Total loss of engine power massive amount black soot exiting exhaust while driving recall # 05v270000 was not performed on vehicle ( I am the original owner) never received notice in mail and dealer somehow missed this "work" and ford should have followed through on this situation. Other repairs done to this vehicle to "fix" this problem was to drain the fuel tank (algae in fuel was the excuse-no algae) fuel pump and filter rail (not problem) two turbochargers were replaced due to excessive sooting (one warranty one at my expense) egr valves and a cam sensor (ford knows the problems exist because ford discountinued the 6.0 litre motor) this problem has occured multiple times over my ownership.
2004 Ford Excursion engine problems
29 complaints (31% of all complaints for this car). Typical mileage when it fails: 74,231.
- owner complaints
- 29
- of this car's complaints
- 31%
- typical mileage
- 74,231
- crashes
- 0
- recalls
- 0
Which part fails
- Engine: diesel7
- Engine6
- Exhaust system2
- Exhaust system: emission control1
- Engine: other fuel types: turbo/supercharger1
- Cooling system1
At what mileage
Complaints by mileage at the time of the problem.
0k-25k
25k-50k
50k-75k
75k-100k
100k-125k
125k-150k
150k-175k
175k-200k
200k+
Ford Excursion engine problems in other years
Specific symptoms reported on the 2004 Ford Excursion engine
Phrases found in the owners' own descriptions, so one complaint can mention several symptoms.
Related recalls
No recalls on record for this model year.
Related investigations
Spark plug ejection from cylinder head
On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi?s analysis showed, it is possible for a spark plug to detach from the engine cylinder threads in the subject vehicles.however, odi?s analysis of 474 complaints describing such incidents found only a very few alleged any safety-related consequences.none of these showed any evidence of a serious safety consequence.given the large population and relatively long exposure time of the subject vehicles, the complaint analysis indicates that the risk to motor vehicle safety from the alleged defect is very low.in view of the foregoing, it is unlikely that the federal safety agency would issue an order for the notification and remedy of the alleged defect at the conclusion of the investigation requested in the petition.therefore, in view of the need to allocate and prioritize the federal safety agency?s limited resources to best accomplish the agency?s safety mission, the petition is denied.
DP05005
Engine stalling
Twenty five of the odi failure reports are duplicative of ford complaints.twenty odi reports do not contain a VIN (and may or may not be duplicative of ford reports).the 14 alleged crashes and 2 alleged injuries were all minor.submitted during preliminary evaluation (pe) 04-070, ford's response to odi's information request (ir) letter contained about 5,000 consumer reports (mors) and 8,700 field reports (cqis).ford reviewed the complaints and categorized them.the manufacturer reports shown above represent a count of unique vehicles that ford categorized as allegedly stalling due to a subject engine component ('a' category, see ford's ir response letter for further detail); some of these vehicles received multiple reports.odi has not yet confirmed ford's categorization of these reports, nor has odi confirmed ford's categorization of the remaining reports (which ford states do not pertain to the alleged defect).ford submitted nearly 19,000 warranty claims, many of which involved claims for a technical service bulletin (tsb 04-13-08) and field service action (fsa 03b05) which ford identified as potential remedies for stalling complaints.odi has not confirmed that either of these are a remedy for engine stalling complaints.several other dealer communications related to engine stall were also submitted as well as over 50 product modifications, 15 of which involve revisions to the software for the electronic engine control unit.further investigation is required and odi is upgrading pe04-070 to an engineering analysis (ea).during the ea, odi will establish and update manufacturer failure report counts, further investigate the frequency and trend of stalling complaints, and determine the scope and safety implication of stalling events.odi will also investigate ford's remedies, their effectiveness, and whether further action is required.
PE04070
What 2004 Ford Excursion owners say
Most recent owner complaints, unedited.
Tl* the contact owns a 2004 ford excursion. While driving, the vehicle stalled without warning. The contact placed the gear into neutral, while in traffic, and restarted the vehicle. Afterwards, the vehicle was able to drive normally. The vehicle was taken to future ford lincoln (located at 650 automall dr, roseville, ca 95661, (888) 656-7577) where a wiggle test was performed because a failure code could not be found. The injection control pressure was replaced with a used part. The contact stated that the vehicle was worse after the replacement of the used part and the steering wheel became difficult to steer. The vehicle was taken back to the same dealer who stated that a wire harness was needed to repair the vehicle. The vehicle was not repaired. The manufacturer was notified of the failure and informed the contact that the VIN was not included in the federal safety agency campaign number: 05v270000 (electrical system). The approximate failure mileage was 59,000.
Repeatedly ejects spark plugs from cylinder head.
Vehicle engine ejects spark plug from cylinder head.
On 11/26/13 driving back from atlanta heading south leaving the florida welcome center on I-75, 4 miles north of jennings on I-75 south jennings. Leaving the welcome center the vehicles engine lost power while trying to merge back into traffic without any prior indication of a problem. The loss of power caused us to have to divert from the lane until we could gain more speed. The vehicle had no accelerating power above 40 MPH even with the gas pedal depressed all the way to the floor. There were no check engine lights on or any abnormal indicators. I called the ford customer care center on 12/12/13 and they acknowledge they have a problem with the erg failing due to collecting carbon and soot build up. They have not issued any service bulletins to owners letting them know there is an issue or have issued a maintenance program to try to prevent this from occurring. 1)ford designed the engine to pass soot and carbon back thru the erg valve. It is a bad design since it causes every engine to eventually fail. 2)ford does not warranty the egr valve or any component if soot or carbon sticks to the valve or component, even though it is designed to do so. 3)ford knows there is an issue with the egr failing which deposits soot and carbon in the intake of the engine which causes the engine to lose power and or ultimately quit without warning. 4)no service bulletins were issued to owners warning them of this safety problem. 5)cleaning the egr valve is not listed in the issued service manual. 6)no preventative maintenance service was offered to prevent this failure from occurring. 7)dealers enjoy this failure since it is a high labor revenue generator for them to tear down the engine to replace or clean the intake manifold. 8)the repair cost was approximately $3319.90 the vehicle is currently under the highest ford premium care warranty.
While driving the vehicle, it will go into a reduce power mode or sometimes stall. This has happened at various speeds, from around town to highway driving. Very dangerous condition when trying to make left turns and power is lost or engine stalls. Also engine fails to start or starts and stalls right away on occasion. Call ford customer relations and dealer and they tell me my VIN is not covered under the recall. I am experiencing the same symptoms but I am not covered. Don't want to spend more money at dealer if they don't know what is happening and how to fix it.
Tl* the contact owns a 2004 ford excursion. The contact stated that while driving approximately 30 to 45 MPH, the vehicle stalled without any warning. The vehicle was later towed to a dealer. After diagnosis, the contact was informed that the problem may be the fuse near the transmission. The vehicle was repaired. Approximately three months later, the failure recurred. The vehicle was taken back to the dealer. After diagnosis, they advised her that the fuse failed again due to the bracket chafing the wires. The vehicle was repaired. The manufacturer was contacted and they offered no assistance. The failure mileage was approximately 89,000. The current mileage was approximately 90,000. The VIN was unavailable.
The hose from the turbo to the intake cooler will blow off and cause pressure loss. When towing a trailer on a hill the engine turbo system will produce high pressure and will blow the hose connecting the turbo to the intake cooler. The vehicle ends up without power, making the situation extremely dangerous to riders and other vehicles due to the radical deceleration, from 65mph to about 15mph while trying to pull to the side. The problem is a common issue to ford owners with diesel engines 2004 and 2005, maybe others. Internet searched "ford turbo hose blow off".
Tl* the contact owns a 2004 ford excursion. The contact stated that upon starting the vehicle, a large cloud of smoke emitted from the tail pipe. The failure recurred on an intermittent basis. The contact also stated that the engine fan would intermittently create a very loud noise. The vehicle was taken to an authorized dealer and the contact was informed that coolant was leaking into the engine. The contact was informed that the engine would need to be rebuilt. The vehicle was not repaired. The manufacturer was made aware of the failure, but offered no assistance. The failure mileage was 81,000. Updated 11/01/11*lj the consumer stated the engine egr cooler failure resulted in a sudden loss of coolant and there was no warning on the dashboard from the service engine light. White clouds emitted from the tailpipe and auxiliary fan activation, which were both intermittent and inconsistent. The failure occurred over a one week period. When the consumer started the vehicle he noticed a billowing of white clouds coming from the tailpipe. The billowing clouds stopped as the consumer continued to drive, only to reappear intermittently over the next week.
Tl* the contact owns a 2004 ford excursion. While having the vehicle serviced for routine maintenance at an independent repair shop, he was informed water was leaking around the egr cooler and anti freeze was leaking into the exhaust system. The vehicle was not repaired and the failure continues. The failure and current mileages were 95,000.
Questions about the 2004 Ford Excursion engine
Does the 2004 Ford Excursion have engine problems?
Owners have filed 29 complaints about the engine of the 2004 Ford Excursion, 31% of all its complaints, more than any other problem.
At what mileage do 2004 Ford Excursion engine problems start?
The typical (median) mileage in owner complaints is 74,231 miles.
Is there a recall for the 2004 Ford Excursion engine?
There is no recall for this problem on this model year.
Other 2004 Ford Excursion problems
Electrical 21Fuel system 12Acceleration 9Transmission 7Tires 6Brakes 5Visibility 5Airbags 3Body 3Lights 3Locks 3Seats 3Steering 3Suspension 3Seat belts 2Driver assistance 1
VIN decoder
See the problems and recalls for an exact car
Buying a used 2004 Ford Excursion?
Check the exact car before you pay: accidents, salvage or flood titles, odometer readings and previous owners.
Check its history