2003 Ford Excursion: fire, smoke or burning smell

Filed Jul 31, 2015 · Electrical · 140,000 miles · CA · fire

Tl* the contact owns a 2003 ford excursion. The contact stated that the gear shift lever sparked a fire and the wiring of the shifter began to melt. The vehicle was engulfed in smoke shortly after the failure. The contact immediately shut off the vehicle and disconnected the battery. The vehicle was taken to an independent mechanic. The technician stated that the wiring insulation of the lever had worn and caused the failure. As a result, the gear shift assembly would need to be replaced. The vehicle was repaired. The manufacturer was not made aware of the failure. The failure mileage was 145,000. In addition, the contact stated that the silver circuit box inside of the fuse box melted and caught on fire. When the failure occurred, all the gauges on the instrument panel and the alternator failed causing the vehicle to stall. The vehicle was towed to an independent mechanic, who stated that the fuse box would need to be replaced. The manufacturer was made aware of the failure and informed him that the fuse box was discontinued. The vehicle was repaired; however, the failure recurred shortly after. In order to remedy the failure, a modification had to be made to bypass the melting current by placing an external wire and circuit breaker. The vehicle was repaired. The failure mileage was 140,000.

Filed Dec 30, 2008 · Seats · 200,000 miles · MD · fire

The heat in my driver seat stopped working. My husband took the seat cover off and noticed that it had caught fire and burned the wires and seat cushion. This could have been a big problem had the fire continued. My husband fixed the wiring after we were told nothing could be done because of the vehicles age.

Filed Jan 11, 2005 · Visibility · VA

While driving 40 MPH driver noticed smoke coming from the driver's power window switch. The driver was able to take the vehicle to the dealer for inspection, and mechanic determined that power window switch needed to be replaced, and replaced it. However, the problem recurred.

Filed Feb 18, 2004 · Electrical · NM · fire

Vehicle had been driven the most of the day without any incident. Towards the end of the day vehicle caught on fire. The fire department indicated that fire was located behind the third row seat, near the spare tire.

Filed Jan 22, 2004 · Electrical · 15,000 miles · MA · fire

While trying to start vehicle consumer was unsuccessful twice. A few minutes after the second try consumer came outside and found vehicle on fire. Electrical wires melted. Fire department arrived and extinguished the fire. There were no injuries.

Filed Dec 30, 2003 · Engine, Fuel system · 1,049 miles · TX · fire

My 2003 excursion had a major turbo failure while traveling on I-10 on 12-26-03. My family and myself were traveling to houston. The vehicle only had a total of 1,049 life to date miles. While on the interstate for about 30 to 45 minutes we hear a larger pop noise and a large drop in the engine power. I only had a flash of a dash light and it went right back off. I was trying to get off the interstate. Was driving about 25 to 35 MPH trying to get to the next exit. Notice large volume of smoke coming from the rear of the vehicle. I pulled over asap after seeing this. The smoke came into the cab from the ventilation system (A/C). Pulled my daughter from the vehicle, also had my wife get out of the vehicle. At this point released the hood lock, checking the heat on the hood first. Raised the hood found fire coming from exhaust pipe from the turbo. Just smother the fire out to ensure it would not spread. Saw the oil around the exhaust system through out the system. The vehicle has a 6.0 diesel engine and is a 4x4 excursion. Im filing this report for the safety of others not for myself. My concern is for other people who are not exposed to this type of condition which can happen with a diesel engine. Im a vehicle superintendent of a large city transit system. And have seen fires from a turbo failures. 6.0 diesel is a international product, and the series 40 engines are prone for this type of failures. This may be the only failure that is reported for the 2003 6.0 diesel. But with only 1,049 miles this failure should have not occurred. Their should be some way to ensure the check engine light should have came on and stayed on for this condition for a failed turbo. Its at the dealer at this time getting repaired. Best regards, bryan j. Garner