2003 Ford Expedition Service and Repair Manual

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Factory-Grade Data

2003 Ford Expedition service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Built for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and use wiring diagrams and system sections to diagnose problems faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical coverage with wiring diagrams
  • Coverage across key systems: engine, transmission, brakes, steering, suspension, HVAC, and more

Trims covered

  • Eddie Bauer Sport Utility 4-Door
  • XLT Sport Utility 4-Door

Engines covered

  • 4.6L 281Cu. In. V8 GAS SOHC Naturally Aspirated
  • 5.4L 330Cu. 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 Expedition Recalls & Complaints

NHTSA #06E02300013/03/2006Component: EXTERIOR LIGHTING:HEADLIGHTS

CERTAIN ANZO COMBINATION HEADLAMP ASSEMBLIES SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES. SOME COMBINATION LAMPS ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS WH

Consequence

WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING I

Remedy

ANZO WILL NOTIFY OWNERS AND REPLACE THE HEADLAMPS FREE OF CHARGE. THE RECALL BEGAN MAY 9,

NHTSA #09E01200007/04/2009Component: EXTERIOR LIGHTING

SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HE

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAM

NHTSA #03V09400007/03/2003Component: STRUCTURE

CERTAIN PICKUP TRUCK, VAN, AND MINI VAN CONVERSIONS EQUIPPED WITH SOUTHERN COMFORT BUILT RUNNING BOARDS THAT CONTAIN CERTAIN COURTESY LIGHTS MANUFACTURED BY AMERICAN TECHNOLOGY COM

Consequence

THIS OVERHEATING CONDITION CAN CAUSE THE RUNNING BOARD TO MELT OR CAUSE A FIRE.

Remedy

DEALERS WILL REPLACE THE WIRING HARNESS ON THESE RUNNING BOARDS. OWNER NOTIFICATION BEGAN

TSB #11005305

This article supersedes TSB 22-2219 to update the Parts List and Service Procedure to clarify applicable steps by vehicle application. Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 (non-Raptor) vehicles equipped with 4WD may exhib

TSB #10235153

For 2000-2024 Ford and Lincoln vehicles, swapping a module from a vehicle for diagnosis purposes is likely to cause errors and is not recommended. It is also not recommended to order a replacement module using a vehicle identification numbe

TSB #10214754

Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 (non-Raptor) vehicles equipped with 4WD may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (IW

TSB #10181917

Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 vehicles equipped with TOD transfer cases may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (

TSB #10177863

This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint wi

TSB #10156863

Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Fo

TSB #10155551

Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Fo

TSB #10028736

FORD: SOME VEHICLES MAY EXHIBIT OIL SEPARATION FROM THE INTERNAL LUBE FOUND IN THE UNITIZED CARTRIDGE SEAL. OIL SEPARATION APPEARS TO BE AND IS OFTEN MISDIAGNOSED, AS AN AXLE LUBE LEAK. *PE

Showing the 8 most recent of 152 technical service bulletins on file with NHTSA.

20160404Component: SERVICE BRAKESCrash 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

20080819Component: TIRESCrash reported5 injured

I WAS TAKING MY COUSIN TO THE JACKSONVILLE AIRPORT. I WAS APPROXIMATELY 25 MILES OUTSIDE OF JACKSONVILLE WHEN MY TIRE BLEW OUT, CAUSING ME TO LOOSE CONTROL OF MY SUV. THE SUV ROL

20080819Component: AIR BAGS:FRONTALCrash reported5 injured

I WAS TAKING MY COUSIN TO THE JACKSONVILLE AIRPORT. I WAS APPROXIMATELY 25 MILES OUTSIDE OF JACKSONVILLE WHEN MY TIRE BLEW OUT, CAUSING ME TO LOOSE CONTROL OF MY SUV. THE SUV ROL

20160916Component: WHEELSCrash reported4 injured1 fatalities

2003 FORD EXPEDITION, WITH FACTORY ORIGINAL TIRES BY CONTINENTAL, HAD A TIRE TREAD SEPARATION ON JUNE 11 WHICH RESULTED IN ONE DEATH AND FOUR SERIOUS INJURIES. VEHICLE WAS IN MOTIO

Showing the 4 most serious of 800 complaints filed with NHTSA.

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