR

ENGINE WONT TURN OFF WITH KEYS TAKEN OUT, DASHLIGHTS ON AND OFF, AIR CONDITIONER CAME ON WHEN DOOR WAS OPENED, WARNING BELL AND NO KEYS IN IGNITION, HEAD AND TAIL LIGHTS REMAIN ON, SIDE MIRRORS MOVE AND WILL NOT GO BACK, WHEN KEY POD USED ALL THESE PROBLEMS GO OFF AT THE SAME TIME. *TR

WHILE DRIVING ON THE HIGHWAY MY CAR SHUT OFF.I CAME VERY CLOSS TO BEING KILLED OR SERIOUS INJURIED.MY MECHANIC COULDNT FIND THE CAUSE. THIS HAPPENED ABOUT 10 TIMES IN 7 YEARS.CAN YOU HELP ME? *TR

AT 4:40AM, WAS WOKE UP BY THE POLICE AND FIRE DEPARTMENT WHO RESPONDED TO A CALL IN OF OUR VEHICLE, A 2003 FORD EXPEDITION BEING ON FIRE. BASED ON THE INFORMATION RECEIVED FROM THE FIRE CREW CHIEF, THE FIRE HAD STARTED IN THE ENGINE COMPARTMENT, ON THE DRIVER'S SIDE, AND APPEARED TO BE ELECTRICAL IN NATURE. THE CAR HAD LAST BEEN USED THE PRIOR NIGHT AT 8PM, WHEN WE RETURNED FROM EATING DINNER, AND HAD REMAINED IDLE SINCE THAT TIME. UPON HEARING OUR STORY, SEVERAL FRIENDS MENTIONED THAT THEY HAD READ STORIES ABOUT FORD VEHICLES THAT HAD AN ISSUE WITH THE CRUISE CONTROL SWITCH CAUSING FIRES, EVEN IN VEHICLES THAT HAD REMAINED IDLE FOR SEVERAL HOURS. I CHECKED AND IT DOES NOT APPEAR THERE WERE ANY RECALLS FOR MY VEHICLE'S YEAR, BUT HAD BEEN FOR THE PRIOR YEAR'S (2002). HERE IS A LINK TO ONE ARTICLE (ALTHOUGH THERE ARE MANY): HTTP://ARTICLES.CNN.COM/2005-06-16/US/FORD.VEHICLES_1_FORD-VEHICLES-BRAKE-FLUID-CRUISE-CONTROL?_S=PM:US THE CAR IS A COMPLETE LOSS, THE ENGINE MOSTLY GONE AND THE TIRE AND PART OF THE BODY MELTED TO MY DRIVEWAY. THE DAMAGE INSPECTOR FOR OUR INSURANCE COMPANY STATED IT WAS LIKELY THAT THEY WOULD NOT BE ABLE TO COVER OUR FULL LIEN AMOUNT AND I BELIEVE AT THE VERY LEAST FORD SHOULD MAKE WHOLE FOR US. THE INSURANCE COMPANY IS WORKING WITH FORD ABOUT POSSIBLE SUBROGATION, BUT IT IS UNCLEAR AT THIS POINT IN TIME IF THE INSURANCE COMPANY WILL ASK FOR DOLLARS BEYOND WHAT THEY WOULD PAY OUT IN THE LOSS. WE WERE FORTUNATE IT DID NOT SPREAD TO OUR HOME, MY HUSBAND'S FORD PARKED NEXT TO IT OR TO OUR BOAT WHICH WAS DIRECTLY IN FRONT OF IT. IT WAS VERY, VERY CLOSE AND COULD HAVE EASILY HAPPENED. WE FEEL VERY FORTUNATE THAT WE DID NOT PARK THE VEHICLE IN OUR GARAGE OR ANY CLOSER TO THE BOAT, WHOSE COVER HAD MELTED AND COULD HAVE EASILY SET ON FIRE GIVEN THE HEAT AND SEVERITY OF THE FIRE.

MY 2003 FORD EXPEDITION WILL BE DRIVING FINE, THEN ALL OF A SUDDEN IT WILL DIE IN TRAFFIC AND HAVE HAD SEVERAL CLOSE CALLS OF BEING REAR ENDED. ONE OTHER TIME IT DIED AND WHILE COASTING AFTER IT DIED, IT STARTED AGAIN CAUSING VEHICLE TO LUNGE AND MY WIFE ALMOST REAR ENDED SOMEONE ELSE. THE VEHICLE IS AT THE REPAIR SHOP AND IT IS DIAGNOSED AS A PCM THAT IS AND NOW HAS A HARD FAILURE. *TR

ONE OF MY SPARK PLUGS BLEW OUT OF THE HEAD WITH ONLY 47,000 MILES ON MY 2003 EXPEDITION. 4 HOURS TO FIX IT. NOW I HAVE TO GO BACK AND TORQUE THE OTHER 7 PLUGS AND HOPE THE PIECE OF CRAP DOESN'T SPIT OUT ANY OTHER PLUGS. THIS IS MY LAST FORD! *TR

2003 FORD EXPEDITION- AFTER IT RAINS I AM HAVING MANY DIFFERENT THINGS HAPPENING WITHIN THE ELECTRICAL SYSTEM. THE DOORS WON'T LOCK, THE RADIO WON'T LIGHT UP ANY MORE, THE INTERIOR LIGHTS WON'T SHUT OFF, THE FRONT WINDOWS WON'T WORK, MILDEW SMELL IN THE CAR. THE ELECTRICAL PROBLEMS ALONE CAN CAUSE A FIRE BUT WITH THE DOORS NOT BEING ABLE TO BE LOCKED IS A COMPLETELY DIFFERENT STORY AND I AM CONCERNED FOR MY FAMILIES SAFETY. I HEARD FROM THE DEALER AND OTHERS THAT FORD WILL NOT ISSUE A RECALL FOR THIS ONGOING PROBLEM. *TR

ON JUNE 19 2009, RETURNING HOME FROM A SHORT TRIP, THICK SMOKE ERUPTED WITH STRONG RUBBER SMELL FROM UNDERNEATH THE DRIVER SEAT. I IMMEDIATELY TURNED OFF THE IGNITION AND EXITED THE CAR. THE FOLLOWING DAY I CONTACTED FORD MOTOR CO. AND INFORM THEM OF THE SAFETY ISSUE, AFTER GOING BACK AND FORTH, FORD GENERAL CONSUL OFFICE MADE DECISION THAT THE ISSUE IS NOT SAFETY HAZARDS AND WILL NOT REPAIR THE VEHICLE. PAT MILLIKEN FORD HAS THE VEHICLE, AND INSPECTED THE DAMAGE, WHICH DECLARED TO BE VERY EXTENSIVE THE REPAIR COST MAY EXCEED $2000.00. FORD GENERAL CONSUL WAS INFORMED OF THE DAMAGE AND STILL WILL NOT CONSIDER IT AS SAFETY ISSUE BECAUSE THE VEHICLE DID NOT BURST ON FIRE. MY SMART AND QUICK REACTION TO TURN OFF THE VEHICLE AND CUT THE POWER OFF PREVENTED A DISASTER TO HAPPEN, AND YET AS A CONSUMER I'M LEFT WITH HEFTY REPAIR BILLS FOR A POSSIBLE MANUFACTURING DEFECT IN THE WIRING.*TR

LOSS OF BRAKE LIGHTS TO 2003 FORD EXPEDITION, TOOK IT INTO DEALERSHIP THEY FOUND A FIRE IN OVERHEAD WIRING HARNESS. FORD CLAIMS TO HAVE NO PROBLEMS WITH HARNESS. NONE OF THESE WIRES WERE VISIBLE TO US , BUT HAD MELTED THE UNDERSIDE OF OVERHEAD COMPARTMENT. VISIBLE BURN MARKS ON METAL INTERIOR OF ROOF. ALL OVERHEAD WIRING HAS TO BE REPLACED. *TR

WHILE TRAVELING AT HIGHWAY SPEEDS, THE ENGINE WOULD QUIT WITH NO PROCEEDING SYMPTOMS OR INDICATIONS. SHIFTING TO NEUTRAL AND TRYING TO RE-START WOULD NOT WORK. SHIFTING TO NEUTRAL, TURNING OFF THE IGNITION AND THEN TURNING THE KEY TO START DID CAUSE A RE-START. THIS PROBLEM CAUSES THE "SERVICE ENGINE SOON" LIGHT ON THE DASH TO LIGHT, SO A CODE IS BEING GENERATED. FORD IS AWARE OF THIS PROBLEM, SINCE IT HAS ISSUED A NOTICE (NOT A RECALL) TO IT'S SERVICE DEPARTMENTS. THE REPAIR IS THE REPLACEMENT OF THE ALTERNATOR WIRING HARNESS ASSEMBLY AND REPROGRAMMING OF THE PROCESSOR. FORD HAS NOT ISSUED A RECALL FOR THIS VERY UNSAFE PROBLEM, SO THE CHARGE FOR THE WORK IS $ 342.64. *TR