2004 Ford Excursion

The 2004 Ford Excursion is a full-size SUV known for its immense size, towing capacity, and passenger space. This year offered three engine choices: the 5.4L Triton V8 (255 hp, 350 lb-ft torque), the 6.8L Triton V10 (310 hp, 425 lb-ft torque), and the 6.0L Power Stroke Turbo Diesel V8 (325 hp, 560 lb-ft torque). All engines were paired with a 4R100 4-speed automatic transmission, except for the diesel which used the 5R110 TorqShift 5-speed automatic transmission. Owners often praise the Excursion for its ability to comfortably transport large families and tow heavy loads. However, some common complaints revolve around its fuel economy, size (making it difficult to maneuver in tight spaces), and age-related maintenance issues.

Engine

5.4L Triton V8

• Spark Plug Thread Failure
  • Description/Symptoms: Spark plugs can eject from the cylinder head due to weak threads. This often results in a loud popping noise, engine misfire, and potential damage to the ignition coil.
  • Solution: Repair or replace the cylinder head with updated spark plug thread inserts.
  • Estimated Cost to Fix: $1,500 - $3,000+
  • Recalls: None Found
• Manifold Cracks
  • Description/Symptoms: The Exhaust manifold will crack over time causing exhaust noises and potential exhaust leaks.
  • Solution: Replace the cracked exhaust manifold.
  • Estimated Cost to Fix: $500 - $1000
  • Recalls: None Found

6.8L Triton V10

• Spark Plug Thread Failure
  • Description/Symptoms: Similar to the 5.4L, spark plugs can eject from the cylinder head due to weak threads. This often results in a loud popping noise, engine misfire, and potential damage to the ignition coil.
  • Solution: Repair or replace the cylinder head with updated spark plug thread inserts.
  • Estimated Cost to Fix: $1,500 - $3,000+
  • Recalls: None Found
• Manifold Cracks
  • Description/Symptoms: The Exhaust manifold will crack over time causing exhaust noises and potential exhaust leaks.
  • Solution: Replace the cracked exhaust manifold.
  • Estimated Cost to Fix: $500 - $1000
  • Recalls: None Found

6.0L Power Stroke Turbo Diesel V8

• EGR Cooler Failure
  • Description/Symptoms: The EGR (Exhaust Gas Recirculation) cooler is prone to cracking, leading to coolant leaks into the exhaust system, white smoke from the exhaust, and potential engine damage.
  • Solution: Replace the EGR cooler with an updated design. Consider an EGR delete kit for off-road use.
  • Estimated Cost to Fix: $800 - $1,500
  • Recalls: None Found
• Oil Cooler Failure
  • Description/Symptoms: The oil cooler can rupture, causing oil to mix with coolant and vice-versa. This can lead to significant engine damage if not addressed promptly.
  • Solution: Replace the oil cooler and thoroughly flush the cooling system.
  • Estimated Cost to Fix: $1,000 - $2,000+
  • Recalls: None Found
• Injector Issues
  • Description/Symptoms: Injector stiction, caused by oil deposits, can lead to rough running, hard starting, and decreased fuel economy.
  • Solution: Use fuel additives designed to clean injectors, or replace the affected injectors.
  • Estimated Cost to Fix: $300 (additive) - $2,000+ (injector replacement)
  • Recalls: None Found
• High Pressure Oil Pump (HPOP) Failure
  • Description/Symptoms: The HPOP provides the high pressure oil needed for the fuel injectors to function. Failure results in a no-start condition or poor performance.
  • Solution: Replace the HPOP.
  • Estimated Cost to Fix: $1,000 - $2,000+
  • Recalls: None Found

Transmission

4R100 4-Speed Automatic (5.4L & 6.8L Engines)

• Harsh Shifting
  • Description/Symptoms: The transmission exhibits hard or jerky shifts, particularly between 1st and 2nd gear, or 2nd and 3rd gear.
  • Solution: Fluid and filter change, valve body rebuild/replacement, or transmission replacement.
  • Estimated Cost to Fix: $150 (fluid change) - $3,000+ (transmission replacement)
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: Shuddering at highway speeds, particularly under light acceleration.
  • Solution: Replace the torque converter.
  • Estimated Cost to Fix: $800 - $1500
  • Recalls: None Found

5R110 TorqShift 5-Speed Automatic (6.0L Diesel Engine)

• Torque Converter Failure
  • Description/Symptoms: Shuddering at highway speeds, particularly under light acceleration or when towing.
  • Solution: Replace the torque converter with an updated, heavy-duty version.
  • Estimated Cost to Fix: $1,000 - $2,500
  • Recalls: None Found
• Valve Body Issues
  • Description/Symptoms: Erratic shifting, delayed engagement, or slipping between gears.
  • Solution: Rebuild or replace the valve body.
  • Estimated Cost to Fix: $800 - $1,500
  • Recalls: None Found

Suspension

• Leaf Spring Sagging
  • Description/Symptoms: The rear leaf springs sag over time, causing a reduced ride height and compromised load-carrying capacity.
  • Solution: Replace the leaf springs.
  • Estimated Cost to Fix: $500 - $1,200
  • Recalls: None Found
• Ball Joint Wear
  • Description/Symptoms: Loose or worn ball joints can cause excessive play in the steering, clunking noises, and uneven tire wear.
  • Solution: Replace the worn ball joints.
  • Estimated Cost to Fix: $400 - $800
  • Recalls: None Found

Electrical

• Instrument Cluster Issues
  • Description/Symptoms: Intermittent or complete failure of the instrument cluster, including gauges and displays.
  • Solution: Repair or replace the instrument cluster.
  • Estimated Cost to Fix: $300 - $800
  • Recalls: None Found
• GEM (Generic Electronic Module) Failure
  • Description/Symptoms: The GEM controls various electrical functions, including power windows, door locks, and wipers. Failure can lead to erratic behavior or complete loss of these functions.
  • Solution: Replace the GEM.
  • Estimated Cost to Fix: $400 - $800
  • Recalls: None Found

Exterior

• Rust (Lower Body Panels)
  • Description/Symptoms: Rust develops on the lower body panels, especially around the wheel wells and rocker panels.
  • Solution: Repair or replace the affected panels.
  • Estimated Cost to Fix: $500 - $3,000+ (depending on severity)
  • Recalls: None Found

Interior

• Headliner Sagging
  • Description/Symptoms: The headliner fabric detaches from the backing and sags.
  • Solution: Replace or re-glue the headliner fabric.
  • Estimated Cost to Fix: $200 - $500
  • Recalls: None Found

Summary

The 2004 Ford Excursion, while a capable and spacious SUV, suffers from several common issues due to its age and design. Engine problems, particularly spark plug thread failure in the gasoline engines and EGR/oil cooler issues in the diesel, can be costly to repair. Transmission issues, such as torque converter failure, are also prevalent. Suspension and electrical problems add to the potential maintenance burden. Overall, owning a 2004 Excursion requires careful inspection and proactive maintenance to avoid significant repair costs. The severity of these issues varies, but potential buyers should be aware of these common problem areas and budget accordingly.