2004 FORD EXCURSION Engine And Engine Cooling Problems

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". *JS

Mileage: 74,000

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.

Mileage: 81,000

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.

Mileage: 95,000

TL* THE CONTACT OWNS A 2004 FORD EXCURSION. THE CONTACT STATED WHEN DRIVING AT 50 MPH, THE VEHICLE WOULD SPORADICALLY STALL WITHOUT WARNING. THE CONTACT WAS ABLE TO RESTART THE VEHICLE AFTER SEVERAL ATTEMPTS. THE DEALER WAS UNABLE TO DUPLICATE THE FAILURE. THE MANUFACTURER ADVISED THE VEHICLE WAS NOT UNDER RECALL AND WOULD NOT PROVIDE ANY FURTHER ASSISTANCE. THE FAILURE AND CURRENT MILEAGES WERE 100,000.

Mileage: 100,000

2004 FORD EXCURSION DIESEL WITH 6.0 ENGINE. THE ENGINE IS CRAP. THE FUEL INJECTORS ARE BAD IT'S A KNOWN PROBLEM. I WAS IN AN INTERSECTION WHILE MAKING A LEFT TURN WITH AN ON COMING VEHICLE WHEN I HAD NO ACCELERATION AND BLACK EXHAUST WAS COMING OUT OF THE TAIL PIPE. I HAD MY 3YR OLD DAUGHTER ON THAT SIDE OF THE VEHICLE. THIS ISN'T THE FIRST PROBLEM WE HAVE HAD WITH THIS ENGINE AS HAS ALMOST EVERYONE ELSE THAT OWNS IT. IT NEEDS TO BE RECALLED. IT SCARED ME SO BAD I CRIED. I HAVE CALLED THE FORD CONSUMER NUMBER THEY DID NOTHING. I AM PAYING FORD $1,500.00 TO FIX THE PROBLEM THAT I WAS TOLD WOULD CONTINUE TO HAPPEN BECAUSE IT'S A DEFECT IN THIS PARTICULAR ENGINE. IN THE WORDS OF ONE OF FORDS MECHANICS "HE WOULDN'T OWN ONE, THEY ARE CRAP" I'M SCARED TO DRIVE IT EVEN AFTER IT GETS FIXED KNOWING ANOTHER MAY GO SOON OR THE SAME ONE. *TR

TL* THE CONTACT REPORTED THAT THE EXHAUST IS GOING INTO THE 2004 FORD EXCURSION. THIS HAS BEEN HAPPENING FOR 3 MONTHS. WHEN THE VEHICLE IS IDLE OR STOPPED AT A LIGHT THE EXHAUST COMES THROUGH THE HEATING GRATE. THE VEHICLE HAS 30000 THOUSAND MILES ON IT AND HAD 24000 MILES WHEN PROBLEM STARTED. THE DEALER HAS TRIED TO FIX THE PROBLEM BUT NOTHING HAS WORKED PERMANENTLY. THEY DRIVER IS SUFFERING HEADACHES AND DROWSINESS WHEN DRIVING. UPDATED 01/20/10 *BF THE DEALER REPLACED THE LEFT EXHAUST MANIFOLD GASKET. UPDATED 01/22/10. *JB

Mileage: 24,000

TL*THE CONTACT OWNS A 2004 FORD EXCURSION. THE CONTACT STATED THAT THE TURBO CHARGER ON THE DIESEL ENGINE BROKE. THIS WAS CAUSED BY A MALFUNCTION WITHIN THE ENGINE. THERE WAS A 100,000 MILE WARRANTY ON THE VEHICLE AND THE FORD MANUFACTURER WOULD NOT HONOR IT. THE FAILURE MILEAGE WAS 78,318.

Mileage: 78,318

MY 2004 FORD EXCURSION THREW A SPARK PLUG FROM THE CYLINDER HEAD LAST WEEK. THIS CAUSED ME TO LEAVE MY CAR ON THE SIDE OF THE ROAD AND TRY AND FIND A RIDE HOME. ONCE I GOT THE TRUCK HOME I FOUND THE COIL HAD BROKEN OFF OF IT'S MOUNT AND THE PLUG WAS RESTING IN THE HOLE OF THE HEAD. THE THREADS ARE MANGLED ON THE PLUG AND STRIPPED OUT IN THE HEAD. I HAVE RESEARCHED THIS ONLINE AND FOUND HUNDREDS OF COMPLAINTS ABOUT THIS SAME ISSUE. PLEASE MAKE FORD TAKE RESPONSIBILITY... THANK YOU. *TR

Mileage: 74,231

MY 2004 FORD EXCURSION JUST EJECTED A SPARK PLUG AND IT'S THREADED BUSHING. THIS IS A FACTORY DEFECT AND SHOULD BE ADDRESSED BY FORD AND/OR YOUR OFFICE. *TR

Mileage: 85,000

WE PURCHASED 2004 FORD EXCURSION WITH THE 6.0L DIESEL ENGINE NEW IN FEBRUARY 2004. IT HAS BEEN TO THE DEALER NOW 2 TIMES FOR THE BACK UP SENSOR, APPROXIMATELY 5 TIMES FOR THE TURBO, UNABLE TO COUNT THE NUMBER OF TIMES FOR THE LACK OF POWER, THE VENT WINDOWS NOT WORKING, 3 TIMES FOR THE MOTOR ON THE POWER DRIVERS SEAT, BALL JOINTS 1 TIME, AND NOW OTHER FRONT END PARTS. THIS VEHICLE IS PRIMARILY USED TO GO TO CHURCH AND TRAVEL WITH THE ENTIRE FAMILY ON THE WEEKENDS FOR DAY TRIPS. WE HAVE HAD IT TO GRAHAM FORD SEVERAL TIMES, GERMAIN FORD SEVERAL TIMES, (BOTH ARE IN COLUMBUS, OHIO) AND THE LAST PLACE WE HAVE IT IS DONLEY FORD IN MOUNT VERNON, OHIO. WE CAN GET A FULL HISTORY OF ALL REPAIRS ON THIS VEHICLE IF NEEDED. THERE HAVE BEEN SO MANY THINGS GONE WRONG WITH THE TRUCK THAT IT IS DIFFICULT TO KEEP TRACK. THE SERVICE ADVISOR IS NOW TELLING MY WIFE TO "JUST TRADE IT IN". WE JUST WANT ALL OF THE PROBLEMS FIXED CORRECTLY AND FIND THE CAUSE OF THE ELECTRICAL FAILURES/ISSUES/PROBLEMS INSTEAD OF JUST FIXING WHAT BREAKS AND NOT FIXING THE CAUSE. WE PAID 50,000 BUCKS FOR THIS VEHICLE AND HAVE HAD NOTHING BUT PROBLEMS. THE START WAS WHEN WE WANTED TO GO TO MAINE AND COULD NOT TAKE IT BUT HAD TO TAKE OUR OLDER CONVERSION VAN. *TR

WE PURCHASED 2004 FORD EXCURSION WITH THE 6.0L DIESEL ENGINE NEW IN FEBRUARY 2004. IT HAS BEEN TO THE DEALER NOW 2 TIMES FOR THE BACK UP SENSOR, APPROXIMATELY 5 TIMES FOR THE TURBO, UNABLE TO COUNT THE NUMBER OF TIMES FOR THE LACK OF POWER, THE VENT WINDOWS NOT WORKING, 3 TIMES FOR THE MOTOR ON THE POWER DRIVERS SEAT, BALL JOINTS 1 TIME, AND NOW OTHER FRONT END PARTS. THIS VEHICLE IS PRIMARILY USED TO GO TO CHURCH AND TRAVEL WITH THE ENTIRE FAMILY ON THE WEEKENDS FOR DAY TRIPS. WE HAVE HAD IT TO GRAHAM FORD SEVERAL TIMES, GERMAIN FORD SEVERAL TIMES, (BOTH ARE IN COLUMBUS, OHIO) AND THE LAST PLACE WE HAVE IT IS DONLEY FORD IN MOUNT VERNON, OHIO. WE CAN GET A FULL HISTORY OF ALL REPAIRS ON THIS VEHICLE IF NEEDED. THERE HAVE BEEN SO MANY THINGS GONE WRONG WITH THE TRUCK THAT IT IS DIFFICULT TO KEEP TRACK. THE SERVICE ADVISOR IS NOW TELLING MY WIFE TO "JUST TRADE IT IN". WE JUST WANT ALL OF THE PROBLEMS FIXED CORRECTLY AND FIND THE CAUSE OF THE ELECTRICAL FAILURES/ISSUES/PROBLEMS INSTEAD OF JUST FIXING WHAT BREAKS AND NOT FIXING THE CAUSE. WE PAID 50,000 BUCKS FOR THIS VEHICLE AND HAVE HAD NOTHING BUT PROBLEMS. THE START WAS WHEN WE WANTED TO GO TO MAINE AND COULD NOT TAKE IT BUT HAD TO TAKE OUR OLDER CONVERSION VAN. *TR

2004 FORD EXCURSION V-10. COME TO A STOP AND THE TACH SHOWS NORMAL 650-700 RPM, AND WITHIN A FEW SECONDS CAR WILL ACCELERATE TO 1800-2000 RPM BY ITSELF AND THE CAR SURGES FORWARD. DRIVER MUST LEAVE PLENTY OF SPACE BETWEEN THE CAR AND THE ONE AHEAD TO GIVE HIM TIME TO STOP. NO CRASH YET!!!. IT DOES THIS EVERY TIME YOU STOP. *TR

Mileage: 110,000

THIS VEHICLE HAS BEEN SERVICED COUNTLESS TIMES FOR STALLING. EACH TIME THE DEALER HAS REPLACED THE EGR VALVE AND OTHER ITEMS BECAUSE OF FAILURE CODES. EACH TIME THE EGR VALVE HAS FAILED. THE DEALER IS "REPAIRING" THE VEHICLE AND GIVING IT BACK TO ME. WITHIN 5 MINUTES AFTER RECEIVING THE VEHICLE FROM THE SERVICE DEPARTMENT, IT STALLS AGAIN. THE VEHICLE WILL STALL AT LEAST 3 TIMES DURING A 30 MINUTE DRIVE. IT STALLS ON THE FREEWAY, ON RESIDENTIAL STREETS, STARTING FROM A DEAD STOP, AND IF IT IS DRIVING AT A CONSTANT SPEED. THIS VEHICLE IS NOT FIXED AND IT IS OBVIOUS THE DEALER CANNOT FIX IT! IT IS GOING IN TOMORROW FOR THE 3RD TIME THIS MONTH FOR THE SAME PROBLEM. I HAVE ALMOST GOTTEN IN AN ACCIDENT FROM IT STALLING, AND I HAVE HAD MANY TIMES WHERE I HAVE BEEN IN A DANGEROUS SITUATION FROM IT STALLING. THE DEALER CANNOT FIX IT, I CANNOT SALE IT TO ANOTHER PERSON IN THIS CONDITION, AND FORD WON'T DO ANYTHING TO HELP ME. I AM DRIVING A VERY DANGEROUS VEHICLE AND HAVE NO WAY TO FIX IT. WHAT CAN I DO? PLEASE GIVE ME A SUGGESTION. DO I HAVE ANY RIGHTS IF THE VEHICLE CANNOT BE FIX? *TR

TL*THE CONTACT OWNS A 2004 FORD EXCURSION. WHILE DRIVING APPROXIMATELY 25 MPH, IDLING, OR PARKED, THE RPM'S BEGIN TO INCREASE FROM 2,000 TO 3,000 AUTOMATICALLY AND THE VEHICLE WILL OCCASIONALLY STALL. WHEN DRIVING AT LOW SPEEDS, THE RPM'S WILL INCREASE FROM 2,000 TO 5,000. THE VEHICLE HAS BEEN DIAGNOSED BY THE DEALER SEVERAL DIFFERENT TIMES, BUT THE FAILURE STILL PERSISTS. NHTSA CAMPAIGN ID NUMBER 05V270000 (ELECTRICAL SYSTEM:WIRING) WAS REFERENCED. THE CURRENT MILEAGE WAS 48,000 AND FAILURE MILEAGE WAS 15,000.

Mileage: 15,000

TL*THE CONTACT OWNS A 2004 FORD EXCURSION. WHILE DRIVING BETWEEN 35-40 MPH, THE VEHICLE STALLED AND THEN SHUT OFF. THE VEHICLE WAS TOWED TO A MECHANIC AND THEY REPLACED THE NUMBER 1 AND NUMBER 3 FUEL INJECTORS. THE DEALER STATED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER 05V270000 (ELECTRICAL SYSTEM:WIRING). THE CURRENT MILEAGE WAS 130,994 AND FAILURE MILEAGE WAS 108,480. UPDATED 09/10/08 *BF THE ALTERNATOR, CONTROL MODULE FOR THE HEATING AND AC SYSTEM, AND COOLING SYSTEM WERE REPLACED. UPDATED 09/19/08. *JB

Mileage: 108,480

TL*THE CONTACT OWNS A 2004 FORD EXCURSION. THE CONTACT STATED THAT THE CHECK ENGINE LIGHT HAS REMAINED ILLUMINATED IN THE PAST. THE VEHICLE SHUT DOWN AND WAS TAKEN TO THE DEALER WHO REPLACED THE EGR VALVE. WHILE DRIVING 30 MPH, THE FAILURE RECURRED. SINCE THEN, THE EGR VALVE HAS BEEN REPLACED SEVERAL TIMES AND THE TURBO WAS CLEANED. THE VEHICLE IS CURRENTLY AT THE DEALER. THE MANUFACTURER OFFERED TO BUY BACK THE VEHICLE FOR HALF PRICE SO THAT IT CAN BE RESOLD. THE CURRENT MILEAGE IS 72,876 AND FAILURE MILEAGE WAS 47,000. UPDATED 02/01/08. *LJ THE CONSUMER STATED THE VEHICLE BUCKS FORWARD WHILE AT A STOP AND WHILE DRIVING. *JB

Mileage: 47,000

DT*: THE CONTACT STATED WHILE DRIVING VARIOUS SPEEDS, THE ENGINE STALLED WITHOUT WARNING. THE VEHICLE WAS MANEUVERED OFF THE ROAD AND RESTARTED. THE VEHICLE WAS DRIVEN TO THE DEALER ON SEVERAL OCCASIONS FOR THE PROBLEM WHERE A TURBO AND A SENSOR WERE REPLACED. ALTHOUGH THE PROBLEM PERSISTED, THE DEALER WAS UNABLE TO DUPLICATE THE PROBLEM. UPDATED 1/10/2007 - *NM

Mileage: 48,000

TRUCKS MOTOR CUTS OUT LOSING POWER AT DIFFRENT TIMES. WE HAVE BEEN CROSSING INTERSECTIONS AND PULLING OUT INTO TRAFFIC AND HAVE LOSE THE ACCURATION. THIS IS VERY DANGEROUS. TRUCK HAS BEEN IIN SHOP NUMEROUS OF TIMES AND FORD IS UNALBE TO FIX PROBLEM.

Mileage: 11,000

MY VEHICLE'S ENGINE WILL SURGE AND STALL. SOMETIMES BOTH THINGS WILL HAPPEN ON A GIVEN DAY OR JUST ONE. I HAVE HAD MY VEHICLE STALL COMING TO A STOP AND OR DRIVING. MY VEHICLE'S ENGINE HAS SURGED AND CAUSED MY CAR TO MOVE EVEN WITH MY FOOT ON THE BRAKE. THIS HAS BEEN A ONGOING PROBLEM THAT FORD CAN NOT FIX. *AK

WHILE DRIVING AT ANY SPEED WITH THE WINDOWS DOWN CONSUMER CAN SMELL EXHAUST FUMES. DEALERSHIP WAS NOTIFIED, BUT DID NOT RESOLVE THE PROBLEM.*AK

Mileage: 5,100

THE EP AND EGR SENSORS KEPT GOING OUT. WHEN THIS HAPPENED THE VEHICLE WILL RUN, BUT WILL NOT GET ANY POWER, SIMILAR TO STALLING. THIS OCCURRED THREE TIMES, DEALER CONTINUED TO SERVICE THE VEHICLE, AND THE PROBLEMS CAME BACK.*AK

Mileage: 6,000

WHILE DRIVING, THE VEHICLE SURGED. THE CONSUMER WOULD SMELLED GAS FUMES INSIDE THE VEHICLE. THE DEALERSHIP WAS AWARE OF THE PROBLEM, BUT DID NOT RESOLVE IT. *AK THE TURBO WOULD NOT TURN ON AND WOULD NOT GO OVER 3500 RPM'S AND THERE WAS A FLUTTER TYPE OF SOUND COMING FROM THE DRIVER'S SIDE REAR QUARTER PANEL WHEN THE A/C WAS ON ONLY BY THE REAR A/C CONTROLLER. *SC

Mileage: 13,000

WHILE DRIVING, VEHICLE WOULD STALL. THE DRIVER WAS ABLE TO RESTART AND NOTICED THAT THE VEHICLE WOULD ACCELERATED SUDDENLY ON ITS OWN WITHOUT WARNING. THE DRIVER APPLIED THE BRAKES THE PEDAL WENT TO THE FLOOR AND THE VEHICLE CONTINUE TO ACCELERATED WITH SPEED. THE DRIVER WAS ABLE TO MAINTAIN CONTROL OF THE VEHICLE AND DROVE IT TO THE DEALER FOR INSPECTION. THE MECHANIC INFORMED THE DRIVER THAT THE PROBLEM CAN NOT BE DUPLICATED. *NM THERE WAS AN OIL LEAK. *SC

Mileage: 2,248