3.2

definitely annoying
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
43,000 miles

About These NHTSA Complaints:

The NHTSA is the US gov't agency tasked with vehicle safety. Complaints can be spread across multiple & redundant categories, & are not organized by problem. See the Back button — blue bar at the very top of the page — to explore more.

Get notified about new defects, investigations, recalls & lawsuits for the 2003 Ford Expedition:

Unsubscribe any time. We don't sell/share your email.

problem #1

Mar 032007

Expedition 8-cyl

  • Automatic transmission
  • 43,000 miles
Rear heating/ac air blend door actuator has failed. A drive gear inside the actuator has stripped and is missing two teeth. Upon further investigation it appears that the manual temperature control causes the actuator to reach one end of it's internal travel limit prematurely, straining the internal gear drive. Also, the air blend door travel limits are reached before the actuator limits, straining the internal gear drive further at both ends of travel. The two issues cause the effective rotation range of the manual temperature control to be reduced from 300 degrees of rotation to 135 degrees of rotation, and any positioning of the control outside the effective range strains and strips the gears of the blend door actuator.

- San Jose, CA, USA

Add Complaint