RoadVitals

2003 Ford Expedition Brakes Problems

Owner-reported complaints naming the brake system, filed with NHTSA

Data refreshed

Brakes reportsComplaints are reports submitted to NHTSA by owners and drivers. NHTSA does not verify most reports before publishing them, and a complaint does not establish that a defect exists. Volume is influenced by how many of a vehicle were sold, how long it has been on the road, and how much attention an issue has received.
87
Latest Dec 8, 2023
Share of all reportsThis category as a share of every owner report on file for this model year. One report can name more than one component, so the categories overlap.
14%
of 615 total
Crash or fire reportedReports in this category whose submitter recorded that a crash or a fire occurred. The reporter's own answer on the NHTSA form, not a verified finding.
11
Injuries or deaths reportedTotals the submitters entered on their own reports in this category. Not verified by NHTSA and not a casualty statistic.
1

What this page shows

Reports naming service brakes, the antilock braking system, brake hoses, master cylinders or the parking brake. Every record below is an owner-reported complaint about the 2003 Ford Expedition submitted to NHTSA — not a confirmed defect, not a recall and not a manufacturer bulletin. 87 reports on file name it.

Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.

Owner reports naming brake

The 25 most recent of 87, in the owner's own words

BrakesElectricalSteering
Filed Dec 8, 2023
Crash reported

The brakes are burning while driving & the emergency brakes are not applied. The power windows are failing 1 by 1.

NHTSA ID
11559141
Incident
Dec 8, 2023
Brakes
Filed Feb 4, 2017

EXPERIENCED A COMPLETE BRAKE FAILURE AFTER A 6 HOUR DRIVE IN HEAVY TRAFFIC FROM NJ TO VA. PARKED THE CAR IN THE DRIVEWAY FOR 30 MINUTES, AND UPON BACKING OUT OF THE DRIVEWAY, THE BRAKE PEDAL WENT TO THE FLOOR. PARKED THE CAR AND FOUND BRAKE FLUID ON THE GROUND. FOUND BRAKE LINE RUSTED THROUGH ON THE CROSS SUPPORT UNDER THE ENGINE. THIS IS A SERIOUS ISSUE THAT COULD HAVE RESULTED IN AN ACCIDENT AND MAJOR INJURY HAD THIS OCCURRED ON THE DRIVE IN HEAVY CITY TRAFFIC. THE VEHICLE HAS 113000 MILES ON IT. WE HAVE HAD OTHER MANUFACTURERS VEHICLES WITH OVER 200000 MILES AND NO BRAKE LINE ISSUES. THIS IS CLEARLY A DEFECTIVE PART/DESIGN ISSUE AND DUE TO THE SAFETY RISK, FORD SHOULD TAKE ACTION. WE HAD A 1990 F150 THAT HAD THE SAME ISSUE IN 2002 AT 100000 MILES. WE WILL BE CHECKING OUR 2004 F150 VERY CAREFULLY.

NHTSA ID
10949609
Incident
Feb 2, 2017
Mileage
113,789 mi
Brakes
Filed Nov 22, 2016
Crash reported1 injury reported

TL* THE CONTACT OWNED A 2003 FORD EXPEDITION. WHILE DRIVING 15 MPH AND MAKING A SHARP RIGHT TURN, THE BRAKES AND EMERGENCY BRAKE FAILED WITHOUT WARNING. THE VEHICLE CRASHED INTO TWO PARKED VEHICLES. THE AIR BAGS DEPLOYED. A POLICE REPORT WAS FILED. ONE PASSENGER LOCATED IN THE REAR SEAT SUSTAINED A FRACTURED NECK, WHICH REQUIRED MEDICAL ATTENTION. THE VEHICLE WAS TOWED TO A HOTEL. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 169,000.

NHTSA ID
10927434
Incident
Nov 21, 2016
Mileage
169,000 mi
BrakesElectricalEngine
Filed Sep 13, 2016

2003 FOR EXPEDITION NOT RUNNING PROPERLY SHUTTING DOWN WHILE DRIVING PASSENGER WINDOW STUCK BRAKES NOT WORKING PROPERLY WHEN VEHICLE SHUTS DOWN.

NHTSA ID
10905972
Incident
Sep 12, 2016
Mileage
224,000 mi
Brakes
Filed May 26, 2016

OWNER HAS REPLACED BRAKES AND ROTORS SEVERAL TIMES. WHEN DRIVING, THE DRIVER FEELS AS IF THEY ARE PUSHING AGAINST RESISTANCE, LIKE THE EMERGENCY BRAKE IS ENGAGED. VEHICLE IS ABLE TO MOVE WITH EMERGENCY BRAKE FULLY ENGAGED. WHEN BRAKING, A PULSE IS FELT, BUT ROTORS ARE NEW.

NHTSA ID
10870947
Incident
May 26, 2016
Mileage
156,000 mi
Brakes
Filed Apr 4, 2016
Crash reportedFire reported

THE BRAKE LINE THAT IS ROUTED TO THE REAR BRAKES RUSTED COMPLETELY THROUGH, CAUSING ME TO LOSE ALL BRAKING FUNCTION HENCE, CONTROL OF MY VEHICLE. I HAD TO RUN OFF INTO A DITCH TO MISS A SLOWING VEHICLE. AFTER I HAD COME TO REST IN THE DITCH THERE WAS AN ENGINE FIRE CAUSED BY BRAKE FLUID SPRAYING ONTO THE HOT ENGINE EXHAUST MANIFOLD. FORTUNATELY, I HAD A FIRE EXTINGUISHER ON BOARD, SO I WAS ABLE TO PUT THE FIRE OUT BEFORE THERE WAS ANY DAMAGE. THE INTERESTING THING ABOUT THIS INCIDENT IS THAT THERE IS ANOTHER LINE THAT RUNS PARALLEL WITH THE DEFECTIVE LINE THAT SHOWS ZERO EVIDENCE OF CORROSION.

NHTSA ID
10853376
Incident
Mar 27, 2016
Mileage
100,000 mi
Brakes
Filed Feb 3, 2016

MY VEHICLE EXPERIENCED TOTAL BRAKE FAILURE AS I APPROACHED A FOUR-WAY STOP INTERSECTION ON A RURAL COUNTY HIGHWAY. INSPECTION BY AUTO REPAIR TECHNICIANS REVEALED MY BRAKE LINES HAD RUSTED AND HAD EXPERIENCED SEVERAL RUPTURES. THE TECHNICIANS SAID THE RUST WAS THE RESULT OF FORD'S DECISION TO INSTALL STEEL BRAKE LINES IN THE VEHICLE, RATHER THAN ALUMINUM. WHEN EXPOSED TO THE SALT PREVALENT ON LOCAL ROADWAYS IN THE WINTER, THEY EASILY RUST OUT LONG BEFORE THE VEHICLE EVEN APPROACHES THE BEGINNING OF THE END OF ITS LIFE.

NHTSA ID
10823881
Incident
Jan 31, 2016
Mileage
71,000 mi
Brakes
Filed Dec 3, 2015

ABRUPT, NO WARNING(ON DIGITAL DASH) LOSS OF BRAKING ABILITY. ON STOPPING WHILE PULLING IN A PARKING SPACE IN A PARKING GARAGE, BRAKE PEDAL WENT TO THE FLOOR. VEHICLE DID STOP WITHOUT HITTING CONCRETE WALL. VERY SCARY GETTING THE VEHICLE OUT OF THE GARAGE FROM THE 5TH FLOOR TO BE PLACED ON A ROLL BACK. DEALER STATES BRAKE LINES HAVE RUSTED AND DRAINED BRAKE FLUID CAUSING CATASTROPHIC BRAKE FAILURE. STATED THEY HAVE SEEN THIS BEFORE

NHTSA ID
10808297
Incident
Dec 1, 2015
Mileage
116,785 mi
Brakes
Filed Sep 9, 2015
Fire reported

TL* THE CONTACT OWNED A 2003 FORD EXPEDITION. THE CONTACT STATED THAT THE BRAKE PEDAL WAS DEPRESSED AND SMOKE EMITTED INTO THE VEHICLE FROM THE AIR CONDITIONING VENTS. THE CONTACT ALSO NOTICED THAT THERE WERE FLAMES UNDER THE HOOD. THE FIRE WAS EXTINGUISHED BY THE FIRE DEPARTMENT. THE VEHICLE WAS DESTROYED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 180,000.

NHTSA ID
10762498
Incident
Sep 6, 2015
Mileage
180,000 mi
BrakesFuel systemSteering
Filed Jul 9, 2015

TRUCK SHUT OFF AT 60MPH TOWING A CAMPER BECAUSE MY FUEL PUMP RELAY BLEW BECAUSE OF A DEFECT IN THE FUSE BOX!! ALMOST KILLED US........ NOT HAPPY AT ALL. I'VE SPOKEN TO MANY MECHANICS AND BEEN ON MANY FORUMS AND THIS SEEMS TO BE A WIDE SPREAD AND DANGEROUS ISSUE FORD SHOULD TAKE CARE OF. SPOKE WITH THE LOCAL FORD PARTS DEPARTMENT AND THEY ARE AWARE OF THE ISSUE. THIS IS NOT A CHEAP PART BY ANY MEANS, BUT ON TOP OF THAT IT ALMOST KILLED MY WIFE AND FAMILY! PLEASE DO SOMETHING ABOUT THIS DEFECT. I CAN SEND YOU PICTURES OF THE FUSE BOX BOARD SO YOU CAN SEE THE BURNS.

NHTSA ID
10732953
Incident
Jul 3, 2015
Mileage
197,000 mi
Body & structureBrakes
Filed Apr 22, 2014

TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 50 MPH, DECELERATION BECAME VERY DIFFICULT. THE VEHICLE WAS EXAMINED BY AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE BRAKES LINES HAD RUSTED. THE MECHANIC ALSO DISCOVERED THAT THE ROCKER PANELS AND FRAME WAS RUSTED. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS 150,000. UPDATED 06/27/14*LJ

NHTSA ID
10584189
Incident
Apr 1, 2013
Mileage
150,000 mi
Brakes
Filed Jul 23, 2013

TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 10 MPH, THE BRAKE PEDAL DROPPED TO THE FLOORBOARD AS THERE WAS A LOSS OF BRAKING CAPABILITY. THE CONTACT STATED THAT THE ABS WARNING LIGHT ALSO ILLUMINATED AND THE EMERGENCY BRAKES HAD TO BE USED IN ORDER TO STOP THE VEHICLE. THE VEHICLE WAS TOWED TO A DEALER WHERE IT WAS DIAGNOSED THAT THE BRAKE LINES WERE COMPLETELY RUSTED AND NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE AND CURRENT MILEAGE WAS 110,000.

NHTSA ID
10526424
Incident
Jul 18, 2013
Mileage
110,000 mi
Brakes
Filed May 20, 2013

I PREVIOUSLY REPORTED 3 FAILURES OF THE BRAKE SYSTEM ON THIS VEHICLE DUE TO CORRODED BRAKE LINES UNDER NHTSA ID# 10491754. THIS PAST WEEKEND I JUST HAD A FOURTH BRAKE FAILURE DUE TO A CORRODED BRAKE LINE IN 11 MONTHS. THIS BRAKE LINE RUNS ALONG THE LEFT FRONT BELOW THE ENGINE BAY. *TR

NHTSA ID
10512802
Incident
May 18, 2013
Mileage
89,800 mi
Brakes
Filed Jan 7, 2013

BRAKE LINE RUNNING ACROSS THE FRONT END OF THE VEHICLE RUPTURED DUE TO RUST CAUSING LOSS OF BRAKE FLUID AND LOSS OF BRAKING. I HAD A LOCAL GARAGE REPLACE THE RUPTURED LINE AND INSPECT THE OTHER LINES. I WAS ADVISED THEY WERE ALL RUSTED BUT THEY DID NOT SEE A NEED TO REPLACE THEM AT THIS TIME. IN OCTOBER 2012 I HAD ANOTHER BRAKE LINE RUPTURE, THIS TIME IT WAS A BRAKE LINE RUNNING ALONG THE FRAME RAIL ON THE DRIVER'S SIDE TO THE BACK BRAKES. THIS ALSO CAUSED A LOSS OF BRAKE FLUID AND LOSS OF BRAKING. I HAD IT REPAIRED AT A DIFFERENT REPAIR SHOP. I ALSO HAD HIM INSPECT ALL OTHER LINES AND AGAIN I WAS TOLD THE OTHER BRAKE LINES WERE RUSTED BUT HE SAW NO REASON TO REPLACE ANY OTHERS AT THAT TIME. ON JANUARY 6, 2013 I HAD ANOTHER BRAKE LINE FAILURE NEAR WHERE THE BRAKE LINE FAILED IN OCTOBER 2012 (THE OTHER BRAKE LINE RUNNING PARALLEL) AGAIN CAUSING A LOSS OF BRAKE FLUID AND LOSS OF BRAKING. BOTH REPAIR FACILITIES INFORMED ME THIS IS A COMMON PROBLEM. I ALSO WENT TO DIFFERENT REPAIR FACILITY TO HAVE MAINTENANCE PERFORMED WHEN THEY SAW MY NEW BRAKE LINES, THEY ASKED WHAT HAPPENED. WHEN I TOLD THEM THEY SAID, "OH IT'S A COMMON PROBLEM" I CAN NOT UNDERSTAND HOW THE FEDERAL GOVERNMENT ALLOWS VEHICLE MANUFACTURERS TO MAKE BRAKE LINES OUT OF A MATERIAL SO PRONE TO CORROSION. THERE IS NO OTHER SAFETY DEVICE ON A VEHICLE MORE IMPORTANT THAN THE BRAKES. WHAT GOOD ARE THE ANTI-LOCK BRAKES YOU MANDATE IF THE BRAKE LINES FAIL? *TR

NHTSA ID
10491754
Incident
Jun 14, 2012
Mileage
81,743 mi
Brakes
Filed Dec 6, 2012

DRIVING SOUTH ON RT 202 IN LEFT LANE AT 35 MPH /A CAR IN RIGHT LANE CHANGED LANES TO THE LEFT IN FRONT OF CAR IN FRONT OF ME TO GET TO AN EXIT. THE CAR IN FRONT OF ME APPLIED BRAKES / I PRESSED BRAKES HARD TO AVOID REAR END COLLISION.. ABS SYSTEM LOCKED BRAKES BUT PEDAL WENT TO FLOOR. AFTER THAT BRAKES FELT SOFT WHEN APPLIED.. FOUND LEAK IN RUSTED LINES FROM MASTER CYLINDER TO BOOSTER. *TR

NHTSA ID
10487572
Incident
Dec 3, 2012
Mileage
121,000 mi
Brakes
Filed Feb 7, 2011
Crash reported

TL*THE CONTACT OWNS A 2003 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 45 MPH, THE BRAKE PEDAL DROPPED TO THE FLOOR AND THE CONTACT EXPERIENCED A LOSS OF BRAKING CAPABILITY. THE CONTACT STATED HE CRASHED INTO A TREE STUMP AND SNOW ON THE GROUND AND THE VEHICLE CAME TO A STOP. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC. THE APPROXIMATE FAILURE MILEAGE WAS 18,535. UPDATED 3/14/11 *CN IT WAS DETERMINED THE MASTER CYLINDER WAS LEAKING FLUID AND ULTIMATELY FAILED. UPDATED 05/04/11

NHTSA ID
10380957
Incident
Feb 4, 2011
Mileage
18,535 mi
Brakes
Filed Sep 1, 2010

TL*THE CONTACT OWNS A 2003 FORD EXPEDITION EDDIE BAUER. UPON STARTING THE VEHICLE HE ATTEMPTED TO SHIFT IT OUT OF PARK AND THE BRAKE PEDAL DEPRESSED TO THE FLOOR. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER WHERE HE WAS INFORMED THE BRAKE LINES FOR THE FRONT BRAKES WERE RUSTED THROUGH. THOSE BRAKE LINES WERE REPAIRED. THE FAILURE HAS NOT RECURRED SINCE BUT HE EXAMINED HIS VEHICLE AND NOTICED THE BRAKE LINES FOR THE REAR BRAKES WERE VERY RUSTY. THE VEHICLE WAS NOT TAKEN TO BE EXAMINED AND HAS NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 58,900. THE VIN WAS UNAVAILABLE.

NHTSA ID
10353259
Incident
Aug 15, 2010
Mileage
58,900 mi
Brakes
Filed May 4, 2010

BRAKE LINES RUSTED AND LEAKED CAUSING SUDDEN LOSS OF MOST BRAKING. I BOUGHT THIS FORD NEW IN JULY OF 2003. AFTER THE BRAKE FAILURE, THE VEHICLE WAS TOWED. I HAD ALL BRAKE LINES REPLACED, AND STILL HAVE THE PIECE WHICH LEAKED. THE SHOP SAID IT IS BECAUSE THE BRAKE LINES ARE ROUTED ON TOP OF THE FRAME RAILS, AND SALT BUILDS UP. BUT I'VE LIVED IN THIS AREA ALL MY LIFE (I'M 66) AND HAD MANY OLDER OR HIGHER MILEAGE VEHICLES, BUT NEVER HAD THIS HAPPEN BEFORE. I UNDERSTAND THAT YOU ARE INVESTIGATING CHEVY BRAKE LINE FAILURE, AND THINK YOU SHOULD INCLUDE FORDS. *TR

NHTSA ID
10328726
Incident
Mar 1, 2010
Mileage
45,000 mi
BrakesInterior & seatsExterior lighting+1 more
Filed Jan 27, 2009

BRAKES NEED TO BE REPLACED CONSTANTLY. PADS WEAR VERY FAST. ROTORS WEAR EASILY AND NEED REPLACEMENT WITH PADS EACH TIME. WHEN BROUGHT TO HAVE ROTORS TURN, WAS TOLD THEY ARE MANUFACTURED WITH VERY LITTLE TOLERANCE AND COULD NOT BE TURNED EVEN THOUGH THERE WAS MINIMAL VISIBLE WEAR. WAS TOLD THEY DID NOT "MIC" WITH ENOUGH RANGE TO TOLERATE THE CUT WHEN TURNING. ROTORS SHOULD NOT NEED REPLACEMENT WITH EACH BRAKE CHANGE. EXCESSIVE BRAKE DUST. BRAKE DUST HAS EATEN AWAY AT FINISH ON RIMS. AFTER LAST BRAKE REPAIR, FRONT END NOW HAS A CLICKING SOUND. BRAKE PEDAL HAS ALWAYS FELT SPONGY. ON TWO OCCASIONS WITH AGGRESSIVE BRAKING CONDITIONS, BRAKES LOCKED UP. TOLD DEALERSHIP WHO SAID THIS IS NORMAL WITH THE FORD BRAKING SYSTEMS. ADDITIONALLY, WE HAVE HAD AN ONGOING PROBLEM WITH THE PASSENGER SIDE FOG LAMP NOT STAYING LIT AND THE METAL REFLECTOR PIECE IN THE FOG LAMPS COMING LOOSE. WE ARE NOW HAVING PROBLEMS WITH TWO (FRONT DRIVERS/REAR PASSENGERS) DOOR ELECTRIC LOCKS NOT UNLOCKING OR LOCKING THE DOORS. *TR

NHTSA ID
10256448
Incident
Jan 1, 2009
Mileage
200,000 mi
Brakes
Filed Mar 7, 2008
Crash reported

MY 2003 FORD EXPEDITION HAD A SUDDEN BRAKE FAILURE WHILE MY SEVENTEEN YEAR OLD DAUGHTER WAS DRIVING. LUCKILY SHE WAS NOT HURT WHEN THIS INCIDENT TOOK PLACE. I FOUND THE BRAKE RESERVOIR TO BE COMPLETELY EMPTY AND REFILLED IT IMMEDIATELY. THEN I DISCOVERED THE REAL PROBLEM. THE REAR FACTORY BRAKE LINES WERE CONSTANTLY RUBBING AGAINST THE REAR SPRINGS OF THE CAR , THUS WEARING A HOLE IN THE BRAKE LINE. THIS RESULTED IN RAPID LOSS OF BRAKE FLUID , WHICH ALSO LED TO SUDDEN BRAKE FAILURE. THIS WOULD OBVIOUSLY BE A MANUFACTURERS DEFECT AND I CANT IMAGINE WHY SOMEONE AT FORD DIDN'T SEE SUCH AN OBVIOUS PROBLEM. *TR

NHTSA ID
10220394
Incident
Mar 6, 2008
Mileage
153,208 mi
Brakes
Filed Jan 12, 2007

ROTORS NEEDING TO BE REPLACED AT LOW MILEAGE ON FORD EXPEDITION 2003- OR NEWER AND 2004 FORD F150'S 2003 OR NEWER. *JB

NHTSA ID
10178573
Incident
Jan 8, 2007
BrakesSteering
Filed Oct 26, 2006

ON AUGUST 26,2006 TOOK MY SUV TO DEALER TO HAVE IT CHECKED OUT BECAUSE THE FRONT END WAS SHAKING REALLY BAD. WAS TOLD THAT IT NEEDED TO HAVE FRONT AND REAR ROTORS REPLACED HAD ANOTHER DEALER CHECK OUT ONLY NEED FRONT ROTORS REPLACED HAD THEM REPLACED. ON SEPT 8, 2006 TOOK BACK TO DEALER BECAUSE I HEARD A WHINNING NOISE THOUGHT IT WAS THE POWER STEERING FLUID LOW. IT CHECKED OUT OKAY DEALER CHECK IT AND WAS INFORMED THAT THE POWER STEERING PUMP WAS BAD HAD IT REPLACE. PICKED UP MY SUV AND IT WAS STILL MAKING THE SAME NOISE. WAS TOLD TO DRIVE FOR TWO WEEKS TO LET AIR BLEED OUT LINE AND BRING BACK IN TWO WEEKS CALL THEM TO LET THEM KNOW THAT THE NOISE WAS STILL THERE TOOK TO DEALER. NOTHING WAS DONE ABOUT IT. CALL THE FORD CUSTOMER SERVICE LINE AND MAILED THEM A LETTER ABOUT WHAT WAS GOING ON. THEY TOLD ME TO TAKE MY SUV TO ANOTHER FORD DEALER DID THAT WAS TOLD THAT THE POWER STEERING PUMP WAS BAD THAT I HAD PUT ON IN AUG. AND THAT SOMETHING WAS CAUSING THEM TO GO BAD. THE STEERING RACK IS THE PROBLEM. I CALL THE DEALER WHERE I'VE ALL OF MY WORK DONE ON MY SUV AND TALK TO THE GENERAL MANAGER. HE WAS RUDE AND HUNG UP IN MY FACE I CALL BACK I'M GOING TO TAKE MY SUV TO THEM TOMORROW OCT 27,2006 AND SEE IF WE CAN COME TO TERMS TO GET MY SUV FIX. BUT I'VE SEE MANY COMPLAINTS ABOUT THE SAME PROBLEM THAT 'M HAVING. *NM

NHTSA ID
10171938
Incident
Aug 29, 2006
Mileage
57,357 mi
Brakes
Filed Jun 24, 2006

MY BRAKES BEGAN TO SQUEAL AROUND 50K. THIS IS THE FIRST BRAKE SERVICING REQUIRED ON THIS VEHICLE. I WAS TOLD BY A NUMBER OF MECHANICS THAT THE FRONT ROTORS NEEDED TO BE REPLACED BECAUSE THEY WERE WORN DOWN TOO MUCH. I WAS SURPRISED ABOUT THIS AND FOUND THAT THIS IS A VERY WELL KNOWN AND COMMON PROBLEM WITH THE 2003 FORD EXPEDITIONS. APPARENTLY, THESE ROTORS ARE NOT "DEFECTIVE" IN MATERIAL OR WORKMANSHIP OTHERWISE THERE WOULD BE A RECALL. THIS IS A PRIME EXAMPLE OF POOR DESIGN AND ENGINEERING. IT IS COMPLETELY RIDICULOUS TO EXPECT ANYONE TO BELIEVE IT IS NORMAL TO REPLACE BRAKE ROTORS ON EACH BRAKE PAD CHANGE. I HAVE BOUGHT AMERICAN MADE VEHICLES MY ENTIRE LIFE. I WAS ALWAYS TOLD THAT THE FOREIGN CARS WERE JUNK AND COST A LOT OF MONEY TO MAINTAIN. OVER THE YEARS I HAVE SPENT MUCH MONEY AND TIME REPAIRING MY AMERICAN MADE CARS. I HAD BOUGHT THE CHEAPEST CAR I COULD FIND BACK IN 2000. A HYUNDAI ELANTRA. I HAVE HAD ZERO PROBLEMS. NOT A SINGLE ONE. THE MILEAGE IS OVER 100K AND I HAVEN'T EVEN NEEDED TO CHANGE THE BRAKE PADS. THIS CAR WAS THE ABSOLUTE CHEAPEST CAR I COULD FIND ON THE MARKET IN 2000. I WILL TAKE THIS AS AN ILLUSTRATION OF HOW POORLY THE FORD LINE OF PRODUCTS ARE EITHER DESIGNED OR BACKED UP BY THE MANUFACTURER. *JB

NHTSA ID
10160667
Incident
Jun 24, 2006
BrakesOther / unspecified
Filed May 11, 2006

THE BRAKES ON THE 2003 EXPEDITION ISN'T DESIGNED TO HOLD THE HEAVY WEIGHT OF THE EXPEDITION. THIS CAUSE THE BRAKES TO NEED TO BE REPLACED NUMEROUS TIMES. FORD NEEDS TO RECALL THE BRAKES AND PUT BIGGER BRAKE PADS IN THEM. I HAVE HAD TO EVEN REPLACE THEM METAL TO METAL IN THE FRONT 7 TIMES IN 3 YEARS AND UNDER 45,000 MILES. I EVEN HAD TO REPLACE THE MASTER CYLINDER DUE TO LEAKAGE AT 45,000 MILES. ALSO DUE TO ELECTRONIC PROBLEMS I HAVE HAD I WAS UNABLE TO LOCK THE SUV AND HAD THE ALARM SOUND BECAUSE OF IT AND WINDOWS DON'T GO UP AND DOWN CORRECTLY. *JB

NHTSA ID
10157378
Incident
May 3, 2006
Mileage
2,474 mi
Body & structureBrakesHeating & air conditioning+1 more
Filed Oct 7, 2005

CONSUMER IS HAVING PROBLEMS WITH AIR CONDITION MAKING NOISE, POWER WINDOWS ONLY LOWER, RADIO VOLUME GETS LOUDER WHEN ACCELERATING SEAT CONTROL BUTTONS ARE INOPERABLE. *TS WATER LEAKED FROM THE SUNROOF, EVEN THOUGH IT WAS CLOSED. THE VEHICLE WAS TAKEN TO THE DEALER ON 3 SEPARATE OCCASIONS DUE TO BRAKE AND ROTOR NOISE. THE CONSUMER EXPERIENCED LACK OF POWER WHEN ATTEMPTING TO ACCELERATE. THE CONSUMER WAS UNABLE TO HEAR THE RADIO SEPARATELY WHEN THE DVD WAS PLAYING. *JB

NHTSA ID
10139949
Incident
Oct 3, 2005

Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers.

Other components reported on this vehicle

Categories with enough reports to have a page of their own

Elsewhere on this vehicle

Data sources

Data on this page last refreshed .