2004 Ford Excursion Problems: 5 Known Issues
2004 model year · 680+ owner reports · Updated October 2026
According to Au7o's analysis of 680+ owner reports, the 2004 Ford Excursion has 5 documented known issues, with 4 rated critical. The most serious are NV273 Electric Shift Transfer Case Failure ($350-$5,000 repair), 6.0L Powerstroke Head Bolt Failure and Head Gasket Blowout ($3,000-$8,000 repair), 6.0L Powerstroke Oil Cooler Clogging ($800-$2,000 repair) and 6.0L Injection Pressure Regulator (IPR) Valve Leak ($100-$350 repair). The most commonly reported issue is NV273 Electric Shift Transfer Case Failure with 680 owner reports. Across all issues with published estimates, repair costs range from $100 to $8,000. DIY maintenance guides at au7o.io.
2004 · All trims · All engines
Choose the year and equipment for your written issues and visual request.
No email neededHow interest is saved
Interest applies to the selected vehicle and configuration; it is not a reservation. Voting stores a first-party identifier for up to 180 days to prevent repeat votes. No account or email is needed. Clearing cookies or using another device may count separately. Privacy
Visual coming soon
Your interest helps us choose what to build next.
Visual Known Issues · Coming soon
$4.99/month plus taxes at launch · No payment today
All 5 Known Issues
NHTSA Recalls11 recalls
EXTERIOR LIGHTING:TAIL LIGHTS
FORD IS RECALLING CERTAIN MODEL YEAR 2011 RANGER TRUCKS BUILT FROM JANUARY 25, 2011, THROUGH APRIL 25, 2011 AT THE TWIN CITIES ASSEMBLY PLANT, AND SERVICE PARTS DISTRIBUTED TO DEALERS FOR CERTAIN 2004 THROUGH 2011 MODEL YEAR RANGER TRUCKS, 2002 THROUGH 2005 MODEL YEAR EXCURSION VEHICLES, AND 2002 THROUGH 2007 MODEL YEAR F-250, F-350, F-450, AND F-550 TRUCKS FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THE MULTI-FUNCTION SWITCH WAS SHIPPED WITH A SUBCOMPONENT (SLIDER) THAT MAY EXPERIENCE DEFORMATION. A MULTI-FUNCTION SWITCH WITH A DEFORMED SLIDER MAY MALFUNCTION CAUSING THE TURN SIGNAL, TAIL LIGHTS, HAZARD WARNING SIGNAL FLASHERS AND/OR BRAKE LIGHTS NOT TO ACTIVATE.
VEHICLE SPEED CONTROL
ON CERTAIN TRUCKS EQUIPPED WITH SPEED CONTROL, GASOLINE OR NATURAL GAS ENGINES, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT.
ENGINE AND ENGINE COOLING:ENGINE:DIESEL
ON CERTAIN HEAVY DUTY TRUCKS EQUIPPED WITH 7.3L DIESEL ENGINES, THE CAMSHAFT POSITION SENSOR LOCATED ON THE ENGINE OF THE VEHICLE MAY FUNCTION INTERMITTENTLY, POSSIBLY RESULTING IN AN ENGINE STALL.
VEHICLE SPEED CONTROL
ON CERTAIN TRUCKS EQUIPPED WITH SPEED CONTROL, GASOLINE OR NATURAL GAS ENGINES, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT.
ELECTRICAL SYSTEM:WIRING
CERTAIN PICKUP TRUCKS, SPORT UTILITY VEHICLES AND VANS EQUIPPED WITH 6.0L DIESEL ENGINES MAY EXPERIENCE STALLING WITHOUT WARNING WHILE DRIVING AND MAY OR MAY NOT RESTART.
+ 6 more recalls. Check all on NHTSA.gov
Enter your VIN at NHTSA.gov to check recalls specific to your vehicle.
Join 600+ people using Au7o to better understand their vehicles.
Don't see your problem? Describe your symptoms to get a diagnosis, or get a full repair guide.
Other Ford Models
Frequently Asked Questions
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: NV273 Electric Shift Transfer Case Failure, 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: NV273 Electric Shift Transfer Case Failure 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, NV273 Electric Shift Transfer Case Failure, 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 NV273 Electric Shift Transfer Case Failure?
The 2000-2005 Ford Excursion 4x4 equipped with the New Venture NV273 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. The electric… 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 (roughly 7,200-7,800 lb curb weight, 8,900-9,200 lb 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.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.