2003 Ford F-450 SD
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Ford › F-450 SD › 2003
These records cover every 2003 Ford F-450 SD. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
6 recalls name the 2003 Ford F-450 SD. Newest first.
Ford IS recalling certain model year 2011 ranger trucks built from january 25, 2011, through april 25, 2011 at the twin cities assembly plant, and service parts distributed to dealers for certain 2004 through 2011 model year ranger trucks, 2002 through 2005 model year excursion vehicles, and 2002 through 2007 model year F-250, F-350, F-450, and F-550 trucks…
Risk and remedy
Risk
Non-functioning lights could increase the risk of a crash.
Remedy
Dealers will replace the switches free of charge. the safety recall began on august 15, 2011. owners may contact ford motor company customer relationship center at 1-866-436-7332.
Ford IS recalling model years 1995-2003 windstar, 2000-2003 excursion diesel, 1993-1997 and 1999-2003 F-250 sd through F-550 sd diesel, 1992-2003 E-150 through E-550, 1995-2002 explorer, 1997 and 2002 mercury mountaineer, 1995-1997 and 2001-2003 ranger, and 1994 F53 vehicles equipped with the texas instruments speed control deactivation switch (scds). the…
Risk and remedy
Risk
A vehicle fire could occur with or without the engine running.
Remedy
Ford will notify owners that dealers will install a fused wiring harness in line with the scds. on 1999-2003 windstar vehicles with a leaking scds, dealers will also inspect the ABS control module connector and repair as necessary. repairs will be completed free of charge. the safety recall began on october 27, 2009. owners may contact ford at 1-888-222-2751.
On certain heavy duty trucks equipped with 7.3L diesel engines, the camshaft position sensor located on the engine of the vehicle may function intermittently, possibly resulting in an engine stall.
Risk and remedy
Risk
In the event of an engine stall, a crash could result without warning.
Remedy
Dealers will inspect the sensor and replace it with an improved camshaft position sensor free of charge. the recall began on december 29, 2007. owners may contact ford at 1-866-436-7332.
Certain cequent 90 degree 7-WAY right angle adaptors sold by distributors in tow packages for aftermarket sales to tow 5TH wheel rv travel trailers. due to incorrect wiring of the harness, the trailer lights may not operate properly.
Risk and remedy
Risk
If the trailer lights are not working properly, a vehicle crash can occur.
Remedy
All of the defective tow packages are still at the distributor level and have not been sold to any consumers.
On certain trucks equipped with speed control, gasoline or natural gas engines, the speed control deactivation switch may overheat.
Risk and remedy
Risk
Overheating could result in smoke, burn, or an underhood fire.
Remedy
Dealers will install a fused wiring harness into the speed control system free of charge. The recall began on march 12, 2007. owners may contact ford at 1-800-392-3673. (Note: also see recalls 05v017, 05v388, and 06v286)
On certain pickup trucks and sport utility vehicles equipped with 6.0L diesel engines, the engine ground stud that attaches the negative battery terminal eyelet to the engine block may be loose.
Risk and remedy
Risk
If the ground wire IS loose, electrical current may flow to the radio suppression strap causing it to heat and potentially melt or ignite adjacent components which could result in a fire.
Remedy
Dealers will replace the engine ground stud and the radio suppression strap and adjacent components will be inspected for damage and replaced, if necessary. the recall began on july 23, 2004. owners should contact ford at 1-800-392-3673.
Owner complaints
16 complaints
What owners report most
Latest complaints
- Fuel system, diesel
The truck began to shake and lose power, eventually not even being able to stay running. the mechanic upon review found the tank liner had delaminated from inside fuel tank and had plugged up fuel sender. both needed to be replace at a cost of $2800, ford dealer stated there was nothing they could do. *tr
- Fuel system, diesel
The egr, ficm, and injectors on this vehicle have caused traffic hazards. we can not pull out without the engine spitting and sputtering. we have replace all of the above, some more than once. last time in to the ford dealer they suggested that we use a thinner oil to lubricate the injectors…
The egr, ficm, and injectors on this vehicle have caused traffic hazards. we can not pull out without the engine spitting and sputtering. we have replace all of the above, some more than once. last time in to the ford dealer they suggested that we use a thinner oil to lubricate the injectors better. this also doesn't work. we have read many people on the internet that have the same problem with their diesel engines so we know it's not just ours. we paid $8,000.00 to repair and nothing IS better. ford refuses to admit there IS a problem. please help those of us that are stuck with these trucks. the dates of incidents have been ongoing. *Tr
- Fuel system, diesel · Suspension › Front
Truck has no power when first starting and the front end shimmies something terrible. hard to control. *Tr
- Fuel system, diesel
The coating on the interior of ford diesel fuel tanks corrodes and collects as sediment in the fuel system. the sediment, collects at the botton of the fuel tank and IS sucked into the fuel system. the fuel lines become fouled, the fuel pumps become clogged and require replacement. as the…
The coating on the interior of ford diesel fuel tanks corrodes and collects as sediment in the fuel system. the sediment, collects at the botton of the fuel tank and IS sucked into the fuel system. the fuel lines become fouled, the fuel pumps become clogged and require replacement. as the coating continues to deteriorate, the only recourse it to change the fuel tank, the sensors, and entire fuel delivery system. we have had 3 ford vehicles f series experience this problem. the average repair IS approximately $2180 per vehicle. we are reporting this as it seems to be a defect in all the ford diesel fuel systems. as the fuel systems become clogged, the vehicles lose power without warning and create a safety issue and driving hazard not only to the vehicle operator but other motorists.
- Engine and engine cooling
When driving down a hill with lots of turns. The truck stalled (shut off) all of the sudden right before a turn. Luckily was able to keep the truck on the road and restart the truck in neutral. Took truck straight to hansel ford asked them to tell me what was wrong with the truck. They checked the computer in the truck, and said they could not find anything and didn't know what to tell me. *Tr
- Fuel system, diesel
The lining of the fuel tank has been flaking off into my fuel lines, which IS restricting my fuel filters. Because of the lack of fuel, 2 fuel injectors went bad and had to be replaced. And the turbo was over compensating for the lack of power, due to fuel shortage, so the turbo had to be replaced…
The lining of the fuel tank has been flaking off into my fuel lines, which IS restricting my fuel filters. Because of the lack of fuel, 2 fuel injectors went bad and had to be replaced. And the turbo was over compensating for the lack of power, due to fuel shortage, so the turbo had to be replaced as well. Now that we have found the source of the problem, the fuel tank and fuel pump has to be replaced as too. Into this for $5000 already without replacing the tank and pump. Need some help. *Tr
- Fuel system, diesel
The lining of the diesel fuel tank flaked off which clogged the fuel filters, which resulted in poor engine performance. *Tr
- Tires › Tread/belt
Tl*the contact owns a 2003 ford F450 super duty. the vehicle has double coin radial tires, size 225/70/19.5 (na). this complaint IS related to odi number 10239016 regarding the other five defective tires. the tires were serviced by an independent tire mechanic and tread separation was discovered…
Tl*the contact owns a 2003 ford F450 super duty. the vehicle has double coin radial tires, size 225/70/19.5 (na). this complaint IS related to odi number 10239016 regarding the other five defective tires. the tires were serviced by an independent tire mechanic and tread separation was discovered in six tires. there was one tire with a different dot number. the tires were replaced on the vehicle. the failure mileage was 95,773 and current mileage was 96,343. updated 10/16/08. *Lj updated 10/20/08. *Jb
- Tires › Tread/belt
Tl*the contact owns a 2003 ford F450 super duty. the vehicle has double coin radial tires, size 225/70/19.5 (na). the tires were serviced by an independent tire mechanic and tread separation was discovered in six tires. there were five tires with the same dot number. the tires were replaced on…
Tl*the contact owns a 2003 ford F450 super duty. the vehicle has double coin radial tires, size 225/70/19.5 (na). the tires were serviced by an independent tire mechanic and tread separation was discovered in six tires. there were five tires with the same dot number. the tires were replaced on the vehicle. the failure mileage was 95,773 and current mileage was 96,343. updated 10/16/08. *Lj the tires were prorated. Updated 10/17/08. *Jb
- Engine and engine cooling › Engine › Diesel
Events leading to failure: truck was purchased on 12-19-03 1.) on 1-19-04 truck had no power, dealer found 2,3 injector shorted, dealer replaced injectors and checked bore in cyl head per hotline. 2.)1-21-04 engine was missing in fire. Dealer replaced both injectors per hotline. O-rings blown…
Events leading to failure: truck was purchased on 12-19-03 1.) on 1-19-04 truck had no power, dealer found 2,3 injector shorted, dealer replaced injectors and checked bore in cyl head per hotline. 2.)1-21-04 engine was missing in fire. Dealer replaced both injectors per hotline. O-rings blown apart and injector wont seat, hotline suggest looking at bore and found burr in bore not allowing injector to seat . 3.) 2-23-04 engine locked up on hwy, fuel coming out of exhaust. Dealer found excessive fuel in cylinders and turbo, dealer removed engine and disassembled. No. 3 injector damaged and copper washer in pieces o-ring blown apart. Dealer checked deck height, removed rods and pistons to check for being bent, dealer replaced no. 3 piston and rod and turbo bearings, washed out and tested. 4.)10-26-04 steering feels funny when driving down hwy. dealer inspecting steering and steering stabilizer leaking fluid. dealer removed and replaced stabilizer shock. 5.)2-03-05 steering wheel binds up while turning. dealer checked and verified condition flow , pitman arm seized flush system metal in fluid. 6.) 7-19-05 engine hard to start. Whistle noise coming from engine when rpms rev high. dealer perform complete engine diag. Removed turbo and replaced ebp sensor per ssm and verified repair. 7.)11-02-05 engine hard to start, must plug block heater in to start. Dealer checked and cyl. 5 missed. Dealer removed and replaced NO.5 injector,turbo charger. Dealer found oil contaminated due to injector, dealer removed and replace 1,3 injector. 8.) hard to start and does not have oil pressure. new dealer replaced high pressure oil pump and turbo pedestal, replaced no. 3 injector. *nm
- Service brakes, hydraulic › Antilock/traction control/electronic limited slip · Steering › Gear box (other than rack and pinion)
Dt: contact states while applying the brakes it IS difficult to turn the wheel left or right. The harder the brake IS pressed the harder it IS to turn the wheel until the steering IS locked up. eventually the steering gear started leaking, leading to replacement of the steering gear. this did not repair the problem. *ak
- Engine and engine cooling
While sitting on the scene of a medical emergency with engine idling, the engine shutdown and them would not turn over to start(locked up)
- Engine and engine cooling › Engine
The motor was leaking numerous amount of oil between the block which could have cause the vehicle to overheat. Consumer took vehicle to the dealer for a new replacement motor, but the problem recurred. *ak
- Wheels › Lugs/nuts/bolts/studs
While driving 65 mph, both rear wheel lugs nuts came off the tires, causing the tires to detach from vehicle. Consumer managed to pull over, and had the vehicle towed. Dealership was notified, but the problem was not resolved.*ak
- Unknown or other
Problems with the attack setup. mr the vehicle did not stop in a safe way. and the problem only occurred when it was towing. Scc. *jb
- Suspension
The vehicle was not properly aligned which caused the vehicle to pull to the left. two tires were also ruined. the dealer was contacted. *nlm
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Engine stalling
In a december 3, 2007 letter, ford advised nhtsa that it will conduct a safety recall to replace the cam position sensor (cps) in approximately 1.2 million subject vehicles to address reports of engine stalling.a new design cps with improved performance and durability will be installed as a remedy.owner notifications…
In a december 3, 2007 letter, ford advised nhtsa that it will conduct a safety recall to replace the cam position sensor (cps) in approximately 1.2 million subject vehicles to address reports of engine stalling.a new design cps with improved performance and durability will be installed as a remedy.owner notifications will begin in december 2007. The subject vehicles are durable, full-sized, medium duty trucks commonly used for commercial purposes, rescue/emergency response, and commercial or recreational towing.cps failure IS comparable to unexpectedly turning the key off since the signal it produces IS vital to the electronic engine control system.cps signal loss terminates fuel injection resulting in an engine stall.once stalled, the engine may restart right away, or may restart after a delay (typically 5 to 10 minutes), or may not restart at all.in addition to exposing the driver and other motorists to crash risk due to loss of motive power or vehicle disablement, engine stalling also effects the power assisted steering and braking. Through consumer interviews, odi determined that cps failures occurred without any form of warning, at any vehicle speed (50% at highway speeds), and under any driving condition, such as accelerating.consumers reported that about a third of the vehicles failed to restart, with another third reporting delayed restarting.half the vehicles that did restart experienced another stall on the same or a subsequent drive cycle (before cps replacement) re-exposing those consumers to the risks associated with a stalling event.in their voq reports, half of the odi complainants described difficulty controlling the vehicle due to lose of power assist systems, especially those who were towing at the time of the incident. The one alleged injury incident occurred in an intersection when a subject vehicle stalled while turning across oncoming lanes of traffic.although unsubstantiated, the complainant alleged an injury to a child occupant during odi's interview.the other crash allegations mostly involved low speed, loss of control incidents often caused by lack of power assist; no injuries are reported in these incidents, and property damage, if any, was minimal.consumers also reported other incidents with significant safety risks, such as disablement in a lane or on a shoulder of a high-speed roadway or interstate, or extended disablement in remote areas during severe weather conditions. The population above IS ford's estimate of the 1.4 million subject vehicles produced that are currently registered.the ford complaint and warranty counts noted above are current as of ford's last submission dated june 21, 2007; they do not include F-450, F-550, or econoline counts as these products were not formally within scope of the investigation when failure information was requested.warranty data analysis indicates that about half the claims involved a stall while driving event ( ford's assessment) and that poor cps durability was a longstanding concern.ford reported that the new cps design should meet or exceed their 10 year, 150K mile life expectancy design requirement.
- Engine stalling
In a june 7, 2005 letter, ford notified odi that it would be conducting a safety recall of approximately 180,000 ford f-super duty, excursion and e-series vehicles equipped with 6.0L diesel engines to correct two wiring related conditions that could result in engine stall (nhtsa recall no. 05V-270, ford no. 05S34).the…
In a june 7, 2005 letter, ford notified odi that it would be conducting a safety recall of approximately 180,000 ford f-super duty, excursion and e-series vehicles equipped with 6.0L diesel engines to correct two wiring related conditions that could result in engine stall (nhtsa recall no. 05V-270, ford no. 05S34).the affected vehicles were built between september 29, 2003 and may 31, 2004.according to ford, vehicles with the conditions may stall without warning and may or may not restart.ford will instruct owners of vehicles included in the recall to take their vehicles to a dealer to have the fuel injector control module wire harness upgraded or replaced and or have a new injection control pressure sensor connector installed.during a may 2005 presentation to odi, ford identified a number of potential failure mechanisms that could affect engine performance in various segments of the subject vehicle population, including the wiring conditions addressed by 05v-270.the wiring conditions, which both affect engine fueling, were the most likely conditions to result in engine stall.the recalled vehicles comprise approximately 43% of the subject vehicle population and account for 75 of the 113 odi reports that have a valid vin (66%).the voq complaint rate for the recall population IS 45/100k while the rate for vehicles outside the recall population IS 17/100k and their trend (by date of receipt) IS declining.based on the analysis, odi believes ford?s actions are sufficient to address the current safety risks and the investigation IS thus closed.the closing of this investigation does not constitute a finding by nhtsa that a safety related defect does not exist.further action will be taken if warranted by future circumstances.
- Accelerator pedal sensor (etc)
Failure counts from odi?s analysis are stated above; see the additional problem experience discussion in the summary report.ford data contained duplicative reports for 4 odi complaints and 1 crash.three crashes were allegedly due to intermittent operation of the electronic throttle control (etc) pedal, one crash…
Failure counts from odi?s analysis are stated above; see the additional problem experience discussion in the summary report.ford data contained duplicative reports for 4 odi complaints and 1 crash.three crashes were allegedly due to intermittent operation of the electronic throttle control (etc) pedal, one crash occurred when an etc disabled vehicle was struck by another motorist, one report contained no detail.the injuries were minor.an issue involving fixed etc pedals was investigated also, however failure reports and populations are not shown above; see summary report for detail.although ford has used etc based throttle control systems for many years, the pap feature was new for my 2002.the subject etc sensor produces two output signals which the engine management system (ems) utilizes TO:1) determine fueling requirements; and 2) perform sensor diagnostics.one signal IS linearly proportional to throttle pedal position; the second IS a digital signal.by design, the detection of a sensor fault results in the engine returning to (or remaining at) the idle state.ford identified a defect in the pap etc sensor which prematurely affected an output signal; the migration of internal sensor lubricant caused a loss of proportional signal.the failure mechanism IS progressive and as the sensor deteriorates, the ems will detect a fault, store a fault code, illuminate a warning lamp, and the engine may remain at/return to idle.in the early stages, normal operation can be regained by pedal re-application.the failure progresses until the engine remains at idle.the engine does not stall, power assisted steering and braking systems are unaffected. Ford corrected the etc sensor defect and conducted field service action (fsa) 03b03 to replace etc pedals, addressing 50% of vehicles.at agency request to improve completion rate, ford extended fsa 03b03 for 6 months.based on odi's analysis of available data, ford's action has appropriately resolved the etc sensor proplem in the subject vehicles.the closing of the investigation does not constitute a finding by nhtsa that a safety-related defect does not exist, and should not be considered as having any precedential value or effect binding the agency in future defect investigations. See the attached summary report for additional information.
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 10243490When 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 acceptable. After 30-Jun-2023, MERCON SP ATF will no longer be manufactured and will only be available until inventory depletes.
- 10189008This 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 being installed.
- 10171326This 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. We don't have evidence that these test results have contributed to a product failure.
- 10171325This 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. We don't have evidence that these test results have contributed to a product failure.
- 10165713Some 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 indicators or auto lamps may occur after successful programing. To ensure the VSM is configured correctly, use the Integrated Diagnostic System (IDS) scan tool and select the blue ball and socket icon in the upper left corner. Select the utility knife in the bottom left corner. Select Update/Special Function and enter 53061 in the blue box then press the tick mark. The screen will go back to the system utilities page. Navigate to the toolbox tab and run the Programmable Module Installation (PMI) on the VSM. The procedure will prompt you to manually enter the as-built into the VSM. Obtain the as-built data from PTS > OASIS > As-Built.
- 10056196Ford: 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.
- 10055648Ford: 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 duty.
- 10055629Ford: 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 2003-2007 f super duty, 2004-2010 e series, 2003-2005 excursion.
- 100243256.0L turbocharger carbon deposit diagnostics and service tips. Updated 5/29/08.
- 100238556.0L--mil on--p0401, p0402, p0404, p1335--lack of power or surge with some 2003-2007 f-super duty, 2003-2005 excursion and 2004-2008 e-series vehicles.
- 100236531999-2008 f250-f550 super duty 4X4 with electronic shift transfer case not engaging 4X4.
- 10022675Brake booster system may exhibit a brake pedal kickback and/or grabbing condition when applying the brakes.
- 10022295Dtc's p006a or p132b - lacks power, surge, or flutter after field service action 06e17.
- 100222936.0L diesel engine - oil leak or boost pressure leak at hot side charge air cooler duct.
- 10022243Lack of power due to low fuel pressure - fuel tank liner seperation.
- 10021621Lack of power due to low fuel pressure, fuel tank liner seperation.
- 10021619Air filter water ingestion / snow packing with codes p0103.
- 10021484Adding additional bulbs to turn indicator or hazard flasher circuits.
- 100214646.0L oil seep or boost pressure leak at hot side charge air cooler duct.
- 10021462Cold start driveability - white smoke, lacks power, exhaust odor, surges, runs, rough, or no start.
- 10021281Water in the fuel tank behind rear axle - 6.0L, 6.4L and 7.3L diesel engine. Updated 2/29/08.
- 10021236Lack of cooling fan operation.
- 100212326.0L turbocharger carbon deposit diagnostics and service tips - lack of power, white or black smoke, surge, p0238, p0299, p0404, p2262, and/or p2263.
- 10021229Watch for oil flow from the base engine oil pump. Vehicles equipped with a 6.0L diesel engine.
- 10021174Driveability issues and/or dtc p132b, p006a immediately after reprogramming.
- 10021173Oil flow from the base engine oil pump.
- 10020069Misfire, lack of power, buck/jerk, excessive smoke or crank/no start.
- 10019949Water-in-fuel (wif) lamp on.
- 10019945Voluntary emission recall 06e17 supplement #1: control module recalibration. Corrosion may exist at the electrode surface on the exhaust pressure (ep) sensor; fuel delivery timing during cold weather may not be optimal; and/or exhaust gas recirculation (egr) system operation at idle may not be optimal.
- 10019808Exhaust pressure sensor input no longer used if pcm IS reprogrammed - service tip.
- 10019795P0404 service tip.
- 10019385Coolant degas bottle overflow - 6.0L.
- 10019380White smoke, lacks power, exhaust odor, surges, runs rough, or no start - 6.0L.
- 10018939Coolant degas bottle overflow.
- 10018070Torqshift transmission - intermittent clunk when shifting from reverse gear or drive gear to park. Multiple vehicles. Ford oasis. To include 2006 ford F-53.
- 10018067Vacuum pump inoperative or runs continuously - climate control defaults to defrost mode.
- 10018062Coolant degas bottle overflow.
- 10018054Service kit available for wiper motor wiring.
- 10017928Diagnostic procedure for trailer tow lights or no power due to open fuse.
- 10017873Lack of power and/or dtc p2263 or p0299 after turbocharger replacement - service tip.
Every Ford F-450 SD model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.