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hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
98,900 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Ford Excursion engine problems

engine problem

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2004 Ford Excursion Owner Comments

problem #5

Oct 232014

Excursion 8-cyl

  • 142,000 miles


Repeatedly ejects spark plugs from cylinder head.

- Peoria, AZ, USA

problem #4

Jun 202012

Excursion 8-cyl

  • 80,000 miles
Vehicle engine ejects spark plug from cylinder head.

- Peoria, AZ, USA

problem #3

Nov 272013

Excursion 8-cyl Diesel

  • 82,500 miles
On 11/26/13 driving back from atlanta heading South leaving the Florida welcome center on I-75, 4 miles North of jennings on I-75 South jennings. Leaving the welcome center the vehicles engine lost power while trying to merge back into traffic without any prior indication of a problem. The loss of power caused us to have to divert from the lane until we could gain more speed. The vehicle had no accelerating power above 40 mph even with the gas pedal depressed all the way to the floor. There were no check engine lights on or any abnormal indicators. I called the Ford customer care center on 12/12/13 and they acknowledge they have a problem with the erg failing due to collecting carbon and soot build up. They have not issued any service bulletins to owners letting them know there is an issue or have issued a maintenance program to try to prevent this from occurring. 1)Ford designed the engine to pass soot and carbon back thru the erg valve. It is a bad design since it causes every engine to eventually fail. 2)Ford does not warranty the egr valve or any component if soot or carbon sticks to the valve or component, even though it is designed to do so. 3)Ford knows there is an issue with the egr failing which deposits soot and carbon in the intake of the engine which causes the engine to lose power and or ultimately quit without warning. 4)no service bulletins were issued to owners warning them of this safety problem. 5)cleaning the egr valve is not listed in the issued service manual. 6)no preventative maintenance service was offered to prevent this failure from occurring. 7)dealers enjoy this failure since it is a high labor revenue generator for them to tear down the engine to replace or clean the intake manifold. 8)the repair cost was approximately $3319.90 the vehicle is currently under the highest Ford premium care warranty.

- Parkland, FL, USA

problem #2

Dec 282012


  • 101,000 miles
While driving the vehicle, it will go into a reduce power mode or sometimes stall. This has happened at various speeds, from around town to highway driving. Very dangerous condition when trying to make left turns and power is lost or engine stalls. Also engine fails to start or starts and stalls right away on occasion. Call Ford customer relations and dealer and they tell me my VIN is not covered under the recall. I am experiencing the same symptoms but I am not covered. Don't want to spend more money at dealer if they don't know what is happening and how to fix it.

- Dyer, IN, USA

problem #1

Oct 012012


  • 89,000 miles
The contact owns a 2004 Ford Excursion. The contact stated that while driving approximately 30 to 45 mph, the vehicle stalled without any warning. The vehicle was later towed to a dealer. After diagnosis, the contact was informed that the problem may be the fuse near the transmission. The vehicle was repaired. Approximately three months later, the failure recurred. The vehicle was taken back to the dealer. After diagnosis, they advised her that the fuse failed again due to the bracket chafing the wires. The vehicle was repaired. The manufacturer was contacted and they offered no assistance. The failure mileage was approximately 89,000. The current mileage was approximately 90,000. The VIN was unavailable.

- Chino Hills, CA, USA

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