definitely annoying
Crashes / Fires:
0 / 1
Injuries / Deaths:
0 / 0
Average Mileage:
34,720 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.

2003 Ford Excursion fuel system problems

fuel system problem

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2003 Ford Excursion Owner Comments

problem #7

Apr 012004

Excursion 8-cyl Diesel

  • 1,000 miles


The 2003 Ford Excursion 6.0 liter diesel, first broke down while driving home from the dealer who was working on recall items. The vehicle stalled while driving less than 2 miles from the dealer (dealer now out of business). After a while the vehicle began losing power, but not stalling while driving, especially up hills. After many attempts to clean parts, egr valve etc, it was stated that the injectors were bad. All injectors replaced. Front main leaf spring broke on the vehicle, and had to be replaced - the spring was no longer available, -the repair facility stated that this vehicle has been historically undersized, and they stopped making the original spring, because too many were breaking. We then again started experiencing a loss of power while driving - at this time my kids were driving the car, and this was particularly worrisome. My repair shop sent the vehicle to a heavy truck and diesel repair shop, specializing in ambulances. After charging me $3000 to fix my problems (various pieces an part related to the engine, fuel system, etc), the vehicle seemed to operate well. While up in cleveland for thanksgiving, the vehicle lost power on the highway -. had to have it towed to a dealer, and rent a replacement during our vacation. The dealer said more of the fuel/engine issues and after charging me another $1500, I was able to drive home. Less than one month later, same stalling issues. The vehicle would simply stall, at low speed, high speed, under load, or no load - towed again to my repair person, and he sent it to a different diesel mechanic who told me that diesel is leaking into the engine, the injectors again need to be replaced, that it has never been fixed properly, and that this engine is notorious for having very significant problem. I am out of a vehicle, down to one for the family, and unable to afford getting it fixed - again.

- Cincinnati, OH, USA

problem #6

Dec 012010


  • 74,000 miles
The contact owns a 2003 Ford Excursion. The contact stated that while driving 25 mph, the vehicle suddenly stalled. The vehicle was taken to a diesel garage specialist who stated that the fuel lines, filter and supply lines were all blocked and the fuel tank liner was damaged. The vehicle had not been repaired. The current and failure mileages were approximately 74,000.

- Hollywood , FL, USA

problem #5

Jun 192009


  • 98,000 miles
My 2003 Ford Excursion with a 6.0L diesel has been surging and will stall suddenly and without warning. It has caused several near collisions. The dealer had to replace the icp sensor. Apparently this was recalled in 2004 models and newer but not the 2003 model. I feel that I have fallen through the cracks because Ford didn't start installing the 6.0L in the 2003 model until late in the model years. Seems like they forgot about me and my truck has the exact same dangerous condition as the 2004 models.

- Cincinnati, OH, USA

problem #4

Dec 052008

Excursion Diesel

  • 67,000 miles


2003 Ford Excursion limited with 6.0L diesel engine. Only two weeks ago, my truck began to surge in acceleration at both idle and while cruising. It has also begun to stall out at both idle and while cruising. Also the vehicle has begun to have a strong smell of diesel fuel which enters the passenger cabin at start up. My service engine light has begun to light up and I checked the light with a digital diagnostic code reader. The code was P2285 (injector control pressure sensor circuit low). The situation is quite dangerous. My wife had complained that the vehicle surged ahead and she almost hit the car in front of her while stopped at a red light. When I drove the vehicle, it also began to buck and surge in both forward and reverse. While backing out of my driveway, the vehicle accelerated rearward and only by my having my foot near the brake pedal, stopped it from racing rearward. The vehicle has also cut off while at idle and while driving now. Again, a very dangerous condition. I have seen on the Ford truck enthusiast websites that I am not alone. There have been many complaints of this condition and faulty injector control pressure sensors especially in the '03 models but even later models. I am just out of warranty by a week, and Ford said they could do nothing for me. I have seen what the dealers have quoted others to fix the problem up to $2000 for wide ranging solutions (replacing turbos, replacing all injectors, etc.) I use this truck to Transport my disabled child and definitely cannot afford the dealer to rip me off for $2000. It is a $140 part and should take no longer than an hour of a technician's time to replace the sensor and pigtail harness. Clearly, Ford knows that they have a problem as they had a cust. Service program 03B05 and 03B06 regarding this issue for 47,000 other '03 trucks with the 6.0L engine. They said my vehicle's VIN did not fall into those 47,000. Obviously it affects many more trucks than the 47,000.

- Miami, FL, USA

problem #3

Dec 262003

Excursion 4WD 8-cyl Diesel

  • Automatic transmission
  • 1,049 miles
My 2003 Excursion had a major turbo failure while traveling on I-10 on 12-26-03. My family and myself were traveling to houston. The vehicle only had a total of 1,049 life to date miles. While on the interstate for about 30 to 45 minutes we hear a larger pop noise and a large drop in the engine power. I only had a flash of a dash light and it went right back off. I was trying to get off the interstate. Was driving about 25 to 35 mph trying to get to the next exit. Notice large volume of smoke coming from the rear of the vehicle. I pulled over asap after seeing this. The smoke came into the cab from the ventilation system (A/C). Pulled my daughter from the vehicle, also had my wife get out of the vehicle. At this point released the hood lock, checking the heat on the hood first. Raised the hood found fire coming from exhaust pipe from the turbo. Just smother the fire out to ensure it would not spread. Saw the oil around the exhaust system through out the system. The vehicle has a 6.0 diesel engine and is a 4X4 Excursion. IM filing this report for the safety of otherS not for myself. My concern is for other people who are not exposed to this type of condition which can happen with a diesel engine. IM a vehicle superintendent of a large city transit system. And have seen fireS from a turbo failures. 6.0 diesel is a international product, and the series 40 engines are prone for this type of failures. This may be the only failure that is reported for the 2003 6.0 diesel. But with only 1,049 miles this failure should have not occurred. Their should be some way to ensure the check engine light should have came on and stayed on for this condition for a failed turbo. ItS at the dealer at this time getting repaired. Best regards, bryan J. garner

- Manchaca, TX, USA

problem #2

May 202003

Excursion 4WD 8-cyl Diesel

  • Automatic transmission
  • 1,993 miles
Engine "skips", getting progressively worse, fuel consumption rises dramatically. After first repair it quit entirely on us leaving us stranded on I-75 South of atlanta. It has now been in the shop three times for this problem, and we have a little over 3,000 miles on the vehicle.

- Crystal River, FL, USA

problem #1

Jan 202003

Excursion 4WD 8-cyl Diesel

  • Automatic transmission
  • miles
I have a 2003 Ford Excursion that while driving just shuts motor off and you lose steering and brakes at highway speeds. No warning at all. Ford not very concerned with it and being very elusive about whats wrong. I can not get an answer just keep telling me they are fixing it, after they fixed it it broke down on them on the test drive, and still not willing to tell me what they are doing to truck other than dont worry about it its under warranty. I guess it is not a concern to them as long their faimly is not in front of me when I cant stop vehicle due to reasons they dont want to talk about. Also asked to talk to owner of dealership but he is unavailable to even return a call. I belive this to be a very serious concern as the driver of the vehicle, it is not a good felling when it shuts down and you know that safe control of the vehicle is not there. Ford dealer says its the fuel freezing up I dont agree I have been using winterized fuel and adding howes anti-gel formula to tank at fill-ups. And vehicle has been in a heated garage and shut down three times within 5 minutes. The Ford dealer is brighton Ford, Michigan phone is 1-810-227-1171 service dept ester is rep. They told me today about it breaking down on them and that diesel tech has been off work last two days sick! well my question is whos been working on my truck then?

- Whitmore Lake, MI, USA

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