2002 Ford Excursion Engine cooling Problems
- Complaints
- 31about this part
- Share
- 24%of 129 total for the year
- Median mileage
- 71,218miles
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
NHTSA recorded 31 complaints about the engine cooling of the 2002 Ford Excursion, 24% of the 129 complaints for this model year. Where a mileage was given, the median is 71,218 miles. 2 a fire, according to the filers. 1 recall campaign on record is filed under a similar system.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“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 miles“The spark plug popped out of the head of my 2002 Ford Excursion. The dealer repaired it at a cost of around $500.00. They told me they never heard of this before and I was lucky I didn't blow the motor at a $7000,00 cost. I first felt lucky when I called customer service they too said it was new to them also. Many of my friends say this problem is a common one. Now I want to know how common and if so why do I have to pay for their design flaw.”
NHTSA complaint #10110569, filed 2005-02, 71,436 miles“My 2002 Ford lexcursion blew out it's spark plug yesterday. You all know the story by now: corporate will not help. My local dealer will not help. And, as most of you already know, the government to this date has done nothing to help either. These kinds of things are exactly what is wrong with this country: more often than not there is no accountability for things that go wrong. I will never buy a Ford again, this whole situation is breaking my heart because I really do love america and my beautiful american-made Ford truck. It's a Excursion, people. …”
NHTSA complaint #10323553, filed 2010-04, 120,000 miles“In early december 2006 we were out christmas shopping when I heard a loud pop followed by a sharp decrease in power and following pop sounds. I pulled over and checked the engine. At first I just noticed the coil had blown off the head. I thought it may have just been a weird occurrence with a bad cop but later found that the spark plug had blown out of the #6 cylinder destroying the cop. The truck was towed back to my residence and the next morning I looked it over. The spark plug had blown out stripping the threads. …”
NHTSA complaint #10179171, filed 2007-01, 100,000 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). I took it to tune-up 2000, where they told me the spark plug threads had stripped out causing it to blow form the engine. …”
NHTSA complaint #10146767, filed 2006-01, 39,000 milesRelated recalls
- 07V553000Dec 5, 2007On certain heavy duty trucks equipped with 7.3l diesel engines, the camshaft position sensor located on the engine of the vehicle may function intermittently…Covers: Ford Excursion 1997–2003, F-450 SD 1997–2003, E Series 1997–2003 +3 more
Related service bulletins
- 10026321May 26, 2008Ford: 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…
- 10023943Oct 1, 2007Some 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…
- 10018745Nov 14, 2005Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running.
- 10014666Mar 7, 2005Intermittent rough idle - non-commanded egr (exhaust gas recirculation valve) flow.
- 10013403Dec 27, 2004Hard start or no start.
- 10011162Aug 23, 2004Engine misfire or running - coil on plug (cop) ignition systems - wds cop kit diagnostic tips. To include various 2005 models. * ar this article 04161 supersedes tsb 03-14-04.
- 10013071Oct 1, 2002Loud squealing noise from the engine area when the engine fan clutch is under load while operated in hot dusty climates. Vehicles equipped with a 7.3l engine.
Engine cooling: other model years
Other parts of the 2002 Ford Excursion
27 complaintsBrakes
17 complaintsVehicle speed control
16 complaintsElectrical system
10 complaintsEngine
6 complaintsBody and structure
6 complaintsFuel system
5 complaintsSteering
5 complaintsSuspension
5 complaintsTransmission and drivetrain
4 complaintsVisibility (wipers, defrost, mirrors)
4 complaintsSeat belts
3 complaints
← All problems reported for the 2002 Ford Excursion
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.
To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology