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definitely annoying
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
46,543 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 #7

Sep 282011

Excursion 4WD 8-cyl Diesel

  • Automatic transmission
  • 81,000 miles


The contact owns a 2004 Ford Excursion. The contact stated that upon starting the vehicle, a large cloud of smoke emitted from the tail pipe. The failure recurred on an intermittent basis. The contact also stated that the engine fan would intermittently create a very loud noise. The vehicle was taken to an authorized dealer and the contact was informed that coolant was leaking into the engine. The contact was informed that the engine would need to be rebuilt. The vehicle was not repaired. The manufacturer was made aware of the failure, but offered no assistance. The failure mileage was 81,000. Updated 11/01/11 the consumer stated the engine egr cooler failure resulted in a sudden loss of coolant and there was no warning on the dashboard from the service engine light. White clouds emitted from the tailpipe and auxiliary fan activation, which were both intermittent and inconsistent. The failure occurred over a one week period. When the consumer started the vehicle he noticed a billowing of white clouds coming from the tailpipe. The billowing clouds stopped as the consumer continued to drive, only to reappear intermittently over the next week.

- Las Cruces, NM, USA

problem #6

Feb 232010

Excursion Diesel

  • miles
2004 Ford Excursion diesel with 6.0 engine. The engine is crap. The fuel injectors are bad it's a known problem. I was in an intersection while making a left turn with an on coming vehicle when I had no acceleration and black exhaust was coming out of the tail pipe. I had my 3yr old daughter on that side of the vehicle. This isn't the first problem we have had with this engine as has almost everyone else that owns it. It needs to be recalled. It scared me so bad I cried. I have called the Ford consumer number they did nothing. I am paying Ford $1,500 to fix the problem that I was told would continue to happen because it's a defect in this particular engine. In the words of one of Ford mechanics "he wouldn't own one, they are crap" I'm scared to drive it even after it gets fixed knowing another may go soon or the same one.

- St Robert, MO, USA

problem #5

Nov 282009


  • 78,318 miles
The contact owns a 2004 Ford Excursion. The contact stated that the turbo charger on the diesel engine broke. This was caused by a malfunction within the engine. There was a 100,000 mile warranty on the vehicle and the Ford manufacturer would not honor it. The failure mileage was 78,318.

- Port Charlotte, FL, USA

problem #4

Jan 272007

Excursion 4WD 8-cyl Diesel

  • Automatic transmission
  • 108,480 miles


The contact owns a 2004 Ford Excursion. While driving between 35-40 mph, the vehicle stalled and then shut off. The vehicle was towed to a mechanic and they replaced the number 1 and number 3 fuel injectors. The dealer stated that the VIN was not included in NHTSA campaign id number 05V270000 (electrical system:wiring). The current mileage was 130,994 and failure mileage was 108,480. Updated 09/10/08 the alternator, control module for the heating and ac system, and cooling system were replaced. Updated 09/19/08.

- Delta, CO, USA

problem #3

Jun 022004

Excursion 4WD 8-cyl Diesel

  • Automatic transmission
  • 47,000 miles
The contact owns a 2004 Ford Excursion. The contact stated that the check engine light has remained illuminated in the past. The vehicle shut down and was taken to the dealer who replaced the egr valve. While driving 30 mph, the failure recurred. Since then, the egr valve has been replaced several times and the turbo was cleaned. The vehicle is currently at the dealer. The manufacturer offered to buy back the vehicle for half price so that it can be resold. The current mileage is 72,876 and failure mileage was 47,000. Updated 02/01/08. The consumer stated the vehicle bucks forward while at a stop and while driving.

- Yukiah, CA, USA

problem #2

Nov 012004

Excursion 4WD Diesel

  • Automatic transmission
  • 11,000 miles
Trucks motor cuts out losing power at diffrent times. We have been crossing intersections and pulling out into traffic and have lose the accuration. This is very dangerous. Truck has been iin shop numerous of times and Ford is unalbe to fix problem.

- Monroe, WA, USA

problem #1

Feb 052005

Excursion 8-cyl Diesel

  • Automatic transmission
  • miles
My vehicle's engine will surge and stall. Sometimes both things will happen on a given day or just one. I have had my vehicle stall coming to a stop and or driving. My vehicle's engine has surged and caused my car to move even with my foot on the brake. This has been a ongoing problem that Ford can not fix.

- Discovery Bay, CA, USA

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