2004 Ford Excursion

Introduction:

The 2004 Ford Excursion is a full-size SUV that was produced until 2006. It was offered with four engine options and two transmission options. The base engine was a 5.4L V8 with 265 horsepower and 350 lb-ft of torque. A 6.0L V8 with 300 horsepower and 365 lb-ft of torque was also available, as well as a 7.3L V8 diesel with 250 horsepower and 505 lb-ft of torque. The most powerful engine option was a 6.8L V10 with 310 horsepower and 425 lb-ft of torque. All engines were paired with either a 4-speed automatic transmission or a 5-speed manual transmission, except for the 7.3L diesel which was only available with the automatic transmission.

Many owners of the Excursion are satisfied with its powerful engines, spacious interior, and off-road capability. However, there are some issues that have been reported with the vehicle.

Engine

5.4L V8

• Intake Manifold Runner Control Failure: The intake manifold runner control may fail, which can cause the engine to run rough, stall, or experience decreased power. The solution is to replace the intake manifold runner control. Estimated cost to fix: $200-$400

• Spark Plug Blowout: Spark plugs can blow out of the cylinder head on 5.4L V8 engines produced before 2004. This can cause catastrophic engine damage. The solution is to have the cylinder repaired by a mechanic. Estimated cost to fix: $2,000-$5,000

• Timing Chain Tensioner Failure: The timing chain tensioner may fail on 5.4L V8 engines produced before 2004, which can lead to engine damage. The solution is to replace the timing chain tensioner. Estimated cost to fix: $500-$1,000

6.0L V8

• Intake Manifold Gasket Failure: The intake manifold gasket may fail, which can cause coolant and oil leaks. The solution is to replace the intake manifold gasket. Estimated cost to fix: $500-$1,000

• Head Bolt Failure: Head bolts can fail on 6.0L V8 engines produced between 2003 and 2005, which can lead to severe engine damage. The solution is to replace the head bolts. Estimated cost to fix: $2,000-$4,000

7.3L V8 Diesel

• Turbocharger Failure: The turbocharger may fail on 7.3L V8 engines, which can lead to decreased power and increased emissions. The solution is to replace the turbocharger. Estimated cost to fix: $1,000-$2,000

6.8L V10

• Exhaust Manifold Bolt Failure: Exhaust manifold bolts can fail on 6.8L V10 engines, which can cause exhaust leaks. The solution is to replace the exhaust manifold bolts. Estimated cost to fix: $500-$1,000

Transmission

4-Speed Automatic Transmission

• Torque Converter Failure: The torque converter may fail on 4-speed automatic transmissions, which can cause slippage and loss of power. The solution is to replace the torque converter. Estimated cost to fix: $1,000-$2,000

5-Speed Manual Transmission

• No Major Issues Found

Suspension

• Front Suspension Ball Joint Failure: The front suspension ball joints may fail, which can cause the vehicle to pull to one side or the other while driving. The solution is to replace the ball joints. Estimated cost to fix: $500-$1,000

• Rear Leaf Spring Failure: The rear leaf springs may fail, which can cause the vehicle to sag in the rear. The solution is to replace the leaf springs. Estimated cost to fix: $500-$1,000

Electrical

• Battery Drain: The battery may drain on Excursions equipped with the factory-installed remote start system. The solution is to disconnect the remote start system. Estimated cost to fix: $0

Exterior

• No Major Issues Found

Interior

• Climate Control Failure: The climate control system may fail, which can cause the air conditioner or heater to stop working. The solution is to replace the climate control unit. Estimated cost to fix: $500-$1,000

• Power Window Failure: The power windows may fail, which can cause the windows to become stuck in the up or down position. The solution is to replace the power window motor or switch. Estimated cost to fix: $200-$400

Summary:

The 2004 Ford Excursion is a capable and spacious SUV, but it has some common issues. The most severe issue is the head bolt failure in the 6.0L V8 engine, which can lead to catastrophic engine damage. The other issues are generally less severe and less expensive to fix.