2001 Ford Excursion

The 2001 Ford Excursion is a full-size SUV known for its immense size, towing capacity, and passenger space. Engine options include the 5.4L Triton V8 (255 hp and 350 lb-ft of torque), the 6.8L Triton V10 (310 hp and 425 lb-ft of torque), and the 7.3L Power Stroke Turbo Diesel V8 (275 hp and 525 lb-ft of torque). All engines were paired with a 4-speed automatic transmission. Owners generally appreciate the Excursion’s ability to haul large families and tow heavy loads. Common complaints revolve around its size, fuel economy, and age-related maintenance issues.

Engine

5.4L Triton V8

• Spark Plug Ejection
  • Description/Symptoms: Spark plugs being forcefully ejected from the cylinder head due to stripped threads. This results in a loud popping noise, misfire, and engine performance issues.
  • Solution: Repairing or replacing the cylinder head, installing thread inserts.
  • Estimated Cost to Fix: $500 - $2000+
  • Recalls: None Found

6.8L Triton V10

• Spark Plug Ejection
  • Description/Symptoms: Spark plugs being forcefully ejected from the cylinder head due to stripped threads. This results in a loud popping noise, misfire, and engine performance issues.
  • Solution: Repairing or replacing the cylinder head, installing thread inserts.
  • Estimated Cost to Fix: $500 - $2000+
  • Recalls: None Found
• Exhaust Manifold Bolts Breaking
  • Description/Symptoms: Broken exhaust manifold bolts, causing exhaust leaks, reduced fuel economy, and increased engine noise.
  • Solution: Replacing the broken bolts, often requiring extraction and potentially cylinder head repair.
  • Estimated Cost to Fix: $300 - $1000+
  • Recalls: None Found

7.3L Power Stroke Turbo Diesel V8

• Cam Position Sensor Failure
  • Description/Symptoms: Engine stalling, rough running, or failure to start due to a faulty cam position sensor.
  • Solution: Replacing the cam position sensor.
  • Estimated Cost to Fix: $100 - $300+
  • Recalls: None Found
• Glow Plug Failure
  • Description/Symptoms: Hard starting or no start in cold weather due to failed glow plugs.
  • Solution: Replacing the glow plugs.
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found
• Fuel Injector Issues
  • Description/Symptoms: Rough idle, poor fuel economy, black smoke, and reduced power due to worn or clogged fuel injectors.
  • Solution: Replacing or rebuilding the fuel injectors.
  • Estimated Cost to Fix: $800 - $3000+
  • Recalls: None Found

Transmission

4R100 4-Speed Automatic (All Engines)

• Torque Converter Failure
  • Description/Symptoms: Transmission slipping, shuddering, or complete failure due to a worn or damaged torque converter.
  • Solution: Replacing the torque converter.
  • Estimated Cost to Fix: $800 - $2000+
  • Recalls: None Found
• Valve Body Issues
  • Description/Symptoms: Hard shifting, delayed engagement, or erratic shifting patterns due to a faulty valve body.
  • Solution: Replacing or rebuilding the valve body.
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found

Suspension

• Leaf Spring Sagging/Breaking
  • Description/Symptoms: Rear end sagging, reduced load capacity, and potential handling issues due to worn or broken leaf springs.
  • Solution: Replacing the leaf springs.
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found
• Ball Joint Failure
  • Description/Symptoms: Loose steering, clunking noises, and uneven tire wear due to worn ball joints.
  • Solution: Replacing the ball joints.
  • Estimated Cost to Fix: $300 - $1000+
  • Recalls: None Found

Electrical

• Instrument Cluster Failure
  • Description/Symptoms: Intermittent or complete failure of the instrument cluster, resulting in inaccurate or missing readings.
  • Solution: Repairing or replacing the instrument cluster.
  • Estimated Cost to Fix: $300 - $800+
  • Recalls: None Found
• Alternator Failure
  • Description/Symptoms: Battery not charging, dimming lights, and potential engine stalling due to a faulty alternator.
  • Solution: Replacing the alternator.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found

Exterior

• Rust on Lower Body Panels
  • Description/Symptoms: Rust formation on the rocker panels, wheel wells, and lower doors, especially in areas with road salt exposure.
  • Solution: Rust repair or replacement of affected panels.
  • Estimated Cost to Fix: $500 - $3000+
  • Recalls: None Found

Interior

• Blend Door Actuator Failure
  • Description/Symptoms: Inconsistent or incorrect temperature control due to a malfunctioning blend door actuator.
  • Solution: Replacing the blend door actuator.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found

Summary

The 2001 Ford Excursion is a capable but aging vehicle. The 5.4L and 6.8L engines are known for spark plug ejection issues, and the 7.3L diesel can suffer from cam sensor, glow plug, and injector problems. Transmission issues, especially torque converter and valve body failures, are common across all engine options. Suspension components, particularly leaf springs and ball joints, are prone to wear and tear. Electrical problems, such as instrument cluster and alternator failures, can also occur. Rust is a concern in areas with road salt. While some repairs are relatively inexpensive, others can be costly, particularly engine and transmission work. The severity of these issues varies, but buyers should be prepared for potential maintenance and repairs due to the vehicle’s age and mileage.