2004 Ford Excursion
2004 Ford Excursion
Overview
The 2004 Ford Excursion, a heavy-duty SUV, was known for its robust construction and powerful engine options designed for towing and hauling. While generally considered reliable for its class, like any vehicle of this age and type, certain components can experience issues. This analysis focuses on documented common problems beyond routine maintenance, providing insights into potential areas of concern for owners and prospective buyers. The Excursion’s large size and intended use mean that some wear is expected, but this report highlights specific recurring technical faults.
Engine
5.4L Triton V8
Spark Plug Blowout
- Symptoms: Engine misfires, rough idling, loss of power, audible popping sound from engine bay.
- Solution: Requires re-threading spark plug holes with inserts or replacing cylinder heads.
- Cost: $600 - $1200
Intake Manifold Gasket Leaks
- Symptoms: Coolant leaks, engine overheating, rough idle, check engine light.
- Solution: Replacement of the intake manifold gaskets.
- Cost: $400 - $700
6.8L Triton V10
Spark Plug Blowout
- Symptoms: Engine misfires, rough idling, loss of power, audible popping sound from engine bay.
- Solution: Requires re-threading spark plug holes with inserts or replacing cylinder heads.
- Cost: $600 - $1200
Intake Manifold Gasket Leaks
- Symptoms: Coolant leaks, engine overheating, rough idle, check engine light.
- Solution: Replacement of the intake manifold gaskets.
- Cost: $400 - $700
6.0L Power Stroke V8 Diesel
Head Gasket Failure
- Symptoms: Coolant loss, white smoke from exhaust, overheating, loss of power.
- Solution: Replacement of head gaskets and often studs.
- Cost: $2000 - $4000+
EGR Cooler Failure
- Symptoms: Coolant loss, white smoke, overheating, check engine light.
- Solution: Replacement of the EGR cooler.
- Cost: $500 - $1000
Oil Cooler Failure
- Symptoms: Overheating, loss of engine power, check engine light.
- Solution: Replacement of the oil cooler.
- Cost: $600 - $1100
FICM (Fuel Injection Control Module) Failure
- Symptoms: Hard starting, rough running, misfires, loss of power.
- Solution: Repair or replacement of the FICM.
- Cost: $400 - $800
Transmission
4R100 (Gasoline Engines)
No widespread issues reported.
- Symptoms: N/A
- Solution: N/A
- Cost: Varies
5R110W TorqShift (Diesel Engine)
No widespread issues reported.
- Symptoms: N/A
- Solution: N/A
- Cost: Varies
Suspension
Standard Chassis
No widespread issues reported.
- Symptoms: N/A
- Solution: N/A
- Cost: Varies
Electrical
General Electrical System
Instrument Cluster Failures
- Symptoms: Gauges not working, flickering lights, intermittent power loss to accessories.
- Solution: Repair or replacement of the instrument cluster.
- Cost: $300 - $700
Window Regulator Failures
- Symptoms: Power windows not operating, slow window movement, grinding noises.
- Solution: Replacement of window regulators.
- Cost: $200 - $400 per window
Exterior
Body and Trim
No widespread issues reported.
- Symptoms: N/A
- Solution: N/A
- Cost: Varies
Interior
Cabin Components
No widespread issues reported.
- Symptoms: N/A
- Solution: N/A
- Cost: Varies
Summary Verdict
The 2004 Ford Excursion, particularly with the gasoline V8 and V10 engines, demonstrates reasonable reliability for its class, with the most common significant issues being spark plug blowout and intake manifold leaks. The 6.0L Power Stroke diesel engine, however, is known for more complex and costly potential failures, including head gasket issues, EGR cooler problems, and oil cooler failures, which are critical to address. Transmission options appear robust. Electrical components like instrument clusters and window regulators can be points of failure. Overall, while the Excursion is a capable vehicle, potential buyers should be aware of the specific engine-related concerns, especially with the diesel variant, and budget accordingly for potential repairs.