Ford Expedition 2003–2006
2nd generation · U222
NHTSA data through 12 August 20262,028 complaints, 1,632 with mileageMethod
On this generation, failures are spread across the mileage range, with the middle half between 42,000 and 118,000 miles.
- Rest of the range
- Median
- 200,000+ — 61 complaints (3.7%), plotted separately
- 10%
- 10,756
- 25%
- 42,000
- Median
- 80,000
- 75%
- 118,000
- 90%
- 158,612
Show the numbers
| Mileage | Complaints | Share |
|---|---|---|
| 0–5,000 | 103 | 6.3% |
| 5,000–10,000 | 43 | 2.6% |
| 10,000–15,000 | 51 | 3.1% |
| 15,000–20,000 | 40 | 2.5% |
| 20,000–25,000 | 40 | 2.5% |
| 25,000–30,000 | 30 | 1.8% |
| 30,000–35,000 | 34 | 2.1% |
| 35,000–40,000 | 46 | 2.8% |
| 40,000–45,000 | 35 | 2.1% |
| 45,000–50,000 | 46 | 2.8% |
| 50,000–55,000 | 45 | 2.8% |
| 55,000–60,000 | 50 | 3.1% |
| 60,000–65,000 | 72 | 4.4% |
| 65,000–70,000 | 58 | 3.6% |
| 70,000–75,000 | 59 | 3.6% |
| 75,000–80,000 | 61 | 3.7% |
| 80,000–85,000 | 85 | 5.2% |
| 85,000–90,000 | 56 | 3.4% |
| 90,000–95,000 | 55 | 3.4% |
| 95,000–100,000 | 47 | 2.9% |
| 100,000–105,000 | 57 | 3.5% |
| 105,000–110,000 | 40 | 2.5% |
| 110,000–115,000 | 43 | 2.6% |
| 115,000–120,000 | 36 | 2.2% |
| 120,000–125,000 | 49 | 3.0% |
| 125,000–130,000 | 36 | 2.2% |
| 130,000–135,000 | 34 | 2.1% |
| 135,000–140,000 | 33 | 2.0% |
| 140,000–145,000 | 25 | 1.5% |
| 145,000–150,000 | 19 | 1.2% |
| 150,000–155,000 | 23 | 1.4% |
| 155,000–160,000 | 19 | 1.2% |
| 160,000–165,000 | 26 | 1.6% |
| 165,000–170,000 | 6 | 0.4% |
| 170,000–175,000 | 10 | 0.6% |
| 175,000–180,000 | 9 | 0.6% |
| 180,000–185,000 | 9 | 0.6% |
| 185,000–190,000 | 19 | 1.2% |
| 190,000–195,000 | 11 | 0.7% |
| 195,000–200,000 | 11 | 0.7% |
| 200,000+ | 61 | 3.7% |
What this can and cannot tell you: these are complaints owners chose to file, not a failure rate. Popular models accumulate more of them simply by being common. How this is built.
Owners filed 2,028 complaints with NHTSA about the 2003–2006 Ford Expedition, and 1,632 of them record the mileage at which the failure happened. That is enough to show not just what fails, but when.
Failures are spread across the mileage range, with the middle half between 42,000 and 118,000 miles. The median is 80,000 miles.
The most-reported areas are the engine and its cooling system (13.9% of complaints, typically around 81,000 miles), the electrical system (12.3% of complaints, typically around 83,000 miles), the engine (10.7% of complaints, typically around 120,000 miles).
What fails, and when
- Engine and its cooling system81,000median 81,023 miles, middle half 59,000 to 100,000
- Electrical system83,000median 83,000 miles, middle half 55,000 to 130,000
- Engine120,000median 120,000 miles, middle half 90,000 to 150,000
- Transmission and driveline62,000median 62,500 miles, middle half 17,000 to 107,000
- Throttle and speed control75,000median 74,650 miles, middle half 50,000 to 92,000
- Airbag system84,000median 84,385 miles, middle half 44,000 to 128,000
- Hydraulic brake circuit19,000median 18,535 miles, middle half 8,000 to 35,000
| System | Complaints | Share | Median | 25–75% |
|---|---|---|---|---|
| Engine and its cooling system | 281 | 13.9% | 81,000 | 59,000–100,000 |
| Electrical system | 250 | 12.3% | 83,000 | 55,000–130,000 |
| Engine | 217 | 10.7% | 120,000 | 90,000–150,000 |
| Transmission and driveline | 145 | 7.1% | 62,000 | 17,000–107,000 |
| Throttle and speed control | 136 | 6.7% | 75,000 | 50,000–92,000 |
| Airbag system | 134 | 6.6% | 84,000 | 44,000–128,000 |
| Hydraulic brake circuit | 120 | 5.9% | 19,000 | 8,000–35,000 |
| Tyres | 98 | 4.8% | 38,000 | 8,000–69,000 |
| Body structure | 91 | 4.5% | 68,000 | 38,000–100,000 |
| Fuel system | 72 | 3.6% | 70,000 | 57,000–108,000 |
Which systems, and when
Complaints about this generation are not spread evenly across the vehicle, and the systems that generate the most of them do not all fail at the same point in a car's life. The median failure across all systems here is 80,000 miles; the figures below show which parts of the car run ahead of that and which run behind.
The engine and its cooling system accounts for 13.9% of complaints (281 reports, 249 of them with a mileage figure), with a median of 81,023 miles, close to the vehicle's overall pattern. The middle half of these reports falls between 59,022 and 100,070 miles.
The electrical system accounts for 12.3% of complaints (250 reports, 205 of them with a mileage figure), with a median of 83,000 miles, close to the vehicle's overall pattern. The middle half of these reports falls between 55,000 and 130,000 miles.
The engine accounts for 10.7% of complaints (217 reports, 191 of them with a mileage figure), and it fails late — a median of 120,000 miles, considerably beyond the vehicle's overall median. That pattern is consistent with normal service life rather than a defect, though it matters for anyone buying an example already near that mileage. The middle half of these reports falls between 90,000 and 150,000 miles.
The transmission and driveline accounts for 7.1% of complaints (145 reports, 118 of them with a mileage figure), with a median of 62,500 miles, close to the vehicle's overall pattern. The middle half of these reports falls between 17,493 and 107,000 miles.
Throttle and speed control accounts for 6.7% of complaints (136 reports, 124 of them with a mileage figure), with a median of 74,650 miles, close to the vehicle's overall pattern. The middle half of these reports falls between 50,500 and 92,000 miles.
The airbag system accounts for 6.6% of complaints (134 reports, 106 of them with a mileage figure), with a median of 84,385 miles, close to the vehicle's overall pattern. The middle half of these reports falls between 44,000 and 127,500 miles.
Differences between model years
Within this generation, complaint volume is not constant across model years. The 2003 model year drew the most — 800 complaints — while 2004 drew the fewest at 381. The median year sits at 423.
The first year of the generation, 2003, sits above the median. That is a common pattern — early production of a redesigned vehicle tends to surface problems that later years do not repeat — and it is worth weighing when choosing between years.
Recalls and what they cover
No recall campaigns covering this generation appear in NHTSA's post-2010 recall file. That is not the same as an absence of problems — recalls address safety defects specifically, and many of the complaints above concern faults that are expensive or annoying without meeting that threshold.
Reported severity
Of the 2,028 complaints filed against this generation, 188 reported a crash; 71 reported a fire; 223 reported an injury; 8 reported a fatality. Crash-involved reports represent 9.3% of the total.
These are owner-reported outcomes, not verified investigations, and they are not adjusted for how many of these vehicles are on the road. They are included because the distinction between a fault that strands a car and a fault that causes a collision is the one that matters most, and it is not visible in a complaint count alone.
What this means if you are buying one
For a buyer, failures on this generation are spread rather than concentrated: the middle half falls between 42,000 and 118,000 miles, with a median of 80,000. There is no single mileage threshold to watch, which means condition and maintenance records are more informative than the odometer.
On inspection, the engine and its cooling system and the electrical system are where this generation's reports concentrate, so those are the areas worth a specific look. The engine and its cooling system in particular shows a median failure mileage of 81,023, which gives a concrete number to compare against the odometer of any car you are considering.
None of this is a substitute for a pre-purchase inspection on the individual car. Aggregate patterns describe a population; the example in front of you has its own history.
Documented problems
Engine 2005–2006
Three-valve 5.4L two-piece spark plug design: the lower ground-shield section seizes in the head from carbon buildup and snaps off during removal, requiring specialized extraction and often head damage.
Engine 2005–2006
Variable cam timing phaser rattle. Oil-fed cam phasers lose control authority when hot idle oil pressure or oil condition degrades, producing a diesel-like rattle at cold start and idle, and can progress to timing chain and cam damage.
Suspension
Rear air suspension air spring and compressor failure (independent rear suspension introduced this generation).
By model year
| Year | Complaints | With mileage |
|---|---|---|
| 2003 | 800 | 592 |
| 2004 | 381 | 287 |
| 2005 | 452 | 407 |
| 2006 | 395 | 346 |
What owners reported
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…
2003 · 25 miles · Body structure
Tl* the contact owns a 2003 Ford Expedition. The contact stated while driving 45 MPH the vehicle failed to absorb impact from driving over a pot hole. The contact believed the failure may be caused by the upper and lower control arm bushing and ball joints prematurely wearing out. The vehicle was not taken to the…
2003 · 45 miles · Suspension
2003 Ford Expedition headlights are too dim to drive safely. Husband has returned vehicle to Ford dealer and had them checked, not long after we bought it new. Service dept says headlights are fine. Both my husband and i feel that it is a safety hazard to drive with the dims on, because we can't see far enough in…
2003 · 100 miles · Exterior lighting
2003 Ford Expedition eddie bauer edition. Side rear view mirrors with backup assist will malfunction at anytime causing you to constantly be aware that the mirrors are never going to be reset to the drivers desired setting. This is a road hazard that needs to be recalled. If the drivers of these particular vehicles…
2003 · 125 miles · Visibility equipment
Built from 1,632 NHTSA complaints with mileage · snapshot 2026-08-12 · open data · reproduce this page