hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
50,575 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 fuel system problems

fuel system problem

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2004 Ford Excursion Owner Comments

problem #4

Dec 042010

Excursion 8-cyl Diesel

  • Automatic transmission
  • 82,300 miles


The contact owns a 2004 Ford Excursion. The contact was stopped at a light when the vehicle attempted to accelerate forward. The contact stated that the brakes were applied during the failure. The following day, the vehicle failed to start and was towed to an authorized dealer. The dealer advised him that the vehicle would need a new injection control pressure sensor and a fuel injection control module. The vehicle was not repaired. The contact referenced NHTSA campaign id number: 05V27000 (electrical system: Wiring) and was advised by the dealer and the manufacture that his VIN was not included in the recall. The approximate failure mileage was 82,300 and the approximate current mileage was 82,400. Updated 02/03/11 updated 02/11/11

- Randolph, NJ, USA

problem #3

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 #2

Jun 012009


  • 120,000 miles
Vehicle will not get fuel. Attempt to accelerate and car either will not move or dies. Fourth time vehicle has been in for repairs. Occurs every three to six months. Vehicle is 6.0 2004 XLT diesel Excursion. Egr valve and ficm module, right bank of injectors replaced February 2009. May 2009 vehicle towed again and egr valve replaced again and ficm reprogrammed again. Vehicle is working for the time being. However, both banks of injectors, ficm module, egr valve X 3, high pressure oil pump, ipr valve, fuel pump regulator all replaced. Car continues to have safety issues regarding stalling and lack of acceleration. Almost gotten hot multiple times due to car stalling and not running. Safety is very much compromised. To my knowledge no parts are available that were replaced. Car runs well for short time and then needs to be fixed once again.

- Beloit, WI, USA

problem #1

Jul 142004


  • miles
We purchased 2004 Ford Excursion with the 6.0L diesel engine new in February 2004. It has been to the dealer now 2 times for the back up sensor, approximately 5 times for the turbo, unable to count the number of times for the lack of power, the vent windows not working, 3 times for the motor on the power drivers seat, ball joints 1 time, and now other front end parts. This vehicle is primarily used to go to church and travel with the entire family on the weekends for day trips. We have had it to graham Ford several times, germain Ford several times, (both are in columbus, Ohio) and the last place we have it is donley Ford in mount vernon, Ohio. We can get a full history of all repairs on this vehicle if needed. There have been so many things gone wrong with the truck that it is difficult to keep track. The service advisor is now telling my wife to "just trade it in". we just want all of the problems fixed correctly and find the cause of the electrical failures/issues/problems instead of just fixing what breaks and not fixing the cause. We paid 50,000 bucks for this vehicle and have had nothing but problems. The start was when we wanted to go to Maine and could not take it but had to take our older conversion van.

- Marengo, OH, USA

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