hardly worth mentioning
Crashes / Fires:
0 / 1
Injuries / Deaths:
0 / 0
Average Mileage:
75,460 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.

2002 Ford Excursion engine problems

engine problem

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2002 Ford Excursion Owner Comments

problem #15

Oct 132011


  • 100,000 miles


The contact owns a 2002 Ford Excursion. The vehicle was included in the recall under NHTSA campaign id number: 07V553000 (engine and engine cooling:engine:diesel) and was repaired. After the repair while driving approximately 65 mph, the vehicle began to decelerate independently. The vehicle was taken to the dealer for diagnostic testing where the technician performed repairs to the vehicle but the contact was unaware of the exact repairs. The failure continued. The vehicle was not further repaired. The approximate failure mileage was 100,000.

- Houston, TX, USA

problem #14

Jan 182012

Excursion 8-cyl

  • 146,000 miles
#4 spark plug blew out of engine head, threads destroyed. Ford dealer service department told me this is a known defect in the Ford 5.4 Triton engine head and that Ford is doing nothing about it.

- Wills Point, TX, USA

problem #13

Jun 122011


  • 110,000 miles
Was starting from a stop to make a left turn when driver heard a loud pop. There was a sudden loss of power and some smoke. The vehicle was towed and diagnosed. The #3 plug on the right bank has blown completely out and damaged the coil pack. A phone call to the dealer yielded no help other than we can have it towed there to be repaired, as it likely needs a new head. Some internet research and talking to other Ford owners definitely suggest that this is a design problem with the alum heads blowing out spark plugs, and the #3 R plug seems to be common. This could cause fuel/vapors to be exhausted and sprayed on a hot manifold and cause a fire. It sounds like there may have already been some fires attributed to this problem. This sound like a case where the dealer/Ford refuses to admit that it is a problem and fix it for owners. Before there are serious injuries from a crash or a fire, Ford should be compelled to fix this issue. Its unlikely that Ford will answer the call without pressure from NHTSA. There seem to be far too many of the same type of problems with this 5.4L motor for it to be a coincidence.

- Lakeside, CA, USA

problem #12

Jan 252010


  • 120,000 miles


My 2002 Ford lexcursion blew out it's spark plug yesterday. You all know the story by now: Corporate will not help. My local dealer will not help. And, as most of you already know, the government to this date has done nothing to help either. These kinds of things are exactly what is wrong with this country: More often than not there is no accountability for things that go wrong. I will never buy a Ford again, this whole situation is breaking my heart because I really do love America and my beautiful american-made Ford truck. It's a Excursion, people. My point is that it was built here in America, not outside our borders like some of the other cars we buy. The manufacturer includes a numbered certificate with each lexcursion to verify that it was built by americans, in America, for americans. I am ashamed of Ford, and of my govenment for letting this go on for so long. This has been happening with Ford V8, V10 all trition engines spanning back 11 years, and that's just what I've found so far: I've been searching online for only about ten minutes now. When I googled the issue I didnt even put Ford's name in the search box. I just typed "why do spark plugs blow out"", and it spit out a ton stuff about Ford, in particular their Triton 6.8 V10. How many millions of these have they installed" good people of America: They won't acknowledge the problem because to do that would cripple them. This is their version of the Toyota accelerators. I even called my congressman today, left a message, which breaks my heart even more because I already know I probably won't be called back. I am a Ford owner, and now I own a truck that I no longer trust or believe in, built by a company that I no longer trust or believe in. My family was with me and I was stuck on the beltway disable and anything could had happen. There are thousands and thousands of the same problem. I dont know what to do. Please help. This issue keeps happening over and over and seems there is no fix.

- Barstow, MD, USA

problem #11

Jun 162009


  • 54,062 miles
Exhaust manifold bolts, rusted and broken off, right bank.

- Warren, OH, USA

problem #10

Aug 152009


  • 68,500 miles
While driving down the highway at approx 60 mph the spark out of the # 1 cylinder was ejected from engine. Brought to local mechanic who installed a heli coil and replaced spark plug.

- Valdez, AK, USA

problem #9

Jun 122009

Excursion 10-cyl

  • 116,000 miles


I have a Ford Excursion 2002 V10 with 116000 miles on it. After 8 hours of a road trip one of the spark plugs ejected from the engine. This is the second time this has happened with this motor. I purchased the vehicle at 100,000 miles and the owner had it happen once to him.

- Mascoutah , IL, USA

problem #8

Dec 172008

Excursion 10-cyl

  • 112,500 miles
2002 Ford Excursion with 6.8L V10 Triton blew a spark plug out. Spark plug had been in engine for 30000+ miles and was professionally installed and torqued.

- Corona, CA, USA

problem #7

May 032007


  • 76,827 miles
Camshaft position sensor needed to be replaced. I had defective part replaced at my expense and then received safety recall notice for same part. I am having trouble being reimbursed for the cost of the repair.

- Canby, MN, USA

problem #6

May 052008

Excursion 10-cyl

  • 57,844 miles
Slight ticking sound, like an exhaust leak, leading to the spark plug blowing out of the cylinder head, damaging the threads and also coil pack to break.

- Hesperia, CA, USA

problem #5

Oct 232007

Excursion 8-cyl Diesel

  • Automatic transmission
  • miles


Auto stalls without warning and will not start - has occurred several time every years starting in 2003. I have had it!- I do not know where to turn to. Hopefully you will E able to do something.

- Simi Valley, CA, USA

problem #4

Apr 052006

Excursion 4WD 8-cyl Diesel

  • Automatic transmission
  • 39,888 miles
Truck started to stop and stall. Happened approximately 5 times leaving me stranded on the side of the road when it finally stopped the truck dead.

- Norco, CA, USA

problem #3

Feb 072006

Excursion 4WD 10-cyl

  • Automatic transmission
  • 79,284 miles
: the contact stated while merging with traffic on the interstate at 55mph, a spark plug blew upward into the engine which caused the vehicle to stall and operate at a reduced speed. The contact managed to pull the vehicle to the side of the road. The vehicle was towed to a local dealer. The dealer suggested replacing the engine because of the damage sustained by the spark plug, but no repairs were made.

- Upper Marlboro, MD, USA

problem #2

Mar 202005

Excursion 4WD 8-cyl Diesel

  • Automatic transmission
  • 51,000 miles
The vehicle caught on fire under the hood while being parked in the driveway for more then 10 hours or more. The local fire department arrived to extinguish the fire. The cause of the fire was not determined. The consumer notified the dealer and the manufacturer. The main body of the fire was coming from the engine.

- Madison, CT, USA

problem #1

Aug 262002

Excursion 4WD 8-cyl

  • miles
The vehicle has a front suspension problem which causes the vehicle to vibrate, the vehicle has been to the dealer 3 times but the problem still exist, both driver side doors are misaligned with respect to the fender trim, the differential was originally misaligned with respect to the rear fender trims, now the differential is properly aligned and the consumer questioned the technicians who stated that they did nothing to correct the misalignment, the consumer feels this is a definite safety problem if the differential goes in and out of alignment on is own, the A/C was not cooling and needed to be recharged, the consumer can hear static in radio when turning on the rear tv switch, A/C and turn signal, steering gear and hydro boost line replaced, tire out of balanced causing vibration at 75-70 mph, steering out of adjustment (off center), calipers replaced, transmission experiencing a delay when shifting, both wiper blades off center, drain plug leaking oil, weather stripping on right rear door failed, headliner is coming loose on the left side, windshield washers inoperative, fuel gauge read incorrectly, faulty accelerator pedal caused the vehicle to stall when coming to a stop. Nlm

- San Antonio, TX, USA

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