2002 Ford Excursion

2002 Ford Excursion

Overview

The 2002 Ford Excursion, a heavy-duty full-size SUV, was built for towing and hauling with its robust chassis and powerful engine options. While generally considered a capable vehicle, like any large SUV of its era, it has specific areas that have seen more reported issues than others. This analysis focuses on common mechanical and electrical concerns, excluding routine maintenance. Understanding these potential problem areas can help owners anticipate and address issues, ensuring the longevity and reliability of this substantial vehicle.

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Engine

5.4L Triton V8

Spark Plug Blowout

• Symptoms: Engine misfires, rough idling, loss of power, audible popping sound from engine bay.
• Solution: Requires specialized tools to extract broken spark plug fragments and re-thread cylinder head. Often involves installing inserts or using a larger spark plug size.
• Cost: $400 - $800

Camshaft Position Sensor Failure

• Symptoms: Check Engine Light illumination, rough idle, stalling, difficulty starting.
• Solution: Replacement of the camshaft position sensor.
• Cost: $150 - $300

6.8L Triton V10

Spark Plug Blowout

• Symptoms: Engine misfires, rough idling, loss of power, audible popping sound from engine bay.
• Solution: Requires specialized tools to extract broken spark plug fragments and re-thread cylinder head. Often involves installing inserts or using a larger spark plug size.
• Cost: $400 - $800

Camshaft Position Sensor Failure

• Symptoms: Check Engine Light illumination, rough idle, stalling, difficulty starting.
• Solution: Replacement of the camshaft position sensor.
• Cost: $150 - $300

7.3L Power Stroke V8 Diesel

Injector Control Pressure (ICP) Sensor Failure

• Symptoms: Hard starting, rough idle, stalling, loss of power, black smoke.
• Solution: Replacement of the ICP sensor.
• Cost: $200 - $400

Fuel Injector Issues

• Symptoms: Rough idle, smoke, loss of power, hard starting.
• Solution: Diagnosis and replacement of faulty fuel injectors.
• Cost: $800 - $1500+

Transmission

4R100 (4-Speed Automatic)

Torque Converter Issues

• Symptoms: Slipping gears, shuddering, delayed engagement, overheating.
• Solution: Rebuild or replacement of the torque converter and potentially the transmission.
• Cost: $1000 - $2500+

Overheating

• Symptoms: Transmission fluid smells burnt, delayed shifting, slipping.
• Solution: Installation of an auxiliary transmission cooler, fluid and filter change.
• Cost: $300 - $700

Suspension

Standard Chassis

Ball Joint Wear

• Symptoms: Clunking noises over bumps, uneven tire wear, steering wander.
• Solution: Replacement of worn ball joints.
• Cost: $400 - $700

Leaf Spring Sagging

• Symptoms: Rear end sag, reduced load capacity, poor handling.
• Solution: Replacement of rear leaf springs.
• Cost: $500 - $1000+

Electrical

General Electrical System

Instrument Cluster Failures

• Symptoms: Gauges not working, flickering lights, intermittent power loss to cluster.
• Solution: Repair or replacement of the instrument cluster.
• Cost: $300 - $600

Window Regulator Failure

• Symptoms: Power windows not operating, slow window movement, grinding noises.
• Solution: Replacement of the window regulator and motor assembly.
• Cost: $200 - $400

Exterior

Body Panels and Trim

Rust on Body Panels

• Symptoms: Visible rust, bubbling paint, corrosion, especially around wheel wells and lower body panels.
• Solution: Rust repair and repainting, or replacement of affected panels.
• Cost: $500 - $2000+

Interior

Interior Components

HVAC Blower Motor Failure

• Symptoms: No air coming from vents, or intermittent airflow, strange noises from dashboard.
• Solution: Replacement of the HVAC blower motor and resistor.
• Cost: $250 - $500

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Summary Verdict

The 2002 Ford Excursion is a formidable vehicle, but its age and size mean certain components are prone to wear and failure. The Triton V8 engines share a common spark plug blowout issue, while the Power Stroke diesel can experience ICP sensor and injector problems. The 4R100 transmission, though robust, can suffer from torque converter issues and overheating, especially under heavy use. Suspension components like ball joints and leaf springs are also common wear items. Electrical gremlins, such as instrument cluster and window regulator failures, are not uncommon. Rust can be a significant concern depending on the vehicle’s climate history. Despite these potential issues, with proper maintenance and timely repairs, the Excursion can remain a reliable workhorse.