2nd generation · U222 · 2,028 complaints, 1,632 with mileage
Owners filed 2,028 complaints with NHTSA about the 2003–2006 Ford Expedition, and 1,632 of them record the mileage at which the failure happened. That is enough to show not just what fails, but when.
Failures are spread across the mileage range, with the middle half between 42,000 and 118,000 miles. The median is 80,000 miles.
The most-reported areas are the engine and its cooling system (13.9% of complaints, typically around 81,023 miles), the electrical system (12.3% of complaints, typically around 83,000 miles), the engine (10.7% of complaints, typically around 120,000 miles).
| System | Complaints | Share | Typical mileage | Middle half |
|---|---|---|---|---|
| Engine And Engine Cooling | 281 | 13.9% | 81,023 | 59,022–100,070 |
| Electrical System | 250 | 12.3% | 83,000 | 55,000–130,000 |
| Engine | 217 | 10.7% | 120,000 | 90,000–150,000 |
| Power Train | 145 | 7.1% | 62,500 | 17,493–107,000 |
| Vehicle Speed Control | 136 | 6.7% | 74,650 | 50,500–92,000 |
| Air Bags | 134 | 6.6% | 84,385 | 44,000–127,500 |
| Service Brakes, Hydraulic | 120 | 5.9% | 18,535 | 8,000–35,000 |
| Tires | 98 | 4.8% | 38,000 | 8,100–68,550 |
| Structure | 91 | 4.5% | 68,500 | 38,000–100,000 |
| Fuel System, Gasoline | 72 | 3.6% | 70,000 | 56,981–107,500 |
| Year | Complaints | With mileage |
|---|---|---|
| 2003 | 800 | 592 |
| 2004 | 381 | 287 |
| 2005 | 452 | 407 |
| 2006 | 395 | 346 |
Complaints about this generation are not spread evenly across the vehicle, and the systems that generate the most of them do not all fail at the same point in a car's life. The median failure across all systems here is 80,000 miles; the figures below show which parts of the car run ahead of that and which run behind.
The engine and its cooling system accounts for 13.9% of complaints (281 reports, 249 of them with a mileage figure), with a median of 81,023 miles, close to the vehicle's overall pattern. The middle half of these reports falls between 59,022 and 100,070 miles.
The electrical system accounts for 12.3% of complaints (250 reports, 205 of them with a mileage figure), with a median of 83,000 miles, close to the vehicle's overall pattern. The middle half of these reports falls between 55,000 and 130,000 miles.
The engine accounts for 10.7% of complaints (217 reports, 191 of them with a mileage figure), and it fails late — a median of 120,000 miles, considerably beyond the vehicle's overall median. That pattern is consistent with normal service life rather than a defect, though it matters for anyone buying an example already near that mileage. The middle half of these reports falls between 90,000 and 150,000 miles.
The transmission and driveline accounts for 7.1% of complaints (145 reports, 118 of them with a mileage figure), with a median of 62,500 miles, close to the vehicle's overall pattern. The middle half of these reports falls between 17,493 and 107,000 miles.
Throttle and speed control accounts for 6.7% of complaints (136 reports, 124 of them with a mileage figure), with a median of 74,650 miles, close to the vehicle's overall pattern. The middle half of these reports falls between 50,500 and 92,000 miles.
The airbag system accounts for 6.6% of complaints (134 reports, 106 of them with a mileage figure), with a median of 84,385 miles, close to the vehicle's overall pattern. The middle half of these reports falls between 44,000 and 127,500 miles.
Within this generation, complaint volume is not constant across model years. The 2003 model year drew the most — 800 complaints — while 2004 drew the fewest at 381. The median year sits at 423.
The first year of the generation, 2003, sits above the median. That is a common pattern — early production of a redesigned vehicle tends to surface problems that later years do not repeat — and it is worth weighing when choosing between years.
No recall campaigns covering this generation appear in NHTSA's post-2010 recall file. That is not the same as an absence of problems — recalls address safety defects specifically, and many of the complaints above concern faults that are expensive or annoying without meeting that threshold.
Of the 2,028 complaints filed against this generation, 188 reported a crash; 71 reported a fire; 223 reported an injury; 8 reported a fatality. Crash-involved reports represent 9.3% of the total.
These are owner-reported outcomes, not verified investigations, and they are not adjusted for how many of these vehicles are on the road. They are included because the distinction between a fault that strands a car and a fault that causes a collision is the one that matters most, and it is not visible in a complaint count alone.
For a buyer, failures on this generation are spread rather than concentrated: the middle half falls between 42,000 and 118,000 miles, with a median of 80,000. There is no single mileage threshold to watch, which means condition and maintenance records are more informative than the odometer.
On inspection, the engine and its cooling system and the electrical system are where this generation's reports concentrate, so those are the areas worth a specific look. The engine and its cooling system in particular shows a median failure mileage of 81,023, which gives a concrete number to compare against the odometer of any car you are considering.
None of this is a substitute for a pre-purchase inspection on the individual car. Aggregate patterns describe a population; the example in front of you has its own history.
Three-valve 5.4L two-piece spark plug design: the lower ground-shield section seizes in the head from carbon buildup and snaps off during removal, requiring specialized extraction and often head damage.
Variable cam timing phaser rattle. Oil-fed cam phasers lose control authority when hot idle oil pressure or oil condition degrades, producing a diesel-like rattle at cold start and idle, and can progress to timing chain and cam damage.
Rear air suspension air spring and compressor failure (independent rear suspension introduced this generation).