2005 Ford Excursion
2005 Ford Excursion
Overview
The 2005 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 size, it can experience specific issues. This analysis focuses on documented mechanical and electrical problems beyond routine maintenance, providing insights into potential areas of concern for owners and prospective buyers. The Excursion’s large size and powerful engines, while advantageous for its intended purpose, can also contribute to certain wear patterns and component stresses over time.
Engine
5.4L Triton V8
Spark Plug Blowout
- Symptoms: Engine misfires, rough idling, loss of power, audible popping sound from engine.
- Solution: Requires specialized tools to extract broken spark plug and re-thread cylinder head, often with inserts.
- Cost: $400 - $800
Intake Manifold Gasket Leaks
- Symptoms: Coolant leaks, engine overheating, rough idle, white smoke from exhaust.
- Solution: Replacement of intake manifold gaskets.
- Cost: $300 - $600
6.0L Power Stroke V8 Diesel
EGR Cooler Failure
- Symptoms: White smoke from exhaust, loss of coolant, engine overheating, reduced engine power.
- Solution: Replacement of the EGR cooler, often with an upgraded unit.
- Cost: $600 - $1200
Oil Cooler Failure
- Symptoms: High oil temperature, low oil pressure, potential engine damage if not addressed.
- Solution: Replacement of the oil cooler.
- Cost: $500 - $1000
Head Gasket Failure / Head Studs
- Symptoms: Coolant loss, white smoke, overheating, coolant in oil or vice versa.
- Solution: Replacement of head gaskets and often upgrading to ARP head studs.
- Cost: $2000 - $4000+
6.8L Triton V10
Spark Plug Blowout
- Symptoms: Engine misfires, rough idling, loss of power, audible popping sound from engine.
- Solution: Requires specialized tools to extract broken spark plug and re-thread cylinder head, often with inserts.
- Cost: $400 - $800
Intake Manifold Gasket Leaks
- Symptoms: Coolant leaks, engine overheating, rough idle, white smoke from exhaust.
- Solution: Replacement of intake manifold gaskets.
- Cost: $300 - $600
Transmission
4R100 (4-Speed Automatic)
Torque Converter Issues
- Symptoms: Slipping, shuddering, delayed engagement, overheating transmission fluid.
- Solution: Rebuild or replacement of the torque converter and potentially the transmission.
- Cost: $800 - $2000
Overheating
- Symptoms: Transmission slipping, harsh shifting, burning smell, fluid leaks.
- Solution: Installation of an auxiliary transmission cooler, fluid flush, and inspection for internal damage.
- Cost: $200 - $500
5R110W (5-Speed Automatic)
Solenoid Issues
- Symptoms: Harsh shifting, delayed engagement, transmission fault codes.
- Solution: Replacement of transmission solenoids.
- Cost: $400 - $800
Torque Converter Clutch (TCC) Problems
- Symptoms: Shuddering at certain speeds, slipping, poor fuel economy.
- Solution: Replacement of the torque converter and related seals.
- Cost: $700 - $1500
Suspension
Standard Chassis
Ball Joint Wear
- Symptoms: Clunking noises, steering wander, uneven tire wear.
- Solution: Replacement of worn ball joints.
- Cost: $300 - $600
Leaf Spring Sagging
- Symptoms: Rear end sag, reduced load capacity, rougher ride.
- Solution: Replacement of rear leaf springs.
- Cost: $500 - $1000
Electrical
Instrument Cluster
Gauge Malfunctions
- Symptoms: Speedometer, tachometer, fuel gauge, or other gauges not working or reading erratically.
- Solution: Repair or replacement of the instrument cluster.
- Cost: $400 - $800
Power Window Motors
Window Operation Failure
- Symptoms: Power windows not moving up or down.
- Solution: Replacement of power window motor and regulator assembly.
- Cost: $200 - $400
Exterior
Body Panels
Rust
- Symptoms: Corrosion on body panels, frame, and undercarriage, especially in rust-belt regions.
- Solution: Rust repair and treatment, potentially involving panel replacement.
- Cost: $500 - $2000+
Tailgate/Liftgate
Hinge and Latch Issues
- Symptoms: Difficulty opening or closing tailgate, sticking latches.
- Solution: Lubrication, adjustment, or replacement of hinges and latches.
- Cost: $100 - $300
Interior
HVAC System
Blend Door Actuator Failure
- Symptoms: Inability to control temperature or direct airflow (e.g., only hot air, or air only from defrost vents).
- Solution: Replacement of the blend door actuator(s).
- Cost: $200 - $400
Seat Mechanisms
Power Seat Adjustment Failure
- Symptoms: Power seats not moving forward, backward, up, or down.
- Solution: Repair or replacement of seat motors or control modules.
- Cost: $300 - $600
Summary Verdict
The 2005 Ford Excursion, particularly models equipped with the 6.0L Power Stroke diesel engine, is known for potential significant mechanical issues such as EGR cooler failure, oil cooler failure, and head gasket problems, which can be costly to repair. Gasoline V8 and V10 engines are more prone to spark plug blowout and intake manifold gasket leaks. Transmission issues like torque converter problems and overheating can also arise. Suspension components like ball joints and leaf springs may require attention due to the vehicle’s weight and intended use. Electrical issues, particularly with the instrument cluster and power windows, are also documented. While capable and robust, prospective buyers should be aware of these potential reliability concerns and factor in potential repair costs.