2003 Ford F-250 SD problems & reliability

Each complaint is counted once (by NHTSA case number), even when it names several vehicles.

Most reported problems

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 53,197 miles (middle 50% between 16,000 and 85,636 miles), based on 147 complaints that included mileage.

Complaints by incident year

What owners report

• “Tl* the contact owns a 2003 ford f-250 sd. While the vehicle was parked, the contact noticed that the fuel tank was hanging down. The contact looked underneath the vehicle and saw that the fuel tank strap was fractured and the fuel gauge was damaged. The dealer was not contacted. The vehicle was not diagnosed or…”

  Fuel/propulsion System · filed Jul 10, 2019

• “I have american eagle - 20 " eagle alloy wheels. They are approximately 24 months old. This summer a spoke cracked all the way through on one wheel. The dealer would not warranty it and I had to purchase a replacement. This week I noticed another of the wheels cracked all the way through. I have not hit any major pot…”

  Wheels · filed Dec 14, 2016

• “I have had several problems with the spark plugs blowing out of motor and breaking coil causing it too leak fuel vapors out possibly causing a fire this has happened several times. Three different certified mechanics have advised this is caused to defect in the aluminum heads from factory not having enough threads…”

  Electrical System · filed Jun 1, 2016

Verbatim excerpts from complaints filed with NHTSA. Reports are not independently verified.

Federal defect investigations

• ENGINE STALLING

  Engineering Analysis EA06012 · opened Jun 22, 2006 · closed Dec 7, 2007 · led to recall 07V553000

• SPARK PLUG EJECTION FROM CYLINDER HEAD

  Defect Petition DP05005 · opened Sep 22, 2005 · closed Jan 4, 2006

• ENGINE STALLING

  Engineering Analysis EA05003 · opened Feb 15, 2005 · closed Nov 2, 2005 · led to recall 05V270000

• ENGINE STALLING

  Preliminary Evaluation PE04070 · opened Oct 7, 2004 · closed Feb 15, 2005

• ACCELERATOR PEDAL SENSOR (ETC)

  Engineering Analysis EA04006 · opened Feb 23, 2004 · closed Feb 10, 2005

Technical service bulletins

87 manufacturer communications (TSBs, service campaigns, warranty extensions) are on file with NHTSA for the 2003 Ford F-250 SD. The 10 most recent:

• When performing any transmission fluid changes or topoffs involving MERCON SP, MERCON LV has replaced all versions of MERCON SP and can be used going forward. Mixing MERCON LV and MERCON SP in the same transmission is…

  SSM 51909 · Service Bulletin/Repair Instructions · issued Sep 7, 2023

• This SKU is a Transmission Line. The customer communication requested return of unsold inventory to inspect the connector. The transmission line connector may have an incorrect thread size, which will prevent it from…

  RFI20210210_624- · Service Bulletin/Repair Instructions · issued Feb 10, 2021

• This SKU is a Spare Tire Hoist. Test results identified that the pull force parameter was not within specification, as a precautionary measure unsold inventory was requested to be returned for testing and containment…

  DOR-U2J7Y-02 · Service Bulletin/Repair Instructions · issued Jan 13, 2020

• This SKU is a Spare Tire Hoist. Test results identified that the pull force parameter was not within specification, as a precautionary measure unsold inventory was requested to be returned for testing and containment…

  DOR-C2C6H-02 · Service Bulletin/Repair Instructions · issued Jan 13, 2020

• Some 2002-2008 F-Super Duty, F-150 and Mark LT vehicles may exhibit concern during or after programing the VSM. The programming may fail or vehicle symptoms such as inoperative door locks, dome lamps, door ajar…

  SSM 48157 · Service Bulletin/Repair Instructions · issued Sep 2, 2019

• This SKU is a front upper ball joint. The Customer communication requested return of unsold inventory to inspect for ball studs with excessive rotational friction in the ball joint assembly. Excessive friction in the…

  DOR-B8H4Z-11 · Service Bulletin/Repair Instructions · issued Oct 2, 2018

• 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…

  ASI-44534 · Service Bulletin/Repair Instructions · issued May 1, 2014

• Ford: the restraint control module (rcm) when using vcm ii, would have an error code 35 and diagnostic trouble code (dtc) b1035, and difficulty attempting programmable module installation (pmi). Model 2001-2004 f-super…

  ASI-44408 · Service Bulletin/Repair Instructions · issued Feb 1, 2014

• Ford: on some trucks, there is a no crank situation and if voltage on transmission range sensor at pin 21, is less than 5 volts, disconnect the engine cooling fan clutch, electronically, and recheck voltage. Model…

  ASI-44404 · Service Bulletin/Repair Instructions · issued Feb 1, 2014

• Ford trucks service campaign: see document search button for owner letter. Vehicles have experienced severe steering wheel and front wheel vibrations and oscillations after traveling over a bump or dip in the road…

  LP-09L02 · Service Bulletin/Repair Instructions · issued Dec 1, 2013

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 F-250 SD has 4 NHTSA recall campaigns — recall repairs are free at franchised dealers regardless of the vehicle’s age.