2002 Ford Excursion Problems
- Complaints
- 129filed with NHTSA
- Median mileage
- 63,050miles, 89 complaints with mileage
- Recalls
- 4campaigns on record
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
Sources: NHTSA records for the 2002 Ford Excursion (complaints, recalls, investigations). Report an error
What owners report
Owners of the 2002 Ford Excursion most often write about spark plugs blowing out of the cylinder heads, which typically produces a sudden loud exhaust-type noise and lost power, and about tire failures - mostly tread separations and sidewall problems on the original-style tires, several tied to a tire recall. Brake complaints center on poor or inconsistent stopping, pulling to one side, and warped rotors at low mileage, and a smaller group describes smoke or fire originating at the cruise-control switch under the hood or in the steering column.
- Tires
Tire tread separation and sidewall failure
- 27 complaints (21%)
- median 35,500 mi at 2.8 yrs old (18 state mileage)
- 1 mention a crash, fire or injury
- filed 2003–2019
Complaints describe blowouts, tread separating from the carcass, sidewall bubbles or peeling, and irregular wear, often at highway speed and sometimes with body damage from flailing tread. Several owners mention recall notices for the original tires and difficulty getting replacement tires or reimbursement, with dealers and the tire maker pointing at each other. Mostly reported between about 5,000 and 60,000 miles on the tires, frequently at highway speed; later complaints involve tires fitted years after purchase.
What to check: Check tire date codes and look for sidewall cracking, bubbles or uneven wear, and confirm whether any original tires were replaced under a tire recall.
2 excerpts from owner complaints in NHTSA records
“4/4/04 I rec'd a flat ti,e told it was irreparable since air was seeping out of the sidewall. 4/5/04, I receive letter from firestone/Ford reagrding tire recall on my 2002 Ford Excursion.. 4/6/04 I phone 3 Ford dealerships and 5 firestone stores trying to locate replaceable tires. Told they had no idea when tires would be avail. I called Ford corp., they blame firestone, call firestone hotline, they blame Ford. Ford corp- keisha, cust. …”
NHTSA complaint #10068060, filed 2004-04, 5,000 miles“While driving on I-84 east bound, between the dalles and pendleton oregon, our 2002 Ford Excursion experienced a tire tread separation on the right rear. We experienced a recurring popping sound just prior to the tread separation. We were pulling a light trailer. Tread separated but tire remained inflated. I was able to see the tread leave the tire in my right mirror as it happened. We were traveling up hill at the time so speed was approximately 63mph. Dry roads and 93 degrees.”
NHTSA complaint #10424129, filed 2011-09, 183,000 miles - Engine
Spark plug blown out of cylinder head
- 20 complaints (16%)
- median 92,400 mi at 7.8 yrs old (18 state mileage)
- owner-quoted repair $500 (median of 5 quotes)
- filed 2004–2016
Owners describe a loud pop or a noise like a broken exhaust, followed by a misfire, rough running or loss of power while driving. Inspection usually finds a spark plug ejected from its bore with the threads in the aluminum head damaged and often the coil pack cracked. Repairs reported include thread inserts, drilling and tapping the head, or head replacement, and some owners say the problem returned on another cylinder after repair. Reported from roughly 50,000 to 170,000 miles, with many examples in the 60,000 to 110,000 mile range and during ordinary driving.
What to check: Ask whether any spark plug thread repair has been done and listen for a ticking or exhaust-like noise at cold start; a compression or leak-down check on each cylinder is worth the cost.
2 excerpts from owner complaints in NHTSA records
“I started my truck after sitting for 36 hours and what sounded like bad exhaust leak ..after being checked out by mechanic found that a spark plug and coil has been spit out of motor ..I had them repace spark plug and coil on top which repaired the problem ..today I was driving to town 10 miles and after stoppi g to get gas the noise started again !”
NHTSA complaint #10820717, filed 2016-01, 167,000 miles“While driving my 2002 Ford Excursion on the interstate at about 65 MPH, I heard a thump under the hood and then my engine began to make a loud clunky sound (almost as if there were no muffler). One of the sparks plugs had blown out of the engine! Luckily, my Excursion was still drivable and I was within a few miles of my home and could park it until I could seek repairs on monday. I did not take it to the Ford dealership (trust issues). …”
NHTSA complaint #10146767, filed 2006-01, 39,000 miles - Brakes
Brakes pull, fade or feel weak
- 17 complaints (13%)
- median 33,100 mi at 2.6 yrs old (11 state mileage)
- 4 mention a crash, fire or injury
- filed 2002–2013
Owners report the pedal going to the floor or little stopping response, pulling hard to one side under braking, shudder through the wheel, and rapid pad and rotor wear. Some complaints describe repeated caliper, booster and hydraulic unit replacements without a lasting fix, and a few describe a brake line worn through by a wheel well liner. Most often reported below about 50,000 miles, including several under 30,000 miles.
What to check: Drive and brake firmly from highway speed on a test drive, watch for pulling or pulsation, and have the brake lines and hoses inspected for corrosion or rubbing.
2 excerpts from owner complaints in NHTSA records
“I seem to be having a braking problem with my 2002 Ford Excursion. I have had to replace brake pads and rotors on a number of instances. It seem to be caused by the brake caliper slide brackets which prevent the proper caliper travel when activated. This was a complaint I have addressed since my purchase of the vehicle. The problem gives the vehicle an uneven brake activation, which causes poor handling while braking. The dealer say that it is not a warranty issue. …”
NHTSA complaint #10297795, filed 2010-01, 44,285 miles“I started experiencing vibrating in my steering wheel during braking several months ago. The vibration continued to get worse. I had the brakes checked and I found out that all four rotors were warped on the vehicle. The vehicle only has 27000 miles on it and the brake pads are in excellent condition. Through research I found that many other people have had rotor problems at a very early stage on their Ford excursions. Ford refuses to acknowledge a problem with the rotors or repair the problem at their cost.”
NHTSA complaint #10078547, filed 2004-06, 26,500 miles - Engine cooling
Engine stalls, hard starts (sensor-related)
- 32 complaints (25%)
- median 50,000 mi at 4.5 yrs old (21 state mileage)
- 2 mention a crash, fire or injury
- filed 2002–2019
Owners report the engine shutting off without warning, sometimes with all warning lights on, and then requiring several restart attempts; others describe intermittent rough idle or a no-start. Repairs reported include replacing the camshaft or crankshaft position sensor, and some owners describe trouble being reimbursed after a recall notice for the same part. Reported across a wide mileage range, from about 60,000 to over 200,000 miles.
Recall 07V5530002 related service bulletins
What to check: Ask for service records showing whether the camshaft and crankshaft position sensors have been replaced, and confirm any open recall repair was performed and documented.
2 excerpts from owner complaints in NHTSA records
“The electronic controller for the over drive lock switch is shorting out in my 2002 Ford Excursion. I experienced a problem with the gauges turning off while I was driving around atlanta, ga with my family. The battery went dead because the fuse that controls the dash gauges blew. The alternator quit charging the battery, and the gauges quit working. I did not notice this problem until I was stopped at a red light and the engine died. …”
NHTSA complaint #10132548, filed 2005-08, 63,050 miles“Crank position sensor failed without warning, vehicle motor immediately shutoff and was unable to restart. Vehicle was towed to dealer for repairs. Fortunately this happened in a parking lot. If this happened on the highway while towing 10,000 lbs, loss of engine power would cause a inability to control the vehicle resulting in a likely accident with possible injuries or deaths.”
NHTSA complaint #10202189, filed 2007-09, 71,000 miles - Vehicle speed control
Cruise control switch smoke or fire
- 13 complaints (10%)
- median 110,000 mi at 7.2 yrs old (8 state mileage, few)
- 6 mention a crash, fire or injury
- filed 2002–2013
Complaints describe smoke or flames from the steering column or under the hood traced to the speed control switch, sometimes while the vehicle was parked and sometimes while driving. A separate group describes unintended acceleration or a cruise control that would not disengage when the brake was applied. Reported from about 20,000 to 176,000 miles; several fires occurred while the vehicle was parked.
Recall 09V399000Recall 06V2860001 related service bulletin
What to check: Ask whether the speed control deactivation switch recall work was completed, and check under the hood at the switch on the master cylinder for scorching or brake fluid residue.
2 excerpts from owner complaints in NHTSA records
“My 2002 Ford Excursion caught on fire on june 10, 2008. Ford said it was the speed control switch. They have refused to pay for repairs because they claim that they sent letters, which I never received.”
NHTSA complaint #10232222, filed 2008-06, 110,000 miles“While driving at 20 MPH the vehicle accelerated intermittently. The consumer stated the only way to stop the vehicle was by shutting the engine off. The dealer stated they could not duplicate the problem. Please provide additional information. Manufacturer was notified, but could not offer any remedy.”
NHTSA complaint #10112956, filed 2005-04, 20,000 miles
Buying note. A pre-purchase inspection by a mechanic familiar with these trucks is worthwhile, focusing on cylinder head spark plug threads, brake condition and lines, tire age and condition, and whether speed-control and sensor recalls were completed.
Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.
NHTSA recorded 129 consumer complaints for the 2002 Ford Excursion. 89 of the complaints include a mileage, and 37% of those were filed for vehicles with under 50,000 miles; the median is 63,050 miles. Of all complaints, 13 involved a crash, 9 a fire, 11 an injury, according to the filers. NHTSA lists 4 recall campaigns and 22 technical service bulletins for this model year.
Not compared (before 2008). Model years 2008–2023 of the same vehicle that have at least 25 complaints are compared, and a model needs at least 3 of them.
Which parts are reported most
Complaints can name more than one part, so the counts add up to more than the total. Select a part to see its complaints, recalls and bulletins.
- Engine cooling31 24%
- Tires27 21%
- Brakes17 13%
- Vehicle speed control16 12%
- Electrical system10 7.8%
- Engine6 4.7%
- Body and structure6 4.7%
- Fuel system5 3.9%
- Steering5 3.9%
- Suspension5 3.9%
Also reported: Transmission and drivetrain (4), Visibility (wipers, defrost, mirrors) (4), Seat belts (3), Wheels (3), Air bags (2), Other or unknown (2), Exterior lighting (1), Interior lighting (1), Latches, locks and linkages (1).
Example complaints
Engine cooling: “I have a Ford Excursion 2002 v10 with 116000 miles on it. After 8 hours of a road trip one of the spark plugs ejected from the engine. This is the second time this has happened with this motor. I purchased the vehicle at 100,000 miles and the owner had it happen once to him.”
NHTSA complaint #10274239, filed 2009-06, 116,000 milesTires: “On 6/5/2013, I was driving on freeway at approx. 70mph and tread separated from rt. Rear tire causing vehicle to swerve into adjacent lane. Damage to quarter panel and running board. This is the second tire failure in the past 45 days.the tires are bfgoodrich 265/75r/16 commercial ta load range e. The four new tires were installed on 2/28/2011 and have approx. 14,300 miles of wear at time of failure. The other tire (left front) failed on 4/19/2013. Because of strong front end vibration, I inspected the front tires. I found that it was out of round due to belt separation. …”
NHTSA complaint #10515876, filed 2013-06, 86,800 milesBrakes: “On 8-25-03 , I took my 2002 Ford Excursion in to berryville Ford in berryville arkansas because the vehicle would not stop in a reasonable distance. If you are going downhill and you have to brake suddenly and hard the brakes get hot and you lose them alltogether.this vehicle has only 27,774 miles. It has been in the shop three different times and thet r&r the brake booster they r&r the hydraulic control unit . The brake shoes have been replaced twice the rotors have been resurfaced and this vehicle will not stop . …”
NHTSA complaint #10039561, filed 2003-09, 26,000 milesVehicle speed control: “When the brake was applied, the engine revved and vehicle surged foward into oncoming traffic. The vehicle was struck on the drivers side, and the vehicle finally stopped. The idle air control and headliner was replaced.”
NHTSA complaint #10008933, filed 2003-02, 25,275 milesMileage when problems were reported
37% of the 89 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 37,000 and 103,000 miles.
Complaints by year filed
Trend: stable. Complaints filed in the last 3 full calendar years are within 25% of the 3 years before.
Recalls and investigations
- 11V352000Jul 13, 2011Exterior lighting › Brake lightsCovers: Ford Excursion 2002–2005, Ranger 2004–2011, F-350 2002–2007 +5 more
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…
- 09V399000Oct 13, 2009Vehicle speed controlCovers: Ford Excursion 2000–2003, E-150 1992–2003, E-350 1992–2003 +12 more
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…
- 07V553000Dec 5, 2007Engine and engine cooling › Engine › DieselCovers: Ford Excursion 1997–2003, F-450 SD 1997–2003, E Series 1997–2003 +3 more
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.
- 06V286000Aug 1, 2006Vehicle speed controlCovers: Ford Excursion 2000–2002, F-250 1994–2002, F-350 1994–2002 +10 more
On certain trucks equipped with speed control, gasoline or natural gas engines, the speed control deactivation switch may overheat.
Recall details for the 2002 Ford Excursion → · Check a VIN at nhtsa.gov/recalls
NHTSA investigations
- EA04006Accelerator pedal sensor (etc)Closed · Feb 23, 2004
- PE03044Accelerator pedal sensor failure (etc)Closed · Sep 26, 2003
Technical service bulletins
TSBs are manufacturer notes to dealers about known repair procedures. They are not recalls and do not by themselves mean a vehicle has a fault. 22 on record; the latest 10 are shown.
- 10148818Oct 2, 2018Steering. This SKU is a front upper ball joint. The Customer communication requested return of unsold inventory to inspect for ball studs with excessive rotational friction in the ball joint assembly…
- 10026321May 26, 2008Transmission and drivetrain, Engine cooling. Ford: vehicles mistakenly charged $100 powertrain warranty deductible for fuel injector repair or repairs. No model or model years provided. *pe econoline, excursion and f-series super duty…
- 10023943Oct 1, 2007Engine cooling. Some 1997-2008 vehicles equipped with a 4.6l 2v, 5.4l 2v, or 6.8l 2v engine--spark plug thread repair procedure--not covered under new vehicle limited warranty. *nj this includes f-53 motorhome…
- 10022675Sep 19, 2007Brakes. Brake booster system may exhibit a brake pedal kickback and/or grabbing condition when applying the brakes.
- 10019075Jan 1, 2006Fuel system, Other or unknown. Fuel conditioner. Low power, poor fuel economy, fuel gelling in cold weather, excessive white smoke on cold start, hard start, or coking of components exposed to exhaust.
- 10018745Nov 14, 2005Engine cooling. Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running.
- 10018067Oct 7, 2005Visibility (wipers, defrost, mirrors). Vacuum pump inoperative or runs continuously - climate control defaults to defrost mode.
- 10018054Oct 7, 2005Visibility (wipers, defrost, mirrors). Service kit available for wiper motor wiring.
- 10014138Jun 7, 2005Seat belts. Safety belt retraction speed.
- 10014666Mar 7, 2005Engine cooling. Intermittent rough idle - non-commanded egr (exhaust gas recirculation valve) flow.
Other model years of the Ford Excursion
| Year | Complaints | Median mi | Recalls | Crash ★ | MPG | Score (50 = typical) | Trend |
|---|---|---|---|---|---|---|---|
| 2005 | 65 | 84,000 | 2 | — | — | Not compared (before 2008) | Rising |
| 2004 | 95 | 82,400 | 2 | — | — | Not compared (before 2008) | Falling |
| 2003 | 106 | 57,000 | 5 | — | — | Not compared (before 2008) | Falling |
| 2002 | 129 | 63,050 | 4 | — | — | Not compared (before 2008) | Stable |
| 2001 | 209 | 81,350 | 6 | — | — | Not compared (before 2008) | Rising |
| 2000 | 533 | 80,000 | 5 | — | — | Not compared (before 2008) | Falling |
| 1999 | 7 | 82,500 | 1 | — | — | — | Not enough data |
All Ford Excursion model years · Best and worst years by complaints
Frequently asked questions
What are the most common problems with the 2002 Ford Excursion?
Owners of the 2002 Ford Excursion most often write about spark plugs blowing out of the cylinder heads, which typically produces a sudden loud exhaust-type noise and lost power, and about tire failures - mostly tread separations and sidewall problems on the original-style tires, several tied to a tire recall. The issues reported most often: Tire tread separation and sidewall failure; Spark plug blown out of cylinder head; Brakes pull, fade or feel weak.
How many NHTSA complaints does the 2002 Ford Excursion have?
NHTSA recorded 129 consumer complaints for the 2002 Ford Excursion as of Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
What part of the 2002 Ford Excursion is reported most often?
Engine cooling is named most often, in 31 complaints (24% of the total), followed by tires with 27.
Has the 2002 Ford Excursion been recalled?
NHTSA lists 4 recall campaigns for this model year. To check a specific vehicle, enter its VIN at nhtsa.gov/recalls.
At what mileage are problems with the 2002 Ford Excursion reported?
Among the 89 complaints that include a mileage, the median is 63,050 miles and the middle half falls between 37,000 and 103,000 miles; 37% were filed for vehicles with under 50,000 miles.
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
Complaint counts come from NHTSA’s public complaint database; we count each complaint once. The source records for this vehicle are on nhtsa.gov. Scores and trends are our own summaries of that data, described in the methodology. This page is not legal, safety or repair advice: for a specific vehicle, check its VIN at nhtsa.gov/recalls and ask a qualified mechanic. See an error? Tell us.