2003 Ford Explorer problems & reliability
1,131 owner complaints filed with NHTSA for the 2003 Ford Explorer, alongside 2 safety recall campaigns. Last verified Aug 7, 2026. Complaints are unverified reports submitted by owners to the federal Office of Defects Investigation.
Each complaint is counted once (by NHTSA case number), even when it names several vehicles.
45 complaints report injuries (57 injured, 2 deaths reported).
Federal crash records (FARS 2020–2023): 2003 Ford Explorer vehicles were involved in 112 fatal crashes with 87 occupant deaths. Involvement counts are not adjusted for how many are on the road and do not imply fault or a vehicle defect.
Most reported problems
| Component | Complaints | Share |
|---|---|---|
| Structure | 354 | 31% |
| Power Train | 335 | 30% |
| Engine and Engine Cooling | 69 | 6% |
| Suspension | 63 | 6% |
| Visibility | 57 | 5% |
| Wheels | 56 | 5% |
| Electrical System | 54 | 5% |
| Air Bags | 50 | 4% |
| Unknown OR Other | 43 | 4% |
| Vehicle Speed Control | 37 | 3% |
Component groups as classified by NHTSA. A complaint can name more than one component, so shares may sum to more than 100%.
Common symptoms owners describe
Keyword analysis of complaint narratives; one complaint can describe several symptoms.
Mileage when problems occurred
Half of the failures with a reported odometer reading occurred by 74,000 miles (middle 50% between 43,000 and 110,000 miles), based on 897 complaints that included mileage.
Complaints by incident year
What owners report
“The contact rented a 2003 Ford Explorer. The contact stated that while driving at an undisclosed speed with the seat warmer activated, after arriving at a Rest Stop and exiting the vehicle, the contact became aware that a blister had formed on the back of her left thigh. The contact attributed the blister to a burn…”
Seats · filed Sep 17, 2025
“There is a crack down the middle section of the liftgate for quite some time. The liftgate has been unlocking and opening automatically by itself. On only rare occasions has the liftgate opened all the way while driving. On the morning of 7/28/2022 while the vehicle was parked in my driveway the liftgate was…”
Unknown OR Other · filed Aug 1, 2022
“The contact owns a 2003 Ford Explorer. The contact stated that while driving at approximately 25-35 MPH around a curb, the driver thought that the tire was flat. The contact pulled off the road and noticed that three of the wheel studs on the driver’s side rear wheel had sheared off. The vehicle was towed to an…”
Wheels · filed Oct 27, 2021
Verbatim excerpts from complaints filed with NHTSA. Reports are not independently verified.
Federal defect investigations
- Vehicle Rollaway Allegations
Engineering Analysis EA09013 · opened Aug 18, 2009 · closed Feb 12, 2013
- VEHICLE ROLLAWAY ALLEGATIONS
Preliminary Evaluation PE09020 · opened Apr 21, 2009 · closed Aug 19, 2009
- SPARK PLUG EJECTION FROM CYLINDER HEAD
Defect Petition DP05005 · opened Sep 22, 2005 · closed Jan 4, 2006
Technical service bulletins
122 manufacturer communications (TSBs, service campaigns, warranty extensions) are on file with NHTSA for the 2003 Ford Explorer. The 10 most recent:
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…
TSB 19-2026 · Service Bulletin/Repair Instructions · issued Feb 7, 2019
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…
TSB 19-2026 · Service Bulletin/Repair Instructions · issued Feb 7, 2019
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
TSB-08-19-3 · Service Bulletin/Repair Instructions · issued May 1, 2009
Some 1997-2008 vehicles equipped with a 4.6l 2v, 5.4l 2v, or 6.8l 2v engine--spark plug thread repair procedure--not covered under new vehicle limited warranty. *nj this includes f-53 motorhome chassis. Updated 2/23/10…
07212 · Service Bulletin/Repair Instructions · issued Oct 1, 2007
Low tire indicator on - tpms system sensor wake up. *tt
0637 · Service Bulletin/Repair Instructions · issued Jan 1, 2006
Malfunction indicator lamp on with pcm diagnostic trouble code p0463 and/or ic diagnostic trouble code b1201 - fuel gauge drops to empty or slow to update after refueling. *tt
05213 · Service Bulletin/Repair Instructions · issued Jan 1, 2006
Limited slip axle chatter, shudder, binding sensation, or vibration during low speed turning maneuvers. *tt
06216 · Service Bulletin/Repair Instructions · issued Jan 1, 2006
Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running. *tt
041601 · Service Bulletin/Repair Instructions · issued Nov 14, 2005
Fuel gauge slow to update after refueling. *eh
042115 · Service Bulletin/Repair Instructions · issued Oct 31, 2005
Noise from rear wheel hub bearings. *tt
051710 · Service Bulletin/Repair Instructions · issued Oct 7, 2005
TSBs are repair guidance manufacturers send to dealers — they are not recalls and repairs are not automatically free. Full documents are available on NHTSA’s site.
Safety recalls
The 2003 Ford Explorer has 2 NHTSA recall campaigns — recall repairs are free at franchised dealers regardless of the vehicle’s age.
Check whether your specific vehicle is affected
Recall campaigns often cover only certain VIN ranges. Enter your VIN on the official NHTSA site to confirm whether your vehicle is included and whether the repair is still open.
Check VIN on NHTSA →Buying a used 2003 Ford Explorer?
- · Decode the seller’s VIN with our free VIN decoder to confirm the exact year, engine and trim.
- · Check for unrepaired recalls by VIN on NHTSA’s official lookup — recall repairs are free.
- · Owners most often reported problems around 74,000 miles — budget accordingly if the car is approaching that mileage.