What are the most common Ford Excursion problems?
According to Au7o's analysis of 680+ owner reports, the 2004 Ford Excursion has 5 documented issues. The most frequently reported are: BorgWarner 4405 Electric Shift Transfer Case Failure (V10 Models), 6.0L Powerstroke Head Bolt Failure and Head Gasket Blowout, 6.0L Powerstroke Oil Cooler Clogging. Of these, 4 are rated critical and should be addressed promptly.
Is the Ford Excursion reliable?
The 2004 Ford Excursion has 5 known issues documented across 680+ owner reports. 4 issues are rated critical: BorgWarner 4405 Electric Shift Transfer Case Failure (V10 Models) and 6.0L Powerstroke Head Bolt Failure and Head Gasket Blowout and 6.0L Powerstroke Oil Cooler Clogging and 6.0L Injection Pressure Regulator (IPR) Valve Leak. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
How much does it cost to fix common Ford Excursion problems?
Repair costs for known Ford Excursion issues range from $100 to $8,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, BorgWarner 4405 Electric Shift Transfer Case Failure (V10 Models), typically costs $350-$5,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What is the 2000-2005 Ford Excursion BorgWarner 4405 Electric Shift Transfer Case Failure (V10 Models)?
The 2000-2005 Ford Excursion equipped with the 6.8L V10 engine and BorgWarner 4405 electric-shift-on-the-fly transfer case experiences multiple failure modes including transfer case shift motor failure, false neutral conditions, and GEM (Generic Electronic Module) control issues. Repairs typically run $350-$5,000. Severity: high.
What is the 2003-2005 Ford Excursion 6.0L Powerstroke Head Bolt Failure and Head Gasket Blowout?
The 6.0L Powerstroke diesel (2003-2005 Excursion) is notorious for TTY head bolt stretching under boost pressure, causing head gasket failure. This is the same engine used in Super Duty trucks and is one of the most problematic diesel engines Ford produced. Repairs typically run $3,000-$8,000. Severity: high.
What is the 2003-2005 Ford Excursion 6.0L Powerstroke Oil Cooler Clogging?
The oil cooler on the 6.0L Powerstroke clogs with debris from deteriorating coolant, reducing cooling capacity and causing elevated oil and coolant temperatures. This leads to cascading failures including EGR cooler rupture and head gasket failure. Repairs typically run $800-$2,000. Severity: high.
What is the 2003-2005 Ford Excursion 6.0L Injection Pressure Regulator (IPR) Valve Leak?
The IPR valve on the 6.0L Power Stroke can develop an external oil leak or fail to regulate injection control pressure, causing hard starting, rough idle, and loss of power. The o-ring seal deteriorates over time. Repairs typically run $100-$350. Severity: high.
What is the 2000-2005 Ford Excursion Front Wheel Hub and Bearing Assembly Failure?
The front hub bearings wear prematurely due to the vehicle's extreme weight (7,600+ lbs GVWR). Symptoms include humming noise that changes with speed and steering wheel vibration. Common on both 4x2 and 4x4 models. Repairs typically run $250-$500. Severity: medium.
