Problems owners report
Complaints filed with NHTSA about the 2004 Ford Excursion, by the system named in each complaint. One complaint can name several.
- Engine and engine cooling22
- Electrical system21
- Vehicle speed control9
- Power train7
- Engine7
- Tires6
- Fuel system, gasoline5
- Visibility5
- Fuel system, diesel4
- Fuel/propulsion system3
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 3 injuries and 0 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Fatal crashes in the US
From 2020 to 2023, 19 2004 Excursion vehicles were involved in crashes on US public roads in which someone died; 7 people died inside them, and 4 of the vehicles rolled over. This is a count, not a crash rate: it grows with the number of cars on the road.
NHTSA Fatality Analysis Reporting System (FARS), crash years 2020–2023 (public domain)
New York safety inspections
At its first New York inspection the 2004 Ford Excursion failed the safety check 0.89% of the time — 60% less often than the average 2004 passenger car (2.21%). Median odometer at inspection: 190,309 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
In New Zealand
1 2004 cars are on the New Zealand register; 100% arrived as used imports, 0% were sold new in New Zealand.
NZ Transport Agency Waka Kotahi, Motor Vehicle Register (March 2026) · CC BY 4.0
Recalls in Canada
1 Transport Canada recall for the 2004 Ford Excursion.
| 2005183 20 Jun 2005 | Fuel System On certain vehicles equipped with a 6.0L diesel engine, the Fuel Injection Control Module (FICM) wire harness may chafe against an engine bolt. Also, the Injec… |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
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 FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THE MULTI-FUNCTION SWITCH WAS SHIPPED WITH A SUBCOMPONENT (SLIDER) THAT MAY EXPERIENCE DEFORMATION. A MULTI-FUNCTION SWITCH WITH A DEFORMED SLIDER MAY MALFUNCTION CAUSING THE TURN SIGNAL, TAIL LIGHTS, HAZARD WARNING SIGNAL FLASHERS AND/OR BRAKE LIGHTS NOT TO ACTIVATE.
CERTAIN PICKUP TRUCKS, SPORT UTILITY VEHICLES AND VANS EQUIPPED WITH 6.0L DIESEL ENGINES MAY EXPERIENCE STALLING WITHOUT WARNING WHILE DRIVING AND MAY OR MAY NOT RESTART.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Ford told its dealers about the 2004 Ford Excursion: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 10243490 | When 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. |
| 10189008 | This 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. |
| 10148818 | This SKU is a front upper ball joint. The Customer communication requested return of unsold inventory to inspect for ball studs with excessive rotational friction in the ball joint assembly. Excessive friction in the ball joint assembly may cause a perceptible increase in steering effort. |
| 10109070 | The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate when reading these PIDs and cannot display quickly enough to validate a concern. The PCM automatically monitors these inputs more accurately and will set diagnostic trouble codes (DTCs) when appropriate. Using these PIDs for diagnostics will lead to inaccurate results and improper ETB replacements. If a concern is intermittent and no DTCs are present, refer |
| 10056196 | FORD: 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. *PE |
| 10055629 | FORD: 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. |
| 10034571 | FORD: RUNS ROUGH, LACKS POWER, HARD START, NO START. SOME VEHICLES AND TRUCKS EQUIPPED WITH 6.0L ENGINE MAY EXHIBIT A RUNS ROUGH, LACKS POWER, HARD TO START, NO START CONCERN WITH OR WITHOUT DIAGNOSTIC TROUBLE CODE (DTC) P0611 CODE OR VARIOUS INJECTOR CIRCUIT CODES. *PE |
| 10030848 | FORD: SOME VEHICLES EQUIPPED WITH THE 6.0L ENGINE MAY EXPERIENCE A P006A, P132, P0401 OR P0402 DIAGNOSTIC TROUBLE CODE (DTC) WITH A LACK OF POWER CONDITION, SURGE, OR TURBOCHARGER FLUTTER AFTER PERFORMING FIELD SERVICE ACTION (FSA) 06E17, OR AFTER RECALIBRATING THE VEHICLE WITH THE INFERRED EXHAUST PRESSURE (EBP) STRATEGY. *PE |
| 10030836 | FORD: MULTIPLE VEHICLES WITH A TORQ SHIFT TRANSMISSION INTERMITTENT CLUNK WHEN SHIFTING BETWEEN DRIVE, REVERSE AND PARK AND/OR DURING 2-3 UPSHIFT. MODELS F SUPER DUTY; E SERIES; EXCURSION; F53 MOTORHOME CHASSIS AND LOW CAB FORWARD. *PE |
| 10028826 | FORD: SOME VEHICLES WITH DIESEL ENGINES MAY EXPERIENCE NO STARTS, HARD STARTS OR ROUGH RUNNING WHEN COLD AND MAY BE ACCOMPANIED WITH DIAGNOSTIC TROUBLE CODES (DTCS) P0611, P1378 AND/OR ALL 8 INJECTOR CIRCUIT CODES. *PE |
| 10028730 | FORD: SOME VEHICLES EQUIPPED WITH 6.0L DIESEL ENGINE MAY EXHIBIT ANY ONE OR COMBINATION OF THE FOLLOWING CONCERNS-LACK OF POWER, WHITE/BLACK SMOKE OR A SURGE. *PE |
| 10028284 | FORD TRUCKS: MISFIRE, LACK OF POWER, BUCK/JERK, EXCESSIVE SMOKE, CRANK/NO START-DIAGNOSTICS FOR FUEL SYSTEM. THERE ARE SEVERAL POTENTIAL CAUSES FOR THESE SYMPTOMS. *PE |
| 10028125 | FORD: VEHICLES MAY EXHIBIT FUEL IN THE ENGINE COOLANT, DUE TO LEAKS IN THE CYLINDER HEAD FUEL INJECTOR AREA. SYMPTOMS MAY INCLUDE FUEL IN ENGINE COOLANT AND COOLANT EXPULSION FROM THE DEGAS BOTTLE. *PE UPDATED 3/20/09. *PE |
| 10026321 | FORD: VEHICLES MISTAKENLY CHARGED $100 POWERTRAIN WARRANTY DEDUCTIBLE FOR FUEL INJECTOR REPAIR OR REPAIRS. NO MODEL OR MODEL YEARS PROVIDED. *PE ECONOLINE, EXCURSION AND F-SERIES SUPER DUTY VEHICLES, MODEL YEARS 2002-2005. UPDATED 10/24/08. *PE CSC LETTER WAS RECEIVED. UPDATED 10/27/08. *PE |
| 10024325 | 6.0L TURBOCHARGER CARBON DEPOSIT DIAGNOSTICS AND SERVICE TIPS. *NJ UPDATED 5/29/08. *NJ |
| 10023943 | SOME 1997-2008 VEHICLES EQUIPPED WITH A 4.6L 2V, 5.4L 2V, OR 6.8L 2V ENGINE--SPARK PLUG THREAD REPAIR PROCEDURE--NOT COVERED UNDER NEW VEHICLE LIMITED WARRANTY. *NJ THIS INCLUDES F-53 MOTORHOME CHASSIS. UPDATED 2/23/10. *PE |
| 10023855 | 6.0L--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. *NJ |
| 10022675 | BRAKE BOOSTER SYSTEM MAY EXHIBIT A BRAKE PEDAL KICKBACK AND/OR GRABBING CONDITION WHEN APPLYING THE BRAKES. *NJ |
| 10022295 | DTC'S P006A OR P132B - LACKS POWER, SURGE, OR FLUTTER AFTER FIELD SERVICE ACTION 06E17. *KB |
| 10022293 | 6.0L DIESEL ENGINE - OIL LEAK OR BOOST PRESSURE LEAK AT HOT SIDE CHARGE AIR COOLER DUCT. *KB |
| 10021619 | AIR FILTER WATER INGESTION / SNOW PACKING WITH CODES P0103. *KB |
| 10021464 | 6.0L OIL SEEP OR BOOST PRESSURE LEAK AT HOT SIDE CHARGE AIR COOLER DUCT. *KB |
| 10021462 | COLD START DRIVEABILITY - WHITE SMOKE, LACKS POWER, EXHAUST ODOR, SURGES, RUNS, ROUGH, OR NO START. *KB |
| 10021236 | LACK OF COOLING FAN OPERATION. *KB |
| 10021232 | 6.0L TURBOCHARGER CARBON DEPOSIT DIAGNOSTICS AND SERVICE TIPS - LACK OF POWER, WHITE OR BLACK SMOKE, SURGE, P0238, P0299, P0404, P2262, AND/OR P2263. *KB |
NHTSA manufacturer communications (public domain)
NHTSA investigations
SPARK PLUG EJECTION FROM CYLINDER HEAD
ENGINE STALLING
ENGINE STALLING
NHTSA Office of Defects Investigation