Photo: IFCAR / Public domain / Wikimedia Commons
Power
Top speed (153 km/h)
What owners say
Our take, from owner reports
Owner sentiment is strongly positive regarding the vehicle's core purpose: immense size, robust towing capability, and durability.
7 problems reported (5 very frequent, 2 recurrent) · high confidence
Problems owners report
- Very frequentRust
Rocker panels, wheel wells, and floor pans are critical failure points; foil heat shields can trap moisture and hide rust.
- Very frequentEngine-Specific Problems (Gas)
Exhaust manifold studs/bolts are prone to breaking. Spark plug thread issues: early models (up to 2002) have minimal thread engagement leading to plug ejection; 2004-2005 models have problematic two-piece plug designs that can seize and break.
- Very frequentEngine-Specific Problems (Diesel 6.0L)
Requires extensive "bulletproofing" (head studs, EGR cooler, oil cooler, etc.) for reliability; stock engines are prone to head gasket failure and other costly issues. High-pressure oil pump (HPOP) causes oil shear. Factory-spec coolant can clog coolers.
+ 4 more issuesShow fewer
- Very frequentAge-Related General Failures
At 20+ years old, components like window motors, seals, relays, and electronics begin to fail regularly. The battery saver relay is noted to cause erratic window and radio operation.
- Very frequentPoor Fuel Economy
Gasoline models (V10) report 9-14 MPG in mixed driving, dropping to 6-7 MPG when towing. Diesel models offer better efficiency but at a higher fuel and maintenance cost.
- RecurrentUnderpowered 5.4L V8
Considered insufficient for the vehicle's weight, resulting in poor performance.
- RecurrentTransmission Life
The 4R100 automatic transmission has an expected lifespan of around 200,000 miles.
The version owners recommend
The 7.3L Powerstroke diesel model (available 2000-2003) is most frequently recommended for its legendary reliability and strong towing performance. It is described as the "most desirable" engine despite its age. The 6.8L Triton V10 is the recommended gasoline engine, described as "quite thirsty" but "much preferable" to the 5.4L V8, which is widely considered underpowered for the vehicle's size. The 6.0L Powerstroke (2004-2005) receives mixed reviews; it can be a good engine if it has been properly "bulletproofed" (a series of aftermarket reliability modifications), but stock or poorly modified examples are viewed as a significant maintenance risk.
Competitors to consider
Owners compare it most often with the Chevrolet Suburban (particularly the 2500 series) and GMC Yukon XL.
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Overall sentiment
Owner sentiment is strongly positive regarding the vehicle's core purpose: immense size, robust towing capability, and durability. The Excursion is consistently praised as the largest SUV ever produced, offering unparalleled interior space and cargo capacity for large families and outdoor activities. It is held in high regard for its heavy-duty truck platform, which provides superior towing and payload ratings compared to lighter-duty competitors. Enthusiast loyalty is very high, with many owners expressing a long-term commitment to their vehicles despite age and mileage. However, this praise is heavily qualified by the realities of owning a 20+ year old, specialized vehicle. Significant and recurrent criticisms focus on elevated maintenance costs, age-related failures, and the specific, often expensive, reliability concerns associated with each engine option. Fuel economy is universally described as poor. The overall consensus is one of deep satisfaction for those who need its unique capabilities and are prepared for the associated costs and upkeep, but it is not recommended as a casual or budget-conscious daily driver.
Positioning vs competitors
Positioned as a heavier-duty, more capable, and larger alternative to the Chevrolet Suburban. Owner comparisons consistently note the Excursion is built on a three-quarter-ton truck platform (F-250/350), whereas the Suburban is on a half-ton platform. This results in the Excursion having higher payload, higher towing capacity, a rougher "truck-like" ride, and greater overall size and interior room. In direct towing comparisons with similar loads (e.g., ~7,500 lbs), owners report the Excursion (particularly with the 7.3L diesel) feels easier to get moving and more stable than a comparable Suburban 2500 with the 8.1L gas engine, though fuel economy is similarly low. The Suburban is acknowledged as having a smoother ride, better fuel economy when empty, and often a lower purchase price for equivalent age and condition. The Excursion is seen as the ultimate tool for maximum space and towing, while the Suburban is viewed as a more refined and car-like people-hauler.
Recommended configurations
4x4 is recommended for winter conditions. The Limited trim is noted as well-equipped. For the V10 engine, an aftermarket throttle body (Accufab) is mentioned to improve responsiveness. For serious towing with the V10, owners suggest verifying axle gearing, as 3.73 gears may be insufficient for loads over 5,000 lbs, prompting consideration of 4.10 or 4.30 gears. A thorough pre-purchase inspection focusing on rust (rockers, wheel wells, floor pans), exhaust manifold studs, and spark plug condition (on gas engines) is strongly advised. For diesel models, verification of "bulletproofing" work or budgeting for it is critical.
General recommendations
Suitable for large families (5+ members) requiring maximum passenger and cargo space. Ideal for owners who regularly tow heavy trailers (7,000+ lbs) and need a heavy-duty platform. Recommended for enthusiasts and DIY mechanics willing to handle the maintenance of an older vehicle. NOT recommended as a primary daily driver for those on a tight budget, due to fuel and maintenance costs. NOT recommended for buyers seeking a refined, comfortable, or efficient people-mover. Essential to have a trusted mechanic familiar with these vehicles or possess the capacity for DIY repairs. Purchase price should factor in immediate and ongoing maintenance costs. Rust-free examples command a significant premium and are worth seeking out.
Remarks
The Ford Excursion occupies a unique, discontinued niche. Owner feedback is almost exclusively from enthusiasts and long-term owners who value capability over convenience. The discussion heavily revolves around three engine families: the revered 7.3L diesel, the capable but thirsty 6.8L V10, and the problematic-but-potentially-great 6.0L diesel. The 5.4L V8 is generally advised against. A significant portion of owner discourse involves troubleshooting, modifying, and repairing these aging vehicles, indicating a dedicated but technically involved ownership base. The vehicle's value is intrinsically tied to its condition and drivetrain, with clean, low-rust, 7.3L diesel models commanding prices $10,000+ above comparable gasoline models. Analysis based on approximately 40 substantive owner discussions and comparisons.
Generation by generation
Owner insights per generation and US complaint/recall records (NHTSA).
Complaints and recalls by model yearWorst year: 2000. Years to avoid: 2000Source: NHTSA (US)Show table
Each year graded against the model's other years: Year Score. See all Ford Excursion years to avoid
| Year | Complaints | Recalls | Most-reported area |
|---|---|---|---|
| 2005 | 65 | 2 | electrical system |
| 2004 | 95 | 2 | engine and engine cooling |
| 2003 | 146 | 5 | electrical system |
| 2002 | 174 | 5 | engine and engine cooling |
| 2001 | 206 | 7 | tires |
| 2000 | 550 | 6 | tires |
Complaint counts come from owner reports filed with the US National Highway Traffic Safety Administration. Higher-selling years naturally accumulate more complaints.
Recall notices27 on record · Source: NHTSA (US)Show recalls
2005 · exterior lighting:tail lightscampaign 11V352000
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.
2005 · electrical system:wiringcampaign 05V270000
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.
2004 · exterior lighting:tail lightscampaign 11V352000
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.
2004 · electrical system:wiringcampaign 05V270000
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.
2003 · exterior lighting:tail lightscampaign 11V352000
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.
2003 · vehicle speed controlcampaign 09V399000
FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002 MERCURY MOUNTAINEER, 1995-1997 AND 2001-2003 RANGER, AND 1994 F53 VEHICLES EQUIPPED WITH THE TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCH (SCDS). THE SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
2003 · vehicle speed controlcampaign 07V078000
ON CERTAIN TRUCKS EQUIPPED WITH SPEED CONTROL, GASOLINE OR NATURAL GAS ENGINES, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT.
2003 · engine and engine cooling:engine:dieselcampaign 07V553000
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.
2003 · electrical system:12v/24v/48v batterycampaign 04V327000
ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES EQUIPPED WITH 6.0L DIESEL ENGINES, THE ENGINE GROUND STUD THAT ATTACHES THE NEGATIVE BATTERY TERMINAL EYELET TO THE ENGINE BLOCK MAY BE LOOSE.
2002 · exterior lighting:tail lightscampaign 11V352000
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.
2002 · vehicle speed controlcampaign 06V286000
ON CERTAIN TRUCKS EQUIPPED WITH SPEED CONTROL, GASOLINE OR NATURAL GAS ENGINES, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT.
2002 · vehicle speed controlcampaign 09V399000
FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002 MERCURY MOUNTAINEER, 1995-1997 AND 2001-2003 RANGER, AND 1994 F53 VEHICLES EQUIPPED WITH THE TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCH (SCDS). THE SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
2002 · engine and engine cooling:engine:dieselcampaign 07V553000
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.
2002 · wheels:hubcampaign 07E106000
CERTAIN FEDERAL-MOGUL REPLACEMENT WHEEL HUB ASSEMBLIES WITH THE BRAND NAMES: NATIONAL, CARQUEST P/NOS. 515020, 515021, 515025, 515053, 515054, 515059, AND 515060, SHIPPED BETWEEN JANUARY 23, 2006, AND DECEMBER 20, 2007, SOLD FOR LIGHT DUTY AND MEDIUM DUTY TRUCKS. THE INBOARD RETENTION NUT USED TO MAINTAIN HUB BEARING ASSEMBLY CAN LOOSEN RESULTING IN AN ABS LIGHT INDICATION, NOISE, AND/OR WHEEL SEPARATION.
2001 · vehicle speed controlcampaign 06V286000
ON CERTAIN TRUCKS EQUIPPED WITH SPEED CONTROL, GASOLINE OR NATURAL GAS ENGINES, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT.
12 older recalls not shown. Check nhtsa.gov with your VIN for the full history.
Specifications
7.3 TD
7.3L 8-cylinder diesel · 253 hp · AWD · automatic
Built 2001–2005