2003 Ford Excursion

The 2003 Ford Excursion is a full-size SUV that was known for its immense size, towing capacity, and powerful engine options. Available engines included the 5.4L Triton V8 (260 hp, 350 lb-ft of torque), the 6.8L Triton V10 (310 hp, 425 lb-ft of torque), and the 7.3L Power Stroke Turbo Diesel V8 (275 hp, 525 lb-ft of torque, available only until mid-year). The transmissions were the 4R100 4-speed automatic. People appreciated the Excursion for its ability to comfortably transport large families and tow heavy loads. Some common complaints included poor fuel economy (especially with the V10), difficulty parking due to its size, and some reliability issues stemming from its age and heavy-duty components.

Engine

5.4L Triton V8

• Spark Plug Thread Issues
  • Description/Symptoms: Spark plugs can become seized in the cylinder heads, leading to stripped threads or broken spark plugs during removal. This is often due to the design of the cylinder heads.
  • Solution: Use penetrating oil before attempting removal. If threads are stripped, a thread repair kit (e.g., Time-Sert) can be used.
  • Estimated Cost to Fix: $300 - $800+ (depending on the number of plugs and repair method).
  • Recalls: None Found
• Manifold Leaks
  • Description/Symptoms: Exhaust leaks, typically near the firewall, are indicated by hissing or ticking noises, especially when the engine is cold. This is due to warping or cracking of the exhaust manifold.
  • Solution: Replace the exhaust manifold, along with gaskets and hardware.
  • Estimated Cost to Fix: $400 - $800+
  • Recalls: None Found

6.8L Triton V10

• Spark Plug Thread Issues
  • Description/Symptoms: Similar to the 5.4L V8, spark plugs in the 6.8L V10 can seize in the cylinder heads, leading to stripped threads or broken plugs upon removal.
  • Solution: Use penetrating oil before removal, and if necessary, repair damaged threads using a thread repair kit.
  • Estimated Cost to Fix: $300 - $1000+ (higher due to the increased number of cylinders)
  • Recalls: None Found
• Manifold Leaks
  • Description/Symptoms: Exhaust leaks similar to the 5.4L.
  • Solution: Replace the exhaust manifold, along with gaskets and hardware.
  • Estimated Cost to Fix: $400 - $800+
  • Recalls: None Found
• Fuel Injector Issues
  • Description/Symptoms: Rough idling, misfires, or poor fuel economy can indicate fuel injector problems.
  • Solution: Replace faulty fuel injectors.
  • Estimated Cost to Fix: $200 - $1000+ (depending on the number of injectors replaced)
  • Recalls: None Found

7.3L Power Stroke Turbo Diesel V8

• Cam Position Sensor (CPS) Failure
  • Description/Symptoms: Stalling, rough running, or a no-start condition.
  • Solution: Replace the CPS.
  • Estimated Cost to Fix: $50 - $200
  • Recalls: None Found
• Injector Driver Module (IDM) Failure
  • Description/Symptoms: Misfires, rough running, or a no-start condition.
  • Solution: Replace the IDM.
  • Estimated Cost to Fix: $200 - $500
  • Recalls: None Found
• High Pressure Oil Pump (HPOP) Issues
  • Description/Symptoms: Hard starting, especially when warm, or a lack of power.
  • Solution: Replace or rebuild the HPOP.
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found

Transmission

4R100 4-Speed Automatic

• Torque Converter Failure
  • Description/Symptoms: Shuddering, slipping, or complete loss of drive.
  • Solution: Replace the torque converter.
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found
• Harsh Shifting/Slipping
  • Description/Symptoms: Delayed or harsh shifts between gears, or slipping during acceleration. This can be due to worn clutches or valve body issues.
  • Solution: Transmission rebuild or replacement, or valve body repair/replacement.
  • Estimated Cost to Fix: $500 - $3000+ (depending on the extent of the damage)
  • Recalls: None Found

Suspension

• Leaf Spring Sagging/Cracking
  • Description/Symptoms: Rear end sag, poor ride quality, or clunking noises from the rear suspension.
  • Solution: Replace leaf springs.
  • Estimated Cost to Fix: $400 - $1000+
  • Recalls: None Found
• Ball Joint Wear
  • Description/Symptoms: Clunking or popping noises from the front suspension, uneven tire wear, or loose steering.
  • Solution: Replace ball joints.
  • Estimated Cost to Fix: $200 - $600+ per side
  • Recalls: None Found
• Steering Stabilizer Wear
  • Description/Symptoms: Excessive play in the steering wheel, especially at highway speeds. Wandering on the highway.
  • Solution: Replace steering stabilizer.
  • Estimated Cost to Fix: $100 - $300+
  • Recalls: None Found

Electrical

• Alternator Failure
  • Description/Symptoms: Dimming headlights, warning lights on the dashboard, or a no-start condition.
  • Solution: Replace the alternator.
  • Estimated Cost to Fix: $200 - $500
  • Recalls: None Found
• Window Motor Failure
  • Description/Symptoms: Windows stop working or operate intermittently.
  • Solution: Replace the window motor.
  • Estimated Cost to Fix: $150 - $400 per window
  • Recalls: None Found
• Instrument Cluster Issues
  • Description/Symptoms: Gauges stop functioning, or behave erratically. Lighting malfunctions.
  • Solution: Replace or repair the instrument cluster.
  • Estimated Cost to Fix: $200-$800+
  • Recalls: None Found

Exterior

• Rust (Especially Rocker Panels and Wheel Wells)
  • Description/Symptoms: Visible rust on the body panels, particularly in areas prone to moisture and road salt.
  • Solution: Rust repair, panel replacement, or body work.
  • Estimated Cost to Fix: $300 - $3000+ (depending on the severity and extent of the rust)
  • Recalls: None Found

Interior

• Headliner Sagging
  • Description/Symptoms: The headliner fabric detaches from the backing board and sags down.
  • Solution: Replace the headliner or re-glue the fabric.
  • Estimated Cost to Fix: $200 - $600
  • Recalls: None Found
• Blend Door Actuator Failure
  • Description/Symptoms: Inconsistent temperature control, with air blowing hot on one side and cold on the other. Clicking noises behind the dashboard.
  • Solution: Replace the blend door actuator.
  • Estimated Cost to Fix: $150 - $400+
  • Recalls: None Found

Summary

The 2003 Ford Excursion, while a capable and spacious SUV, suffers from issues common to vehicles of its age and heavy-duty design. Engine issues, such as spark plug thread damage and exhaust manifold leaks, are prevalent, particularly with the Triton V8 and V10 engines. The 7.3L Power Stroke Diesel can experience sensor and pump failures. Transmission problems are also common, often involving the torque converter and valve body. Suspension components wear out, leading to sagging and noise. Electrical issues like alternator and window motor failures occur. Rust can be a significant concern, especially in areas with road salt. Interior issues like headliner sagging and blend door actuator failure are also common. The severity and cost of these issues vary, with engine and transmission repairs potentially being the most expensive.