Ford Ford Excursion | History, Reliability & Buying Guide

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Ford Excursion: A Comprehensive Guide

The Ford Excursion is a full-size, heavy-duty SUV produced by Ford from 1999 to 2005. Based on the Ford Super Duty pickup truck platform, it was the longest and heaviest SUV ever put into mass production. Designed to compete with the Chevrolet Suburban and GMC Yukon XL, the Excursion offered unparalleled passenger and cargo capacity, as well as impressive towing capability. While praised for its size and power, it also faced criticism for its fuel consumption and sheer dimensions.

Generations

First Generation (1999-2005)

Years: 1999-2005

Key Changes: This generation represents the entirety of the Excursion's production run. While there were running changes and minor updates throughout the years, the fundamental design remained consistent.

Notable Updates by Year:

2000: Introduction of the 7.3L Power Stroke diesel engine. Minor interior trim changes.

2001: 7.3L Power Stroke continued, though some early signs of the 6.0L development were present.

2002: Minor grille revisions. Electronic Shift-On-The-Fly (ESOF) 4x4 system became more common.

2003: Introduction of the 6.0L Power Stroke diesel engine (mid-year change), replacing the 7.3L. Interior updates including a revised instrument panel. New headlamps and taillamps.

2004: Minor interior refinements. Continued refinement of the 6.0L Power Stroke.

2005: Final production year. Very few changes from the previous year.

Trim Levels: XL, XLT, Eddie Bauer, Limited

Reliability & Common Issues

The Ford Excursion, being based on the Super Duty platform, shares many of its strengths and weaknesses. Reliability varies significantly depending on the engine and year. Here's a breakdown:

Engines:

5.4L Triton V8: The least desirable option due to its underpowered nature for the Excursion's weight. Expect frequent downshifting and lower fuel economy than the diesel options. Relatively reliable mechanically, but head gasket issues can occur with high mileage. Spark plug issues are common across the Triton family of engines.

6.8L Triton V10: A more suitable choice for the Excursion. Offers significantly more power and torque than the 5.4L. Similar reliability characteristics to the 5.4L, including potential head gasket and spark plug issues, but the V10's added power generally results in a more relaxed driving experience.

7.3L Power Stroke Diesel V8 (1999-2003.5): Widely considered the most reliable engine offered in the Excursion. This engine is known for its durability and longevity. Key issues include:

Cam Position Sensor (CPS) Failure: A common and relatively inexpensive repair.

Glow Plug Relay Failure: Another common issue, especially in colder climates.

Fuel Injector O-Rings: Can leak over time, leading to rough running and fuel dilution.

High-Pressure Oil Pump (HPOP): Can fail with age, causing starting issues.

Turbocharger issues: Wear on the turbocharger can lead to decreased performance and increased oil consumption.

6.0L Power Stroke Diesel V8 (2003.5-2005): The most problematic engine option. Prone to numerous issues, including:

EGR Cooler Failure: A common problem that can lead to coolant leaks, overheating, and head gasket failure.

Oil Cooler Failure: Another frequent issue that can cause oil contamination and reduced engine lubrication.

Head Gasket Failure: A well-documented problem caused by head bolt stretching and inadequate clamping force. Often results from overheating due to EGR/oil cooler failures.

Fuel Injector Control Module (FICM) Failure: Can cause rough running and starting problems.

Turbocharger VGT Solenoid Failure: Variable Geometry Turbo (VGT) performance issues.

Important Note: While the 6.0L has a bad reputation, many of its issues can be mitigated with proper maintenance and preventative upgrades such as ARP head studs, EGR delete kits, and upgraded oil coolers. However, these upgrades represent a significant investment.

Transmission:

4R100 (Behind 7.3L Diesel and V10): Generally reliable but can suffer from wear and tear with heavy towing. Regular fluid changes are crucial.

5R110W TorqShift (Behind 6.0L Diesel): Stronger than the 4R100, but can still be affected by the added stress of the 6.0L engine's issues. Proper maintenance is essential.

Other Common Issues:

Rust: Wheel wells, rocker panels, and undercarriage are prone to rust, especially in areas with road salt.

Ball Joints & Suspension Components: Heavy weight and frequent towing can lead to premature wear of ball joints, tie rod ends, and other suspension components.

Brake System: Brakes can wear quickly due to the vehicle's weight. Ensure regular inspections and maintenance.

4x4 System: ESOF (Electronic Shift-On-The-Fly) systems can experience issues with the vacuum hubs. Manual locking hubs are generally more reliable.

Driving Experience

Driving an Excursion is a unique experience. Its sheer size is immediately apparent, requiring careful maneuvering in tight spaces. The ride is generally comfortable, especially on the highway, but can be bouncy on rough roads. Wind noise is noticeable at higher speeds. Steering can feel vague and requires more input than smaller vehicles.

Pros:

Unmatched passenger and cargo capacity: Easily accommodates 8-9 passengers and their luggage.

Exceptional towing capability: Can tow heavy loads with ease, especially with the diesel engines.

Solid construction: Built on a robust truck platform, offering a feeling of security and durability.

Aftermarket support: Large aftermarket support for modifications, upgrades, and repairs.

Cons:

Poor fuel economy: Expect very low MPG, especially with the gasoline engines.

Difficult to park and maneuver: Its size makes it challenging to navigate in urban environments.

High maintenance costs: Due to its heavy-duty components, repairs can be expensive.

Can feel outdated: The interior and technology are dated compared to modern SUVs.

Buying Advice

When buying a Ford Excursion, careful consideration should be given to the engine, year, and overall condition. Here's some advice:

Best Years: 2000-2003 with the 7.3L Power Stroke diesel. These years offer the best combination of reliability and power.

Years to Avoid (or be extremely cautious with): 2003.5-2005 with the 6.0L Power Stroke diesel, unless it has been extensively upgraded to address its inherent issues.

Engine Choice: The 7.3L Power Stroke is the most desirable engine for its reliability. The 6.8L V10 is a decent alternative if diesel isn't a necessity, but be prepared for lower fuel economy. Avoid the 5.4L V8.

Pre-Purchase Inspection: A thorough pre-purchase inspection by a qualified mechanic is essential, especially for diesel models. Check for signs of leaks, rust, and previous repairs. Pay close attention to the engine, transmission, and suspension. Compression test on all cylinders is a good idea for any engine considered.

Rust Inspection: Carefully inspect the undercarriage, wheel wells, and rocker panels for rust. Significant rust can be costly to repair and may compromise the vehicle's structural integrity.

Service Records: Look for vehicles with detailed service records, indicating regular maintenance and repairs. This can provide valuable insight into the vehicle's condition and potential future issues.

Pricing: Prices vary depending on condition, mileage, and engine. Be prepared to pay a premium for well-maintained examples with the 7.3L diesel. Factor in potential repair costs when evaluating the price.

Upgrades: Don't be afraid of an Excursion that's had some upgrades done. Aftermarket parts can extend the life and improve performance of the truck.

The Ford Excursion is a unique and capable vehicle that can be a great choice for those who need its exceptional passenger and cargo capacity, as well as its towing ability. However, it's essential to be aware of its potential issues and choose carefully to ensure a rewarding ownership experience.
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