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Ford Expedition 2003–2006 problems by year and mileage

2nd generation · U222

NHTSA data through 18 October 20261,526 complaints, 1,240 with mileageMethod

Which year is yours? Tap it to see what breaks on it.

• 200380kmedian
• 200476kmedian
• 200575kmedian
• 200680kmedian

Tiles: each year’s median failure mileage. Latest: the 2006; earliest: the 2005, and the 2005 is 1 year older (part of the gap is age).

The short answer

“Is the 2003–2006 Ford Expedition reliable?”

Median of reported failures

79,000 mi

90% of reports came by

155,000 mi

Reports with mileage

1,240

Recalls

3

Most reported

1. Engine and its cooling system18.0% of complaints · median 81,000 mi
2. Electrical system16.3% of complaints · median 83,000 mi
3. Engine14.2% of complaints · median 120,000 mi

When each system fails ↓

Documented problems

• Engine2005–2006
• Engine2005–2006
• Suspension

What each one is ↓

Owners filed 1,526 complaints with NHTSA about the 2003–2006 Ford Expedition; the engine and its cooling system leads with 18% of them, and half of the 1,240 that record an odometer reading came by 79,000 miles — complaints, not a failure rate.

No single peak: the middle half runs 42,000 to 113,000 miles.

Before-you-buy checklist ↓At your mileage ↓Check this VIN — NHTSA ↗

How many miles does a 2003–2006 Ford Expedition last?

Figure 1 · Ford Expedition 2003–2006 · 1,240 reports with mileage

Mileage at failure

5,000-mile bins, 0 to 200,000 miles, linear scale; tallest bar 76 complaints

765738190

6.1% of all reports fall between 0 and 5,000 miles

25k50k75k100k125k150k175k200k

• Rest of the range
• Median
• 200,000+ — 34 complaints (2.7%), plotted separately

10%

12,000

25%

42,000

Median

79,000

75%

113,000

90%

155,000

Show the numbers

Complaints by mileage bin

Mileage	Complaints	Share
0–5,000	76	6.1%
5,000–10,000	35	2.8%
10,000–15,000	32	2.6%
15,000–20,000	26	2.1%
20,000–25,000	29	2.3%
25,000–30,000	26	2.1%
30,000–35,000	27	2.2%
35,000–40,000	39	3.1%
40,000–45,000	31	2.5%
45,000–50,000	37	3.0%
50,000–55,000	38	3.1%
55,000–60,000	43	3.5%
60,000–65,000	54	4.4%
65,000–70,000	47	3.8%
70,000–75,000	46	3.7%
75,000–80,000	46	3.7%
80,000–85,000	68	5.5%
85,000–90,000	45	3.6%
90,000–95,000	41	3.3%
95,000–100,000	37	3.0%
100,000–105,000	48	3.9%
105,000–110,000	35	2.8%
110,000–115,000	34	2.7%
115,000–120,000	24	1.9%
120,000–125,000	37	3.0%
125,000–130,000	23	1.9%
130,000–135,000	22	1.8%
135,000–140,000	24	1.9%
140,000–145,000	18	1.5%
145,000–150,000	13	1.0%
150,000–155,000	15	1.2%
155,000–160,000	13	1.0%
160,000–165,000	16	1.3%
165,000–170,000	5	0.4%
170,000–175,000	9	0.7%
175,000–180,000	7	0.6%
180,000–185,000	9	0.7%
185,000–190,000	16	1.3%
190,000–195,000	8	0.6%
195,000–200,000	7	0.6%
200,000+	34	2.7%

Source: NHTSA Office of Defects Investigation, public domain.

How to read these figures

Common Expedition problems, and when they happen

Figure 2 · Ford Expedition 2003–2006

When each system fails

Bar: middle half of reports · notch: median · proportional (log) scale (how to read it)

System0–12,000 mi factory-defect window12,000 mi and beyond wear and service lifeMedian

1. Hydraulic brake circuit113 reportsmedian 19,000middle half 8,000–37,000
2. Transmission and driveline143 reportsmedian 63,000middle half 18,000–107,000
3. Throttle and speed control136 reportsmedian 75,000middle half 50,000–92,000
4. Engine and its cooling system275 reportsmedian 81,000middle half 60,000–101,000
5. Electrical system248 reportsmedian 83,000middle half 55,000–130,000
6. Airbag system130 reportsmedian 85,000middle half 51,000–128,000
7. Engine217 reportsmedian 120,000middle half 90,000–150,000

5001k2k5k10k20k50k100k200k

• Your odometer, once entered below

Ordered by median mileage, earliest first.

All systems in a table

Complaints by vehicle system

System	Complaints	Share	Median	25–75%
Engine and its cooling system	275	18.0%	81,000	60,000–101,000
Electrical system	248	16.3%	83,000	55,000–130,000
Engine	217	14.2%	120,000	90,000–150,000
Transmission and driveline	143	9.4%	63,000	18,000–107,000
Throttle and speed control	136	8.9%	75,000	50,000–92,000
Airbag system	130	8.5%	85,000	51,000–128,000
Hydraulic brake circuit	113	7.4%	19,000	8,000–37,000
Tyres	97	6.4%	38,000	8,000–69,000
Body structure	90	5.9%	67,000	38,000–100,000
Fuel system	71	4.7%	70,000	59,000–108,000

Known problems with the 2003–2006 Expedition

Before you buy a 2003–2006 Expedition: the 3-minute check

Generated from 1,240 mileage-tagged complaints, 3 recall campaigns, 3 documented problem areas.

Expedition problems by mileage: where your car sits

Type your odometer, or read the table.

Your odometer, milesGo

Figure 3 · Ford Expedition 2003–2006 · 1,240 reports with mileage

Share of reports below each mileage

Steps at bin edges (how to read it)

100%75%50%25%0%

25k50k75k100k125k150k175k200k

• 60,000 mi — 35% of reports below
• 90,000 mi — 60% of reports below
• 120,000 mi — 78% of reports below
• 150,000 mi — 89% of reports below
• 200,000 mi — 97% of reports below
• Median (the 50% line)
• Your odometer, once entered

Linear axis, same as Figure 1.

2003–2006 Ford Expedition recalls (3)

NHTSA records 3 recall campaigns covering vehicles in this generation (what a recall is).

Summaries below shorten NHTSA’s own wording.

1. Nov 2005 · 2006 · VisibilityAfter a period of continuous use on the high speed setting, lack of grease on the output shaft gear may cause…

   The defect. On certain trucks, passenger cars and sport utility vehicles, the windshield wiper motor may have been produced without grease being applied to the output shaft gear.

   What can happen. After a period of continuous use on the high speed setting, lack of grease on the output shaft gear may cause the gear to distort or fracture during operation resulting in a loss of wiper function.…

   The free fix. Dealers will inspect the wiper motor for the presence of grease and grease the wiper motor gears if necessary. The recall began on november 22, 2005. Owners may contact Ford at 1-800-392-3673 or…

   NHTSA campaign 05V-520 (2005-11-09).

2. Jul 2005 · 2006 · TiresOver time, the damage may be sufficient to allow belt corrosion ultimately leading to a tread separation…

   The defect. On certain sport utility vehicles, the front and rear tires on the driver's side of affected vehicles may have been damaged at the center tread during production.

   What can happen. Over time, the damage may be sufficient to allow belt corrosion ultimately leading to a tread separation, which could result in a crash.

   The free fix. Dealers will inspect all four tires (to ensure inspection of the left hand side tires that may have been rotated to the other side of the vehicle) for tire tread damage and, if necessary, replace the…

   NHTSA campaign 05V-310 (2005-07-06).

3. Mar 2003 · 2003 · StructureThis overheating condition can cause the running board to melt or cause a fire.

   The defect. Certain pickup truck, van, and MINI van conversions equipped with southern comfort built running boards that contain certain courtesy lights manufactured by american technology components, inc. These units contain a courtesy light or lights that might…

   What can happen. This overheating condition can cause the running board to melt or cause a fire.

   The free fix. Dealers will replace the wiring harness on these running boards. Owner notification began march 7, 2003. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do…

   NHTSA campaign 03V-094 (2003-03-07).

Some of these 3 campaigns also cover Lincoln Navigator 2003–2006 (2 of them), Chevrolet Suburban 2000–2006 (1 of them), Chevrolet Tahoe 2000–2006 (1 of them) and Dodge Grand Caravan 1996–2000 (1 of them): the same campaign number appears in NHTSA’s file against both, which means the same defect and the same free repair.

Crashes, fires and injuries owners reported

Out of 1,526 complaints against this generation, owners also reported:

Crashes

145 (9.5%)

Fires

63

Injury reports

103

Fatality reports

6

Self-reported and overlapping (how to read these).

Expedition problems by model year

The 2003 drew the most complaints of this generation, 615, most of them about the engine and its cooling system, and the 2004 the fewest, 297. A typical year drew about 307.

That makes the 2003 stand out at roughly 2.0 times a typical year (what a yearly count can and cannot say).

What Expedition owners reported

The contact owns a 2003 Ford Expedition. The contact stated that while operating the vehicle, the check engine warning light illuminated and the front end of the vehicle was shaking abnormally, vibrating, and the vehicle stalled. The contact stated that while driving approximately 50 MPH, there was a loud booming…

2003 · 230,000 miles · Engine

The contact owns a 2006 Ford Expedition. The contact stated that while driving 35 MPH, the contact stated that there were exhaust fumes inside the vehicle. The engine warning light was illuminated. The vehicle was diagnosed by an independent mechanic and confirmed the failure was a defective charcoal canister for the…

2006 · 70,000 miles · Fuel system

The contact owns a 2005 Ford Expedition. The contact stated that while driving at an undisclosed speed, the vehicle made an abnormal sound. The vehicle was taken to an independent mechanic, where the contact was notified of an engine misfire. The spark plugs were replaced. Additionally, the contact stated while…

2005 · 89,000 miles · Engine

The contact owns a 2006 Ford Expedition. The contact stated that while driving at a low rate of speed, the vehicle would independently accelerate upon depression of the accelerator pedal without warning. During a recent failure, the contact crashed into a fence as part of the fence had become wedged underneath the…

2006 · 222,000 miles · Airbag system

Built from 1,240 NHTSA complaints with mileage · snapshot 2026-10-20 · open data · how it is built

Other Expedition generations

• Expedition 1997–2002 2,025 reports with mileage, most about the engine and its cooling system
• Expedition 2007–2017 1,014 reports with mileage, most about the transmission and driveline
• Expedition 2018–2024 514 reports with mileage, most about the transmission and driveline

Other full-size SUVs from the same years

• Cadillac Escalade 2002–2006
• Chevrolet Suburban 2000–2006
• Chevrolet Tahoe 2000–2006
• GMC Yukon 2000–2006