2003 Ford E-150 Service and Repair Manual

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Factory-Grade Data

The 2003 Ford E-150 service and repair manual is a detailed, OEM-style reference for diagnostics, maintenance, and repair work. Use it to verify procedures, specifications, and system information before you start a job.

You'll find coverage across key vehicle systems with clear section structure, including wiring diagrams and powertrain, braking, steering, suspension, HVAC, and electrical topics. Digital format makes it easy to search while you work.

Trims covered

  • XL Standard Passenger Van 3-Door
  • Base Standard Cargo Van 2-Door

Engines covered

  • 4.2L 256Cu. In. V6 GAS OHV Naturally Aspirated
  • 5.4L 330Cu. In. V8 GAS SOHC Naturally Aspirated
  • 4.6L 281Cu. In. V8 GAS SOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2003 Ford E-150 Recalls & Complaints

NHTSA #09V39900013/10/2009Component: VEHICLE SPEED CONTROL

FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXP

Consequence

A VEHICLE FIRE COULD OCCUR WITH OR WITHOUT THE ENGINE RUNNING.

Remedy

FORD WILL NOTIFY OWNERS THAT DEALERS WILL INSTALL A FUSED WIRING HARNESS IN LINE WITH THE

NHTSA #04V44500013/09/2004Component: ENGINE AND ENGINE COOLING

ON CERTAIN VANS, THE AIR FILTER ELEMENT MATERIAL PROCESS RESULTED IN AN AIR FILTER PAPER ELEMENT THAT CAN SMOLDER OR BURN. THIS CHANGE IN FILTER PAPER COMPOSITION COMBINED WITH TH

Consequence

THESE HOT PARTICLES MAY IGNITE THE AIR FILTER ELEMENT WITH THE POTENTIAL FOR AIR INDUCTION

Remedy

DEALERS WILL INSPECT AND REPLACE THE AIR FILTER ELEMENT. THE RECALL BEGAN SEPTEMBER 27, 2

NHTSA #04V44400013/09/2004Component: ELECTRICAL SYSTEM:WIRING

ON CERTAIN VANS, A DIODE IN THE ANTI-LOCK BRAKING SYSTEM (ABS) MODULE MAY EXPERIENCE AN ELECTRICAL SHORT.

Consequence

THE ELECTRICAL SHORT MAY CAUSE AN ABS MALFUNCTION THAT WOULD ILLUMINATE THE ABS WARNING LI

Remedy

DEALERS WILL INSTALL A NEW FUSE IN THE ABS CIRCUIT AND INSTALL A HEAT SHIELD OVER THE ABS

TSB #10056196

FORD: WHEN SHIFTING BETWEEN PARK, REVERSE AND/OR DURING 2-3 SHIFT, AN INTERMITTENT CLUNK OCCURS WITH A TORQSHIFT TRANSMISSION. MODEL 2003-2014 F-SUPER DUTY, E SERIES, EXCURSION, F-53 MOTORHOME CHASSIS, LOW CAB FORWARD. *PE

TSB #10022675

BRAKE BOOSTER SYSTEM MAY EXHIBIT A BRAKE PEDAL KICKBACK AND/OR GRABBING CONDITION WHEN APPLYING THE BRAKES. *NJ

TSB #10022232

HEADLIGHT ADJUSTMENT NEEDED. *KB

TSB #10018941

VIBRATION/HARSHNESS ABOVE 45 MPH (72 KM/H) AFTER TIRE BALANCE. *TT

TSB #10018741

MALFUNCTION INDICATOR LAMP ON WITH DIAGNOSTIC TROUBLE CODE P1131 AND/OR P1151 - 4.2L ENGINE. *TT

TSB #10017865

HEADLIGHT ADJUSTMENT - CHASSIS CAB INCOMPLETE VEHICLES. *TT

TSB #10011181

LOW POWER AND/OR DIAGNOSTIC TROUBLE CODE P0299 OR P2263 - TURBOCHARGER DIAGNOSTIC SERVICE TIP. *TT

TSB #10010743

INTERMITTENT CLUNK ON 3-2 DOWNSHIFT DURING COASTDOWN/TIP-IN. OASIS. TO INCLUDE 2005 F-150, E-SERIES AND EXPEDITION. *TT

Showing the 8 most recent of 11 technical service bulletins on file with NHTSA.

20140428Component: SEAT BELTSCrash reported1 injured

TL- THE CONTACT OWNS A 2003 FORD F1-50. THE CONTACT EXPERIENCED THE FAILURE APRIL 26, 2014. THE VEHICLE AIR BAGS DEPLOYED WHILE SITTING IN TRAFFIC. THE CONTACT CURRENT MILLAGE O

20060406Component: VEHICLE SPEED CONTROL:ACCELERATOR PEDALCrash reported

2003 E150 CONVERSION VAN GAS PEDAL GOT STUCK 3 TIMES CAUSING AN ACCIDENT. *TS THE REAR CARGO DOOR WAS REPAIRED, THE FAN CLUTCH WAS REPLACED. THE RUNNING BOARD DID NOT FIT CORRECT

20060406Component: STRUCTURE:BODY:DOORCrash reported

2003 E150 CONVERSION VAN GAS PEDAL GOT STUCK 3 TIMES CAUSING AN ACCIDENT. *TS THE REAR CARGO DOOR WAS REPAIRED, THE FAN CLUTCH WAS REPLACED. THE RUNNING BOARD DID NOT FIT CORRECT

20060406Component: ENGINE AND ENGINE COOLING:COOLING SYSTEM:FANCrash reported

2003 E150 CONVERSION VAN GAS PEDAL GOT STUCK 3 TIMES CAUSING AN ACCIDENT. *TS THE REAR CARGO DOOR WAS REPAIRED, THE FAN CLUTCH WAS REPLACED. THE RUNNING BOARD DID NOT FIT CORRECT

Showing the 4 most serious of 31 complaints filed with NHTSA.

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