Problems with 2003 Ford Expedition ELECTRICAL SYSTEM

Keeps blowing the fuel pump reply. we have had to replace the reply 4 times in the last few days. after removing the reply from the fuse panel and looking at the port it is burning both fuse and fuse panel.this happen when we are running and when the fuse blows it kills the vehicle right away in the middle of the street

This has happened 3 times, first time stopped at a red light, when foot was put onto gas to go vehicle instantly lost power with no stuttering or stalling and had to put in park turn key over to go again. second time, going 65 down the highway vehicle suddenly acted like it lost power and speed decreased, pulled over to side of highway and put in park and started right up. third time, going 65 down highway started to act like it was losing power and showed dash lights as if all power was cut short and then gained all power back without having to pull over and restart.

The truck would just turn off while driving at 55 or 60 miles an hour , no steeringwas on highway ,no brakes put in neural to get to side of road with cars all around me .this has happened 3 times, then it would not start at all when fulled up with gas, had to be towed, then when i was down to 1/4 tank ,would not turn over, had gas in it too, but would not start, had to be towed in shop now again 3rd time ,had problems with the door agar going off had senor replaced still comes up

Tl* the contact owns a 2003 ford expedition. the contact stated that the fuse box failed. while driving 85 mph, the vehicle stalled without warning, the steering wheel seized, and the fuse box made a buzzing sound. the contact coasted the vehicle to the side of the road, reached under the dashboard, and pulled the relay fuse to stop the buzzing noise. the vehicle was towed to the contact's residence where an independent mechanic diagnosed that the fuel pump was burned. another mechanic came also came to the contact's residence and informed her that the fuse relay and the fuse box needed to be replaced. the vehicle was not repaired. the contact called anderson ford (3900 clemson blvd, anderson, sc 29621, (864) 225-4151) and was provided with a quote. the contact stated that the failure recurred several times and the fuel pump/filter, 402 sensors, and fuse relays were replaced numerous times. the manufacturer was not made aware of the failures. the failure mileage was approximately 236,000. *dt *tr

The vehicle was stationary, when unlocking the vehicle with the keyless entry, it moved the sideview mirrors and never movws back. i put the mirrors back where they belong and every following time when i unlock the vehicle with the key fob, it continues to do the same. i bought the vehicle this way.

Sunroof leaks badly it has fuse box shorting out. when it rains my windows go up down alone. all lights shorted out and nothing working any longer

Check engine light came on while driving home and the engine shut down 4 times each time the battery would die instantly. we had to keep jump starting it to get home. 2 days later the check engine light started flashing. scanned it came back p0304 cylinder 5 misfire. changed spark plugs and coils. engine light went off.ran obd2 scanner to double check codes. code p2503 charging system low voltage . took battery to advanced auto parts had them test it. the coca should have been 650cca and was at 11cca so bought a new battery. next day took son to school less the 2 miles ran fine on my way home it died 3 times this time i would wait a few minutes then restart it. check engine light never came on started searching on line and and calling mechanics. so bought new alternator. started the truck to warm up after 5 minutes it shut down again waited a minute and started back up did it again. this time the battery light came on. so after searching many people were saying the fuseable link was bad so went to ford had one ordered installed it to day. battery light still on started it ran for 5 min and died again. so now i bought new spark plugs, coil packs, battery,alternator, fusible lin. now obdii code b1676- battery pack voltage out of range tester battery fully charged tested alternator it's at 14.7 which it supposed to be.

Takata recall i was driving down the interstate at 65 mph when my truck just cut off, had to have it towed in to the shop. had fuel pump replace, 2 weeks later same problem.had to have it towed again fuse was replace. 3 weeks later i'm now having to have the fuse box replace. ford motor company don't think this should be a recall issue. they just came out with the latest update fuse box in 2017.

I have a huge problem with my 03 ford expedition shutting of randomly it is very dangerous on highways you lose power steering and all power to motor almost caused accidents many times i believe many people have this problem and it all relates to the fuse box please make this a recall so many people can get hurt or even killed

Tl* the contact owns a 2003 ford expedition. while driving 75 mph, the engine stalled without warning. the contact pulled the vehicle over to the side of the road. the contact restarted the vehicle after a few minutes and it returned to normal. the vehicle was taken to the dealer where it was diagnosed that the main fuse block needed to be replaced. the vehicle was not repaired. the manufacturer was made aware of the failure. the failure mileage was 120,000.

The engine stops running without warning. i was driving on the freeway at 70+ in heavy traffic. all of a sudden the engine shuts down. i put the vehicle in neutral and engaged the flashers. i tried to restart the vehicle while maneuvering to the side of the road avoiding multiple close calls. once stopped, i put the vehicle in park and tried to restart. after a couple of minutes the car restarted. i took the vehicle to the autozone to see if there were any fault codes. one code indicated the fuel pump was an issue. they advised me that they have seen this before and directed me to go to the dealership. the dealership could not look at it immediately so i had my son pick me up with another vehicle. the following day they ran a diagnostics ($95 fee that was totally unnecessary since this is a well know failure) on the car and indicated that it was the faulty central junction fuse box located inside the vehicle on the passenger side near the feet. pn 3l1z-14-a068-aa-a11 @$517. installation costs $215. when i got home i searched the web and found that this is a common failure for this vehicle. the blogs and comments are of multiple near missed collisions among other things. this part failure happened on vehicles that were less than one year old. it can happen at anytime to any 2003 ford expedition. this part was redesigned for later ford expeditions because ford knew of the problem. if you contact any pick and pull salvage yard you will find that all of these central junction box (fuse boxes) are not available since everyone tries to replace them by themselves because of the high costs. also, there are multiple companies that will repair the faulty part with a re-engineered circuit. ford has since made a new part with a different pn / model number. this should have been a safety recall in the first year. it is very dangerous and lives are at stake.

Tl* the contact owns a 2003 ford expedition. occasionally, the vehicle would not immediately start due to a faulty fuse box. the fuse box was replaced by the owner and the failure was remedied. eventually, while driving, the vehicle shut completely off and could not be restarted. the cause of the failure was not determined. the manufacturer and local dealer (vista ford in woodland hills, ca) were notified of the failure. the failure mileage was 160,000.

The complaint is in regards to the circuit board. the car may stop at random times. we have been in the vehicle going 35 miles an hour and the car suddenly stopped. it appeared that it was a fuse that burned out.... that seemed to fix the problem temporarily but then it happened again at a higher speed. luckily there were no injuries. ford seems to be aware of this problem and should issue a recall. i was told from dealership that what happens is that the water runs down the side and gets into the fuse box. this is causing a short. so, the reason it worked the first time was because we added a new fuse. but, the second time that it stopped it burned the fuse box. now, i had to tow the vehicle and replace the part costing over $500. after researching this issue it appears to be a number of complains with the same issue. ford should issue recall.

2003 for expedition not running properly shutting down while driving passenger window stuck brakes not working properly when vehicle shuts down.

Vehicle stall while driving freeway.my wife first then i experience myself stall vehicle on fast lane very dangerous.vehicle just shut off cannot steer the wheel lucky enough to glide to safety side.fuse box burning the fuel pump relay lots of complaint in internet how many lives to waste before anyone act on it.

Fuse relays keep burning out! i have brought over 10 relays in 2 weeeks. i have done my research and this is a common problem with all 2003 fords and is very exspensive to fix. i was shocked to find that it has not been recalled! there are videos on you tube to prove that all of these trucks have this problem. i was told i had to replace the entire fuse box but eventually i will have the same problem out of that fuse box because thus is a defect in all 2003 ford expeditions. the car cuts off while driving and has almost caused me to be in 2 very dangerous car accidents! it has stopped on me on the highway and street! when i saw that this is a very common problem with the fuel emmision relays and the fuse box i decided to file this complaint in order to get this recalled!

Credit acceptance corporation 25505 w twelve mile road p.o. box 513 southfield,mi 48037 1-800-634-1506 installed a gps device when i purchsed this vehicle used. i had it replaced once by the dealer because it not only disabled the vehicle when not moving,but it created a dangerous problem when i was driving cutting the vehicles power off. credit acceptance denies they had anything to do with it . this started to happen when i fell behind on payments.

While driving on the highway at 70 mph, the vehicle just suddenly lost power and shut down. i managed to get the vehicle to the side of the road. after a few minutes it started and i continued on, after a few miles the same thing happened again. i got it started again and was trying to make a rest stop a few miles away. while pulling into the rest stop the vehicle lost power again and resulted in a collision because of no steering or brakes. the loss of power happened 8 times that day. while looking for answers about the problem, i found on the nhtsb website that other vehicles of the same make, model and year also experienced this same problem that turned out to be a problem with the fuse block. i took it to a ford dealership to have it checked out. they said it was a fuel pump issue. that would not cause a loss of power. i took it to another mechanic who did find that it was indeed a faulty fuse block. the same mechanic told me that this was not the first time they had come across this problem. this is a dangerous condition that needs to be rectified before someone loses their life in an accident because of this. the loss of power occurs without any warning or check engine lights or codes.

My passenger window and both back windows have dropped several times. i have had to have this fixed more than once on the back passenger side window, what happens is ill try to put the window up and the window motor makes a struggling noise and i am unable to roll up the window. at this point i'm sure it must be a defect because of how it has happened to each window more than once. also the bumper that goes around the entire car is extremely faded and i am unable to get fixed i have gone to get estimates for a pain job but have been told due to the material it is just going to fade i would need to get it sanded and have them do some special treatment i cant afford and they will not just paint over it for me because they guarantee there work and would have to redo it too often. all the expeditions i see have the exact same issue.

Cars stalled while turning left against traffic. would not start right away. had to wait a few minutes trying to start it and finally it started and i could clear the intersection. very dangerous and fortunate that oncoming traffic was able to stop. have cleaned throttle body, aic but fuse on fuse box is melted causing intermittent operation. started out once a month and now frequently to include this last one in traffic.

This specific make and model year has a defective fuse box which case a fuse called a pcm relay to melt and causes the vehicle to stall and not start. the fuse box will buzz continuously but the vehicle does not start. you can replace the relay which is about $15 but this is more than likely temporary and it will melt and cause the vehicle to stall. the only remedy is to replace the fuse panel entirely which brings me here, the panel alone is $500 and that doesn't include labor and taxes. ford is well aware of this issue as there are thousands of forums online that refer to this specific manufacturer defect. i've spent thousands replacing parts that did not need repair. ford needs to foot the bill for this defect because it's a manufacture's defect not a consumer (wear and tear) issue.

2003 ford expedition xlt 4.6 fuse box fail fuse pump relay burn, on 01/14/2015 while the truck was in motion on the 5fwy going 70 miles the truck shot off luckily my wife was able to pull to the emergency lane with out hitting any other car on the fwy. i replace the fuse box for another used one that i bought at a junk yard,the truck run got for a year , on 01/05/2016 it happen again while driving the truck on the 118 fwy going 75 the truck shut off again same problem fuse box , fuse relay is burn in have post it 3 videos on you tube look for 2003 ford expedition xlt 4.6 cranks won't start is under javalosrealestate

Tl* the contact owned a 2003 ford expedition. while parked in a residential driveway, the vehicle caught fire and burned down to the frame. a fire report was filed. the vehicle was destroyed. the cause of the fire was unknown. the manufacturer was not notified. the vin was unavailable. the failure mileage was 220,000.

After accelerating from a stop, a loud bang was heard. what had happened? a spark plug blew out of the aluminum head, taking the threads with it. i was not aware that fuel would continue to blow out of the spark plug hole which could have been ignited by the ignition coil or exhaust manifold. ford is aware of this issue, but has not recalled the defective aluminum heads, but rather offered a repair kit to fix the stripped threads when this issue occurs. this could have been a very different ending if the fuel would have ignited. *tr

Engine wont turn off with keys taken out, dashlights on and off, air conditioner came on when door was opened, warning bell and no keys in ignition, head and tail lights remain on, side mirrors move and will not go back, when key pod used all these problems go off at the same time. *tr

I was traveling at 70 mph on the interstate. the car popped, sputtered and died. has steadily gotten more and more frequent. engine dies at idle, dies at slow speeds as well as faster speeds. very dangerous! have replaced the pcm, wiring harness, and fuel pump. is not repaired. power mirrors readjust themselves when the keyless entry is used. several warning lights stay on, door ajar, check fuel cap, advatrac will not turn on. rear window will not work. back up sensor will not work. interior lights as well as exterior lighting will not power off when car is turned off. you must manually turn them off or the battery drains.cd player will not eject cd's loud popping sound in the front end and grinding sound when stopping. i have had this in the shop since june of 2014 and they cannot find the problem. have already spent $1000 trying to repair. this vehicle is dangerous and can very likely cause an accident. it is not safe to drive. ford auto shop wants to charge me $100 an hour to diagnose the problem then they are not sure if they can find the problem, they are telling me it could cost between $500-$1000 just to find the problem. i have checked several web sites and see that there are many, many people with the same problems with the same type of vehicle. this should be looked into before someone is injured or killed in an accident caused from the car stalling!!! *tr

The engine would randomly shut off with no warning. sometimes the engine would shut off while driving, other times would shut off at a stop light. the issue happened 10 times over a 3 day period. i was lucky to not crash as the engine died once while making a turn on a busy road. once it died, so did the power steering and brakes - very scary. there were no engine codes that came up and no indication anything was wrong, the engine would simply shut off. while diagnosing the issue i did some internet research that indicated it could be the fuel pump relay issue. the fuel pump relay is a non-serviceable relay that is soldered to the main fuse box circuit board. i removed the fuse box and disassembled it revealing the fuel pump relay was getting hot and had melted the solder on the board. when the relay cooled, the solder made contact and the engine would start right up. when driving the solder would warm up and break contact. this would shut the fuel pump off and the engine would die. there are reports of this all over the internet. the only repair for this item was to replace the main circuit board as the relay cannot be replaced without soldering to the circuit board. once the fuse box was replaced, the issue was resolved. i believe this could potentially be a huge problem and could lead to serious accidents. i have read this problem affects numerous years of the ford expedition. *tr

Tl* the contact owns a 2003 ford expedition. while driving at 60 mph, the engine stalled without warning. the vehicle failed to restart. the vehicle was towed to the contact's residence where an independent mechanic diagnosed that the fuse box failed and needed to be repaired. the vehicle was repaired, but the failure recurred. the manufacturer was not made aware of the failure. the failure mileage was 130,000.

My 03 ford expedition would not start and was making a ticking sound. found out it was a relay switch changed it and it started but it keeps blowing about every 3-4 weeks. *tr

Tl* the contact owns a 2003 ford expedition. the contact stated that the fuse box in the vehicle smelled like smoke and was overheating. the vehicle was taken to the dealer where it was diagnosed that the fuse box needed to be replaced. the vehicle was not repaired. the manufacturer was not made aware of the failure. the failure mileage was 185,000.

The car was running well and suddenly it die. no lights in dash board, no shakes, no any previous sign of trouble. simply it die. i pumped the accelerator pedal and the car continue running. next time, few days after the incident, the car does the same. this time do not continue running when i pump gas. i have to put in neutral and start it again. it start at once. could be more than two weeks without signal of problem and then, it happen again. some other time, it happen 4 or 5 times in a half hour trip. *tr

Driving down state highway when the battery gauge went to "l" and the abs light came on. the engine was still running. pulled into apartment complex parking lot and the engine shut off. all lights and bells were still working. aaa was called and performed a diagnostic and determined the starter was going bad. the starter is less than 2 years old as is the battery. was told it was safe to drive home. took vehicle to local repair shop where another diagnostic test was performed and was told it was not the starter nor the battery and another diagnostic should be performed to determine cause. engine has not shut off while driving since but am apprehensive to drive very far from home. will wait for 3rd diagnostic test. *tr

On feb 13, 14 the door locks on the right hand side of the expedition failed to lock when the car was placed into motion - which made the car venerable to entry or exit with or without stopping. took the car to the dealer, we were told needed to replace both right side door locks because they are a matched set - cost $500. two weeks a go the same thing has happened to the left side of the car have an appointment for monday feb 23 to investigate the door locking problem. two sets of locks failing (righthand side & lefthand sides) within a year should be investigated for defective parts and possible injury if someone were to open the door while the car was in motion. *tr

Bulbs melting third brake light assembly internally. this happened to original and recently replaced unit. bulbs were seized to the plastic mounting and melted/deformed both bulb mounts and reflector. unit is now defective. *tr

Was driving the 2003 expedition on interstate 10 near pensacola, when the vehicle shut off. the car coasted to a stop, luckily i did not cause a wreck and my family and i was safe. it has happened several times, at least 10 so far. we have replaced the fuel pump, fuel pump relay switch, the fuel filter, had the injectors inspected and it still does it. i did some research into the problem and it turns out the right side front passenger window leaks down onto the interior fuse panel and is causing the electrical system to short out. in all cases once the vehicle cools down, the car starts right back up again. i have taken it to 4 garages and now i have it at the ford dealership in pensacola. where they are looking at it. it turns out that the p0231 code keeps re-appearing in the system (fuel pump relay circuitry) which shows the problem could be the fuse panel since the fuses are soldered to the board and not plugged in. hopefully ford recognizes this problem and will order a recall soon. *tr

While driving down the freeway i put my foot on the gas and did not get any response. in a few seconds i pushed on the gas again and nothing. i started to pull over and pushed on the gas again and the car had power. the same thing happened 25 minutes later getting back onto the freeway. next incident was starting from a stop light the car just died. no warning. engine light, battery light and service now lights come on. again i pulled over put the car in park and it started back up. we had the coils and plugs changed. next time driving at 35 mph out of the blue no power to the gas and the car shuts down. changed a relay. took it to the ford dealership who can't figure out what the problem is. we changed the battery next time i am coming to a stop and the car stops. no battery light, no service light nothing. again i pull over and it took a long time to get the car started again. took it back into ford. this time i gave them a thread of email about others having the same issue. now they have changed another relay and we hope this solves the problem. this is a huge safety concern. for a person who is driving 55-66 mph on a highway or freeway and their car dies is a big accident waiting to happen. i did email ford but so far have been told to talk to the service person. *tr

There are many issues and concerns about my 2003 ford expedition. from reverse back up sensor blinkers windows, four way flashers, cd player, four wheel drive, wipers, back up lights, power mirrors, power seats, dash board gages, power locks, all will stop working suddenly at different periods of times. ford has staitef there are no recalls for this years make and model when all owners of this vehicle have complained about all of these issues. i am fiancing this vehicle for $10 thousand and demand a recall for electrical issues for this vehicle. the internet is pasted with similar issues and ford is taking people's money to try and fix all the issues and never completely fixing the issue. i need an answer to my problem and i want ford to buy back my vehicle.

Open door sound indicator while engine is running--vehicle stopped to let passenger out. when any door is opened, the open-door high pitched steady-hum sound comes on, which is normal, however, the hum will not shut off. it continues loudly for 8-10 minutes and then reduces to a faint hum under the dash. the sound(s) continue even after the suv is turned off, put in park, and the key is removed. we are the original owners of the 2003 eddie bauer expedition and it's otherwise in excellent shape with just 57,000 miles. this problem has recently been verified by a local ford/kia repair shop whose mechanic scratched his head in confusion; however, they want to charge us to tear the dash apart to attempt to figure out why this is happening. they can't turn the indicator speaker off altogether. we want to know what ford knows about the problem; mainly, what is causing the problem. can if be fixed via a simpler solution (maybe a simple fuse or wiring?), is this is a possible future fire danger, and have any others have experienced this unusual occurrence.

We moved it around in our shed at about 10pm on 6/16/12 and we awoke at 4 am to our shop, machine shed, and chicken coop engulfed in flames. we lost over $100,000 in property. the fire marshall determined that our ford expedition was to blame and that it started under the hood, somewhere in the electrical. we only had liability only on 2 of the 3 vehicles in the shop along with our motorcycle and trailer so they were not covered by insurance. i think ford should of compensated us for the items we did not get paid for. they should do a recall on this vehicle, and compensate the people that had fires with this vehicle. *tr

Why is there no warning light,or signal of any kind when the pcm fails? our pcm failed, which caused our catalytic converters, 02 sensors, & fuel pump to fail. our ignition coils had to be replaced. would have been nice if a warning light came on the dash. this has caused our expedition engine to randomly shut off while driving countless times! i have miraculously been able to maneuver my expedition to the side of the freeway &have it towed eight times without killing myself, my family or any one else! we have had odd electrical and performance problems since august of 2002 when we purchased it. not one ford mechanic (3 different dealerships) could ever diagnose or repair issues. because there is no warning light/code when the pcm is out, the damage snowballs. there are no computer codes, or warning lights to show up on the dash board when the pcm is out, which befuddles the mechanics. we are literally $5,000 in the hole so far! ford dealership "repaired" our expedition by replacing the pcm ($1,300.00). 48 hours after they replaced the pcm, and 18 miles after we drove expedition off the ford lot, the "service engine soon" light came up on the dashboard -for the first time ever! we drove back to the ford dealership, and he said for $3,400 plus tax he could replace our new catalytic converters in "bank one" that were destroyed again, & the "bank two" converters which are now very weak, not up to spec. the driver's seat motor that has been fickle since aug of 2002, stopped working when we went to pick it up, so i can't drive it, because i can't reach the gas or brake pedals. $800 will fix that, ford says. if you google "2003 ford expedition eddie bauer engine shuts off randomly", thousands of people are reporting the same issues. until someone crashes and dies, i don't think ford cares. the consumer also stated the vehicle had electrical problems. the consumer stated the driver's seat motor stopped working while being serviced at the dealer, there were problems with the windows as well. *tr

After making a complete stop at a traffic light i made a left turn and began to accelerate when i heard a loud pop which at first i thought was a tire blow out. the engine was running so erratically that i could feel it in my steering. we inspected the vehicle for a flat when we noticed every tire was fine. i opened the hood and removed the top cover to the engine to discover a spark plug laying on top of the engine and the coil that was once attached blown off of the plug and damaged off to the side still connected to its electrical source. this cold have caused a fire. for the record these plugs were the original factory spark-plugs. via the internet i have discovered this website to file a complaint. *tr

While driving at highway speeds the engine cuts out/dies. *tr

At 4:40am, was woke up by the police and fire department who responded to a call in of our vehicle, a 2003 ford expedition being on fire. based on the information received from the fire crew chief, the fire had started in the engine compartment, on the driver's side, and appeared to be electrical in nature. the car had last been used the prior night at 8pm, when we returned from eating dinner, and had remained idle since that time. upon hearing our story, several friends mentioned that they had read stories about ford vehicles that had an issue with the cruise control switch causing fires, even in vehicles that had remained idle for several hours. i checked and it does not appear there were any recalls for my vehicle's year, but had been for the prior year's (2002). here is a link to one article (although there are many): http://articles.cnn.com/2005-06-16/us/ford.vehicles_1_ford-vehicles-brake-fluid-cruise-control?_s=pm:us the car is a complete loss, the engine mostly gone and the tire and part of the body melted to my driveway. the damage inspector for our insurance company stated it was likely that they would not be able to cover our full lien amount and i believe at the very least ford should make whole for us. the insurance company is working with ford about possible subrogation, but it is unclear at this point in time if the insurance company will ask for dollars beyond what they would pay out in the loss. we were fortunate it did not spread to our home, my husband's ford parked next to it or to our boat which was directly in front of it. it was very, very close and could have easily happened. we feel very fortunate that we did not park the vehicle in our garage or any closer to the boat, whose cover had melted and could have easily set on fire given the heat and severity of the fire.

Driving on interstate 70 mpg vehicle stalls then proceeds, this happened several times over a course of 1 year. one later incident engine died but restarted. several months later completely dies. after several hrs vehicle restarts. ford mechanics claim they cannot make a diagnosis. it will never stall or quit when it's in the shop. i'm afraid this vehicle will be someone's death trap. *tr

2003 ford expedition would not start after long tow to mechanic it was a burnt relay switch but now it turns off while driving, change the relay switch and problem is temporarily fixed now since the relay is for the fuel pump and pcm my transmission is acting up not shifting 3rd or over drive no one can figure out the problem but we are scared to drive the truck! *tr

One of my spark plugs blew out of the head with only 47,000 miles on my 2003 expedition. 4 hours to fix it. now i have to go back and torque the other 7 plugs and hope the piece of crap doesn't spit out any other plugs. this is my last ford! *tr

My 2003 ford expedition will be driving fine, then all of a sudden it will die in traffic and have had several close calls of being rear ended. one other time it died and while coasting after it died, it started again causing vehicle to lunge and my wife almost rear ended someone else. the vehicle is at the repair shop and it is diagnosed as a pcm that is and now has a hard failure. *tr

I was driving down the freeway when my expedition made a noise, the inside dash lights flickered and the transmission started acting up. i pulled over at a hotel. i called a tow truck who came to pick it up a few days later. when he started it the wiring harness caught unfire. the entire wiring burned up on the lift side of the vehicle. the mechanic told us we were luck to have stopped. if we continued down the highway my family and i would have been in great danger. i believe the fire was the fault of bad wiring. i check the recall sites and my vehilce was not part of the faulty wiring recall. *tr

I have an 2003 ford expedition suv, the spark plug in the #3 cylinder head pops out every 5-8k miles. resulting in a loss of power, per the 3 dealerships i have spoken to as well as the b.a.r ford is aware of this problem and refuses to fix it. per the b.a.r. it is an casting/manufacturing defect. im worried that i will be on the freeway and loose power, and get in an accident due to not being able to exit the free way under my own power. the problem goes back to the 2000 model year. i have had the car worked on at the ford dealership 2 times to correct this issue,and it is currently broken again. the dealer ship refuses to fix it as an warranty on their repair done on 8/13/09 or as an factory defect from ford direct. don't know where else to turn, any help or direction would be greatly appreciated. [xxx] information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6). *tr

On june 19 2009, returning home from a short trip, thick smoke erupted with strong rubber smell from underneath the driver seat. i immediately turned off the ignition and exited the car. the following day i contacted ford motor co. and inform them of the safety issue, after going back and forth, ford general consul office made decision that the issue is not safety hazards and will not repair the vehicle. pat milliken ford has the vehicle, and inspected the damage, which declared to be very extensive the repair cost may exceed $2000.00. ford general consul was informed of the damage and still will not consider it as safety issue because the vehicle did not burst on fire. my smart and quick reaction to turn off the vehicle and cut the power off prevented a disaster to happen, and yet as a consumer i'm left with hefty repair bills for a possible manufacturing defect in the wiring.*tr