Owner-reported complaints naming the powertrain system, filed with NHTSA
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Powertrain reports that are not specifically the engine or transmission — driveshafts, axles, transfer cases and differentials. Every record below is an owner-reported complaint about the 2003 Ford F-150 submitted to NHTSA — not a confirmed defect, not a recall and not a manufacturer bulletin. 37 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.
The 25 most recent of 37, in the owner's own words
UNKNOWN - however there were NO warning lights or any other indication of malfunction or to service the truck. I took the truck to an independent service center & they did a full inspection & I did receive an estimate for repairs.
Ford placed a decal on the rear differential that wraps all the way around the axle. This decal holds water and has caused any area touching the decal to rust excessively. Ford has told me that this will cause they rear differential fail. When this happens it will likely be when I'm driving with my wife and two young kids. The only way to know that this issue exists is to either get under the truck and remove the decal which causes and also covers the damage, or to have the axle give out while driving. This was recently discovered while working on the vehicle. I don't currently have pictures as the vehicle is in for other repairs, but I can get pictures once I get the vehicle back.
Transmission
TL* THE CONTACT OWNS A 2003 FORD F-150. THE CONTACT STATED THAT WHILE THE KEY WAS IN THE IGNITION SWITCH, THE VEHICLE FAILED TO SHIFT GEAR AS DESIGNED. THE CONTACT HAD TO SHIFT THE GEAR FROM PARK TO NEUTRAL AND BACK INTO PARK THEN NEUTRAL AGAIN FOR THE VEHICLE TO RESUME NORMAL OPERATION AND TURN ON. THE VEHICLE WAS NOT DIAGNOSED NOR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 86,341.
TRANS WENT OUT A MONTH AFTER INTAKE CRACK HAD TO BE REPLACE ALMOST $1,650 TOGETHER ALSO BALL JOINTS AND TIEROD ENDS NO GOOD SHOCK NO GOOD BRAKE ARE FALLING AND REAR END IS GRINDING THIS TRUCK SHOULD HAVE NEVER BEEN SOLD HELP AND THERE'S "MORE".
VEHICLE CAUGHT ON FIRE WHILE PARKED IN DRIVEWAY. HAD NOT BEEN RUN IN OVER A WEEK. COMPLETELY BURNED UP AND CAUSED DAMAGED HOME. VEHICLE BURNED HAD SEVERAL EXPLOSIONS AND BURNED AT A HIGH TEMP UNTIL IT WAS EXTINGUISHED BY FIRE FIGHTERS.
MY REAR DIFF IS MAKING A LOUD NOISE AT 50 TO 55 MILES AN HOUR ON MY 2003 FORD 150. THE REAR DIFF IS ON THE RECALL LIST, BUT THE FORD DEALERSHIP WILL NOT HONOR THE RECALL BECAUSE I HAVE A SALVAGE TITLE. IN NO WAY WAS MY VEHICLE DIFF COMPROMISED IN CONNECTION TO THE SALVAGE TITLE. IT IS SIMPLY DEFECTIVE AND MAKES A LOUD NOISE. IM WONDERING IF IT IS SAFE TO DRIVE DUE TO THE LOUD NOISE. *TR
TL* THE CONTACT OWNS A 2003 FORD F-150. THE CONTACT STATED THAT THE VEHICLE BECAME STUCK IN SNOW WHEN THE 4-WHEEL DRIVE FAILED TO WORK PROPERLY. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC AND THE MANUFACTURER WAS CONTACTED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 20,000 AND THE CURRENT MILEAGE WAS 24,000.
FORD F-150 SPARK PLUG BLOW OUT, COMMON IN F-150'S. *TR
BLOW OUT OF SPARK PLUG ON 2003 FORD F-150 4.6L TRITON V8. *TR
TL*THE CONTACT OWNS A 2003 FORD F150. WHILE DRIVING APPROXIMATELY 30 MPH WHEN THE ROAD WAS SLIPPERY AND ATTEMPTING TO SHIFT INTO FOUR WHEEL DRIVE, IT FAILED TO ENGAGE. THE DEALER LOCATED THE FAILURE AND STATED THAT THE FRONT SHIFT FORK AND THE SUB SHIFT FORK NEEDED TO BE REPLACED. THE CONTACT WAS RESPONSIBLE FOR PAYING $ 1,009 TO HAVE THE FRONT AND SUB SHIFT FORKS REPLACED. HE CONTACTED THE MANUFACTURER; HOWEVER, THE MANUFACTURER DIDN"T TAKE A REPORT OR OFFER ANY ASSISTANCE WITH THE REPAIR. THE FAILURE MILEAGE WAS 66,879 AND THE CURRENT MILEAGE WAS 66,921.
TL* THE CONTACT OWNS A 2003 FORD F-150. HE STATED THAT WHILE DRIVING 10 MPH, THE INDICATOR FOR THE FOUR WHEEL DRIVE FAILED. AS A CONSEQUENCE HE BRIEFLY LOST CONTROL OF THE VEHICLE, WHICH INCREASED HIS RISK FOR A VEHICLE CRASH. HE IS IN THE PROCESS OF TAKING THE VEHICLE TO THE DEALER FOR INSPECTION, AND NOTIFYING THE MANUFACTURER. THE FAILURE MILEAGE WAS 55,400. THE CURRENT MILEAGE WAS 55,792.
DIFFERENTIAL REAR END FACTORY DEFECT. *TR
TL*THE CONTACT OWNS A 2003 FORD F150. THE CONTACT STATED THAT THE FOUR WHEEL DRIVE WORKED SPORADICALLY IN INCLEMENT WEATHER CONDITIONS. THE DEALER REPLACED THE VACUUM SWITCH, BUT THE FAILURE RECURRED SEVERAL DAYS LATER. THE VEHICLE WAS TAKEN BACK TO THE DEALER AND THEY REPLACED THE VACUUM DIAPHRAGM MOTOR ASSEMBLY AND THE SHIFTING FORK CONTROL. AFTER THE REPAIR, THERE HAD BEEN NO FURTHER OCCURRENCES. THE MANUFACTURER DID NOT ASSIST. THE FAILURE MILEAGE WAS 69,300 AND CURRENT MILEAGE WAS 70,000. UPDATED 3/11/09 *CN UPDATED 03/13/09. *JB
WHILE DRIVING IN A SNOWSTORM THE SHIFTING FORK ON THE FRONT DIFFERENTIAL BROKE DISENGAGING THE 4 WHEEL DRIVE WHICH CAUSED ME TO LOOSE CONTROL. I HAVE FOUND OUT TODAY THAT THIS HAS HAPPENED TO SEVERAL PEOPLE I KNOW AND THAT FORD HAS REDESIGNED THIS SHIFTING FORK. I BELIEVE THIS SHOULD BE A RECALL. IF ANYONE HAD BEEN NEXT TO ME WHEN THE FORK BROKE THERE WOULD HAVE BEEN AN ACCIDENT. *TR
MY 2003 FORD F150 SUPERCREWCAB FX4 4X4, WAS IN FOUR WHEEL DRIVE AS I PROCEEDED TO ENTER HIGHWAY 39 FROM MY DRIVE. THE VEHICLE KICKED OUT OF FOUR WHEEL DRIVE WITH THE ROADS BEING WET WHICH CAUSED MY TRUCK'S BACK TIRES TO SPIN OUT. MY TRUCK THEN FISHTAILED AS IT THREW ITSELF INTO A DITCH. THE PROBLEM WITH IT POPPING IN AND OUT OF FOUR WHEEL DRIVE IS A COMMON PROBLEM. IT HAPPENS EVERY TIME THAT I USE IT. I HAVE NOT TAKEN IT TO A DEALER YET, BUT HAVE READ SEVERAL FORUMS ONLINE THAT TALK ABOUT THE SAME PROBLEM.
TL*THE CONTACT OWNS A 2003 FORD F-150. ON NOVEMBER 6, 2006, THE VEHICLE'S COIL PACK FAILED. THE CONTACT STATED THAT BEFORE IT FAILED, THE VEHICLE WAS RUNNING EXTREMELY ROUGH AND THE CHECK ENGINE LIGHT ILLUMINATED. IN DECEMBER OF 2006, SHE TOOK THE VEHICLE TO THE DEALER BECAUSE THE ENGINE LIGHT ILLUMINATED AGAIN, A SECOND COIL PACK FAILED, AND THERE WAS A HOLE IN THE CV BOOT. THE SECOND COIL PACK WAS REPLACED AND THE CONTACT WAS TOLD THAT THE CV BOOT HAD BEEN REPAIRED. UPON RETURNING HOME, SHE DISCOVERED THAT THE CV BOOT HAD ONLY BEEN TURNED ON THE OTHER SIDE AND WAS NOT REPLACED. IN ADDITION TO THE FIRST CV BOOT NOT BEING REPAIRED, THE OTHER AXLE BOOT HAS DETACHED COMPLETELY OFF THE SHAFT. THE VIN, PURCHASE DATE, AND ENGINE SIZE WERE UNKNOWN. THE CURRENT MILEAGE IS 55,000 AND FAILURE MILEAGE WAS 49,000.
DRIVING IN MY BACK YARD, TESTING NEW SNOW TIRES, SPEED APROX. 25 MPH, HIT 10" DEEP HOLE, BROKE AXLE, DIRECTLY BEHIND BRAKE DISC, REAR WHEEL ON THE DRIVERS SIDE, PICTURES AVAILABLE. HAD TO REPLACE AXLE. *NM
2003 FORD F150 ROLLED BACKWARDS WHILE PARKED RESULTING IN THE VEHICLE COLLIDING INTO A BUILDING.*MR THE CONSUMER STATED THE IGNITION WAS OFF. *JB
THE WHEEL DRIVE QUITS WORKING WHILE TRAVLING DOWN THE ROAD. IT ALSO WILL NOT LOCK IN WHEN SITTING. THE LIGHT ON THE DASH INDICATES THAT THE HUBS ARE LOCKED IN BUT ITS NOT WORKING. I CURRENTLY HAVE IT A THE FORD DEALER GETTING IT FIXED AND IT IS NOT UNDER WARRENTY. THE DEALERSHIP CONFIRMED THERE IS A PROBKLEM WITH THIS MODEL AND HAS MANY OTHER COMPLAINTS BUT WILL NOT COVER THE COST. THEY TOLD ME THAT I SHOULD LOCK IN THE HUBS OFTEN TO KEEP THE SEALS LUBERCATD AND THAT ITS THE OWNERS PROBLEM FO RNOT DOING THIS. IT WOULD HAVE BEEN NICE OF THEM TO TELL ME WHEN I BOUGHT THE TRUCK THAT THIS WAS REQURIED TO BE DONE ON A REGULAR BASIS. I HAVE NOT HAD THIS PROBLEM WITH MY OTHER FORD TRUCKS.*AK
I HAVE A 2003 FORD F150 MY 4WHEELDRIVE STOPPED WORKING , BUT THE DASH INDICATOR SAID IT WAS INGAGED. THIS MAKES FOR A VERY UNSAFE OPERATING CONDITION. BECAUSE YOU DO NOT DRIVE THE VEHICLE THE SAME IF THE 4X4 IS WORKING.I BROUGHT IT TO THE LOCAL FORD DEALER AND THEY REPAIRED IT . THIS APPARENTLY WAS A COMMON PROBLEM. THE PART# F75Z*3N139*KT WHICH COST$133.98 AND THE LABOR WAS $302.00. THIS PART IS VERY CHEAPLY MADE AND WILL PROBABLY BREAK AGAIN. THE TECH TOLD ME THERE IS NO WAY TO PREVENT THIS FROM HAPPENING AGAIN. THIS PART IS A SAFETY HAZARD. I HOPE THAT YOU INVESTIGATE THIS MATTER. I HAVE LOOKED ON FORD LINKS AND WEBSITES AND HAVE SEEN NUMEROUS COMMENTS OF THIS PROBLEM. PLEASE IF YOU CAN HELP ME, IT WOULD BE APPRICIATED. I KEPT THE OLD PARTS, THE MATERIAL THEY USE ON THE FORK WON`T HOLD UP TO THE CONDITIONS IN THE FRONT DIFFERENTIAL. *AK
2003 FORD F-150 4X4. AFTER ONLY A FEW HOURS IN 4X4 MODE, TRUCK NO LONGER ENGAGES INTO 4X4 MODE, CREATING HAZARDOUS CONDITION AS PEOPLE EXPECT THIS TO WORK AND TRUCK IS VERY PRONE TO GETTING STUCK IN ROAD OR LEAVING THE ROAD WITHOUT THIS FEATURE (AS ALL SUCH TRUCKS ARE RELATIVELY VERY LIGHT IN THE REAR). OWNERS OF 4X4 VEHICLES EXPECT THIS FEATURE TO WORK AS ADVERTISED AND FAILURE CAN CREATE SERIOUS SAFETY ISSUES. FROM SHORT INVESTIGATION - SPEAKING TO FORD MECHANICS AND VISITING FORD-TRUCKS.COM, THIS IS A VERY COMMON PROBLEM. THIS IS A SERIOUS SAFETY ISSUE FOR REASONS GIVEN ABOVE - AFTER PERSONALLY GETTING STUCK IN A PUBLIC ROAD, AND VERY NEARLY SEVERAL TIMES, THE TRUCK IS NO LONGER USED WHENEVER THERE IS ANY CHANCE OF SNOWY CONDITIONS (I AM IN THE NORTH-EAST). I STRONGLY BELIEVE THIS TO BE A DESIGN DEFECT - THE FORK WHICH ENGAGES THE FRONT AXLES HAS A PLASTIC END WHICH BREAKS OR FALLS OFF AFTER A SHORT PERIOD OF TIME. I REQUEST THAT THIS BE INVESTIGATED AND IF FOUND TO BE A DESIGN RELATED ISSUE, WHICH I BELIEVE IT CLEARLY IS, THAT FORD BE REQUIRED TO FIX THESE VEHICLES WITHOUT COST TO THE OWNER AND PROVIDE AN EXTENDED WARRANTY FOR THIS ISSUE. ALSO NOTE THAT I HAVE TAKEN THE TRUCK TO 2 FORD DEALERS WITH THE SAME DIAGNOSIS, BOTH QUOTED 6-7 HOURS OF LABOR WHEN IT CLEARLY TAKES HALF OR LESS OF THIS TIME (AGAIN, PLEASE SEE THE FORD-TRUCKS.COM/FORUM). I BELIEVE FORD IS USING THIS KNOWN ISSUE TO PURPOSELY OVER CHARGING CUSTOMERS FOR A KNOWN DESIGN DEFECT. THANK YOU FOR YOUR CONSIDERATION OF THIS SAFETY ISSUE. *AK
WHILE DRIVING DOWN HILL IN THE RAIN, THE REAR WHEELS SUDDENLY LOCKED. THE CONSUMER TOOK THE VEHICLE TO THE DEALER AND THE CAUSE WAS DETERMINED TO BE A FAILURE WITH THE RACK AND PINION AND THE DRIVE SHAFT. RECENTLY, THE CONSUMER HAS EXPERIENCED THE SAME PROBLEM. *JB
WHILE DRIVING AT 45 MPH, SUDDENLY THE RIGHT REAR AXLE BROKE AND SNAPPED OFF. THIS RESULTED IN THE RIGHT REAR TIRE FLYING OFF FOLLOWED BY THE DRIVER LOSING CONTROL OF THE TRUCK AND IMPACTING A DITCH . THE DRIVER SUSTAINED MINOR BRUISES. *JB THE ENGINEER STATED THAT THE AXLE FLEW OFF ON IMPACT EVEN THOUGH THE TIRE FLEW OFF PRIOR TO IMPACT. *SC
AS NOTED BY ANOTHER COMPLAINT: HOWLING NOISE IN REAR DIFFERENTIAL. REAR DIFFERENTIAL REPLACED ONCE. NOISE CONTINUES. I CALLED FORD MOTOR COMPANY AND THEY TOLD ME THERE WAS A DESIGN FLAW THAT ONLY AFFECTS CERTAIN VEHICLES BUT THEY ARE WORKING ON THE PROBLEM. I ASKED...WHEN COULD I EXPECT IT TO BE SOLVED. THE ANSWER WAS...IT MIGHT NEVER BE SOLVED. THEY REPLACED SOME GEARS IN THE DIFFERENTIAL, BUT THE PROBLEM HAS STARTED AGAIN. THEY REFUSE TO PUT IN A NEW DIFFERENTIAL SAYING THAT IT WOULD BE "COST PROHIBITIVE".*AK
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.
Categories with enough reports to have a page of their own
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