2003 Ford Excursion

2003 Ford Excursion

Overview

The 2003 Ford Excursion, a heavy-duty SUV, was known for its robust construction and powerful engine options designed for towing and hauling. While generally considered a durable vehicle, like any model of its age, it has specific areas that have seen more reported issues than others. This analysis focuses on common mechanical and electrical concerns that owners have reported, excluding routine maintenance. Understanding these potential problem areas can help current and prospective owners anticipate and address necessary repairs, ensuring the longevity of this capable vehicle.

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Engine

5.4L Triton V8

Spark Plug Blowout

• Symptoms: Loss of power, rough idling, ticking noise from the engine.
• Solution: Repair or replace stripped spark plug threads, often requiring specialized tools or Helicoil inserts.
• Cost: $300 - $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: Loss of power, rough idling, ticking noise from the engine.
• Solution: Repair or replace stripped spark plug threads, often requiring specialized tools or Helicoil inserts.
• Cost: $300 - $800

Intake Manifold Gasket Leaks

• Symptoms: Coolant leaks, overheating, rough idle, vacuum leaks.
• Solution: Replacement of the intake manifold gaskets.
• Cost: $400 - $700

6.0L Power Stroke V8 Diesel

EGR Cooler Failure

• Symptoms: White smoke from exhaust, coolant loss, overheating, loss of power.
• Solution: Replacement of the EGR cooler, often with an upgraded unit.
• Cost: $700 - $1500

Oil Cooler Failure

• Symptoms: Overheating, loss of engine power, potential for turbocharger damage.
• Solution: Replacement of the oil cooler.
• Cost: $600 - $1200

Head Gasket Failure / Head Studs

• Symptoms: Coolant loss, white smoke, overheating, loss of power.
• Solution: Replacement of head gaskets and often upgrading to ARP head studs.
• Cost: $2000 - $4000+

Transmission

4R100 (Gasoline Engines)

Torque Converter Issues

• Symptoms: Slipping, shuddering, delayed engagement, overheating.
• Solution: Rebuild or replacement of the torque converter and transmission.
• Cost: $1500 - $3000

5R110W TorqShift (Diesel Engines)

Solenoid Pack Failure

• Symptoms: Harsh shifting, failure to shift into certain gears, transmission warning light.
• Solution: Replacement of the solenoid pack.
• Cost: $500 - $1000

Torque Converter Clutch (TCC) Issues

• Symptoms: Shuddering during acceleration, slipping, poor fuel economy.
• Solution: Replacement of the torque converter.
• Cost: $800 - $1500

Suspension

Standard Chassis

Ball Joint Wear

• Symptoms: Clunking noises, steering wander, uneven tire wear.
• Solution: Replacement of worn ball joints.
• Cost: $400 - $800

Leaf Spring Sagging

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

Electrical

General Electrical System

Instrument Cluster Failures

• Symptoms: Inaccurate gauges, flickering lights, dead gauges, warning lights not illuminating.
• Solution: Repair or replacement of the instrument cluster.
• Cost: $300 - $700

Window Regulator Failure

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

Exterior

Body and Trim

Rust on Body Panels

• Symptoms: Visible rust, bubbling paint, 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 conditioning or heat, or intermittent operation.
• Solution: Replacement of the blower motor and resistor.
• Cost: $200 - $400

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Summary Verdict

The 2003 Ford Excursion is a formidable vehicle with robust powertrains, but its age means certain components are prone to failure. The gasoline V8s can suffer from spark plug issues, while the 6.0L Power Stroke diesel is notorious for EGR cooler, oil cooler, and head gasket/stud problems, which can be costly to repair. Transmission issues, particularly with the torque converter, are also noted. Suspension components like ball joints and leaf springs may require attention due to the vehicle’s weight and intended use. Electrical gremlins, such as instrument cluster and window regulator failures, are common for vehicles of this era. Rust can be a concern depending on climate. Overall, while capable, potential buyers should be aware of these common issues, especially concerning the 6.0L diesel engine and associated repairs.