3rd Gen Engine and Drivetrain -> 2003-2007 5.9 liter Engine and drivetrain discussion only. PLEASE, NO HIGH PERFORMANCE DISCUSSION!

Common Problems for 2003

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Old Oct 12, 2009 | 01:50 PM
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Common Problems for 2003

What are som eof the more common problems associated with the 03 year model? Is one year stronger than another? I have an 04.5 but my cousin is looking into buying an 03 with ~230k mi for $13k. I know that the first year of the 3rd gen, so naturally i would assume there would be more little problems that eventually get worked out as the model ages. Any info is greatly appreciated. Ill be surfing the 3rd gen forums looking for commonalites, but thanks in advance.


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Old Oct 12, 2009 | 01:52 PM
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also, I have the VIN if that helps
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Old Oct 12, 2009 | 01:57 PM
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fuel filtering system , injectors, lift pump main things other then normal stuff seemss kinda high on the price
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Old Oct 12, 2009 | 02:23 PM
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Common Problems?

Trying to get that ____-eating grin off your face every time you pull a 7% grade hill at 75mph towing 10,000 lbs.

(and knowing you did it without DPF, catalytic converter, 3rd-injection events, etc.)
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Old Oct 12, 2009 | 03:17 PM
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looked up the blue book value, $19k, so this price is actually pretty low.
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Old Oct 12, 2009 | 03:19 PM
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blue book and what the market will handle are to different things. Around here you can get an 03 under 200k miles for around 12k
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Old Oct 12, 2009 | 05:03 PM
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They have problems with the PDC(main fuse box). The trailer turn signal/brake light relays that are built-in fail, have to replace the whole fuse box. This will cause trailer brake/turn signals to stop working on both the 7pin and flat 4. Search on here there are a few threads, couple of them are mine so just serach my user name and you will find the threads.
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Old Oct 12, 2009 | 05:37 PM
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Originally Posted by rich
blue book and what the market will handle are to different things. Around here you can get an 03 under 200k miles for around 12k
I think that might be to the amount of diesel pickup trucks registered in Texas. If you go to ebay and look at the trucks for sale (Dodge, Ford) about 1 in 4 are from your state.
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Old Oct 12, 2009 | 05:58 PM
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gotta chime in, I bought my '05 with 41k on the clock in Januaru '09 for $14,800.. in Arizona.
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Old Oct 12, 2009 | 08:05 PM
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There is an SO (250 HP) and an HO (305 HP) in 03. HO only came with a 6 gear although there are a few HO/48RE auto, made late in the model year. The SO's came with a 47RE normally.

As for problems, they really aren't any worse than another year from what I've gathered on here. Lift pump was weak but most were refitted to in-tank through the dealer. The later 4.5 and up seem to have more issues but I guess there are more of them. I've had no significant problems with mine at 100K miles.

Good luck
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Old Oct 12, 2009 | 09:38 PM
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I replaced the fuel pump with an AirDog at 90K miles (it was still working) just to be on the safe side. Had a water pump go while towing the 5er in 100 degree AZ heat last month @ 110K miles. Replaced the stock tires @ 70K. Other than that zero problems. Treat her well with regular fluid changes and she seems to be doing the same in return.
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Old Oct 13, 2009 | 01:24 AM
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I had an 03.

Check the alternator bracket. They at first used one formed out of sheet steel that was prone to crack.

They can develop a buzz or vibration in the pedals and/or wheel that occur right at 2000 rpm. The cause was pulses from the power steering pump transmitted to the hydrobooster, and the solution was a replacement pressure line with a crimp and a weight mid-span.

All the 3rd gens seem to be prone to HVAC issues, broken blend doors, recirc door, or mode doors.
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Old Oct 13, 2009 | 02:20 AM
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Originally Posted by billie
There is an SO (250 HP) and an HO (305 HP) in 03. HO only came with a 6 gear although there are a few HO/48RE auto, made late in the model year. The SO's came with a 47RE normally.



Good luck
don't forget about us 5 spd'rs . . And don't mind that (250hp) tag, smarty will fix that up . (446hp with smarty + FASS) my 03 ate a front wheel bearing (2wd) at 122k, lift pump at 140kish clutch 140ish, water pump 175k and that's about it, heck I still have the factory batteries . o and the mentioned HVAC issues.
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Old Oct 13, 2009 | 02:35 AM
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Originally Posted by masterphreak
They have problems with the PDC(main fuse box). The trailer turn signal/brake light relays that are built-in fail, have to replace the whole fuse box. This will cause trailer brake/turn signals to stop working on both the 7pin and flat 4. Search on here there are a few threads, couple of them are mine so just serach my user name and you will find the threads.
Exactly what happened to my 04.
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Old Oct 13, 2009 | 05:20 AM
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Originally Posted by Jeff in TD
I had an 03.

They can develop a buzz or vibration in the pedals and/or wheel that occur right at 2000 rpm. The cause was pulses from the power steering pump transmitted to the hydrobooster, and the solution was a replacement pressure line with a crimp and a weight mid-span.
Man I have been trying to figure out what in the h3ll that NOISE is at 2000 rpms for about 6 months now............. Are there any threads on this??????
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