Fuel leaking from emissions vents on fuel tank. Non reparable part.

- Alpharetta, GA, USA

My Ford Expedition started randomly stalling and it stalled in the highway. The engine just shut down in the middle of the highway and it was such a scary a life endangering experience. This total loss of power in the middle of the highway when vehicles are traveling at highway speeds can cause death very, very easily to the occupants of the Ford Expeditions suffering this defect. I have been reading in many forums ( I have included the link to one of many forums) this is a common defect [XXX] ) many have Ford Expedition owners have experienced and have been very concerned and shocked that there was not recall. The issue is that the R303 relay (non serviceable fuel pump relay) fails very commonly on Ford Expeditions. In my Ford Expedition, the relay was melted. The fuel pump relay fails and cuts all current going to the fuel pump causing the engine to stall. This is a life-threatening risk caused by a defective fuse box with a defective fuel pump relay (R303). There were no warnings, the Ford Expedition just stalled randomly. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

- Las Cruces, NM, USA

This is the 2nd time it happened to my 2003 Ford Expedition. While driving heard a loud popping noise, followed by continuous popping loud popping noise like a broken exhaust muffler, sounded like a motorcycle. After investigating, found out that the #3 spark plug popped out (ejected) of the head cylinder, broke the spark ignition coil. When this happened, I smelled fuel, and saw smoke coming from under the hood, so I did not drive the car and towed the car home. I had to replace the ignition coil and spark plug and reinstalled the spark plug but it seemed to be still loose, so I took it out and put thread lock and reinstalled it but did not tighten it to the max and did not start the car till after 24 hours so the thread lock will hold it in place. Yesterday the same thing happened to #8 spark plug, it also broke the coil, and when I tried to install the new spark plug, found out that the threads on the head cylinder will not grab the spark plug, and now I am stuck without a car. When I asked around, people said this is a common problem on the Ford expedtion. This is dangerous and could kill someone if the engine caught on fire, because I smelled gas and smoke. If this is a common dangerous problem on the Ford expedtion, how come there is no recall for it"??? are we waiting for someone to die due to engine / vehicle fire to do something about it? please look into this issue asap and let Ford fix this dangerous problem. Spark plugs ejecting out like this" I noticed that there are only 4 threads on the head cylinder holding the park plug, but the spark plug has 10 or 11 threads and ofcourse only 4 of those threads are being held by the head cylinder. This is a dangerous problem waiting to hurt or kill someone, please ask Ford to fix this big problem, thank you....

- San Antonio, TX, USA

This SUV stalled on the highway while driving in traffic. It was caused by a fault in the fuel pump or fuel pump relay. Please recall this vehicle.

- Folsom, CA, USA

Fuel pump relay shorted out in motion. Highway and city streets. Steering locks up engine just dies in motion. Super dangerous and scary replaced fuse box and same thing happened again. No power steering engine just dies in motion. So scary on highway 75 mph.

- Coolidge, AZ, USA

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.

- Maryville, MO, USA

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

- Palm Bay, FL, USA

Fuel tank crack and leaks

- Palm Bay, FL, USA

"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.

- Little Rock, AR, USA

Take a look: sparkys-answers.com/2011/03/2003-Ford-Expedition-no-run-no-fuel.html my father's car is registering a P0231 code. My mechanic was thinking it was the charging system. (no code was registered for a period of 2 months.) today, it pulled a P0231 code. Much to my surprise there seems to be factual things documented all over the internet. I am taking the car to Cherokee auto tech. Vincent nguyen is a register sae tech with a mechanical enginering degree. He also discovered the ignition cylinder on my 2003 Pontiac Grand Am before it was an issue... this car is not any different. During high periods of driving, the solder "heats up" and stalls the gas. When the car cools off, the solder solidifies and current capacity to the fuel pump resumes... the fuse is not protecting the trace. You have complaints on your website on this model also. Even youtube videos.... https://www.youtube.com/watch?V=1brgvbetkek if it is true with my model, I will give you factual evidence that you need.

- Acworth, GA, USA

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 Expedition 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.

- Phoenix, AZ, USA

The vehicle will randomly shut off at any speed, under any condition. Engine dies unexpectedly at highway speeds creating a panic to get out of the roadway. Power to steering and brakes are gone when the engine dies. Vehicle will restart after a couple minutes. The faulty part is the fuel pump relay. It is integral to the fuse box and cannot be changed without changing the entire fuse box. The fuse box is only available from a Ford dealer for $485.20 parts only.

- Wrightwood, CA, USA

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 Ford 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 Expedition. 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!

- Memphis, TN, USA

I was having problem my car of it losing power until one day it just lost power completely at a stop light I was lucky I was waiting for the light to turn green so I quickly put on my emergency blinkers and I was luckily no one hit me from behind this was around 8:30 P.M. my car had to be towed to the mechanic well it was at the mechanic I went ahead and google what happened with my car and I came across a whole bunch of complaints from the cars doing the same thing my car was doing but I found out a lot of people ended up wasting a lot of money to figure out at the end what the problem was if you're traveling on the freeway and this happens you can be in serious trouble I think this should be a recall and investigate on this part

- Wylie, TX, USA

The truck just quits like running out of gas stall no steering now braking very unsafe it is because the fuel pump relay is built into the fuse junction box not serviceable and if you have a moon roof the drain runs down that side the water drips on fuse box shorts out the relay and off your truck goes they only did it 2 years and they obviously now about it and changed it and the new part different number

- Reading, PA, USA

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

- Panorama City, CA, USA

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.

- Plano, TX, USA

Truck shut off at 60mph towing a camper because my fuel pump relay blew because of a defect in the fuse box!! almost killed us........ not happy at all. I've spoken to many mechanics and been on many forums and this seems to be a wide spread and dangerous issue Ford should take care of. Spoke with the local Ford parts department and they are aware of the issue. This is not a cheap part by any means, but on top of that it almost killed my wife and family! please do something about this defect. I can send you pictures of the fuse box board so you can see the burns.

- Goldendale, WA, USA

The contact owns a 2003 Ford Expedition. While the vehicle was undergoing routine maintenance by an independent mechanic, it was discovered that the medal strap was missing that secures the fuel tank. The dealer stated that the missing part was no longer manufactured. The manufacturer was notified. The approximate failure mileage was 80,000.

- La Palma, CA, USA

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.

- Pensacola, FL, USA