Avoid: 2000 (lowest Year Scores on complaints per year on the road, crash reports and recalls)
Best: 2005
6 model years of NHTSA owner complaints and recalls · How we grade
Across 6 model years, the Ford Excursion has 1,236 owner-filed NHTSA complaints and 27 recalls on record. The most-reported areas are tires and engine and engine cooling. 2000 drew the most complaints (550), 2005 the fewest (65).
Source: NHTSA complaints and recalls filed for Ford Excursion vehicles (US, public record). Typical used asking price $10,400–$19,549.
Complaint volume by model year. Raw NHTSA totals, not adjusted for sales volume or time on the road, so older and higher-selling years accumulate more. Every year links to its full breakdown.
Highest: 2000 (550 complaints). Lowest: 2005 (65).
Owner sentiment is strongly positive regarding the vehicle's core purpose: immense size, robust towing capability, and durability.
Rocker panels, wheel wells, and floor pans are critical failure points; foil heat shields can trap moisture and hide rust.
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.
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.
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.
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.
Owner insights cover all generations of the Excursion. Individual model years are broken down above.
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