2003 Ford Excursion Problems

What owners report

Complaints on this model year center on two very different engines: many describe 6.0L diesel stalling, surging, hard starting and injector work, while others describe V10 and V8 gas engines that lose power or have spark plugs blow out of the cylinder head. Wandering steering and worn front ball joints, brake pull or a sticking pedal, and electrical faults such as gauge failures, dead batteries and alternator or wiring trouble round out the reports.

1. 1
   Engine cooling

   Diesel engine stalling, surging and rough/no-start

   Mentioned in 17 of 60 sampled complaints

   Owners of the 6.0L diesel describe the engine stalling without warning while driving or coming to a stop, and sometimes surging or lurching at idle and cruising speed. Several say the engine would crank but not fire, or would not restart for a while, and that dealers pointed to injectors, injector control pressure sensors or camshaft position sensors, sometimes replacing parts without a lasting fix. Complaints also mention turbocharger trouble, excessive smoke and fuel odors in the cabin. Reports are spread from very low mileage (under 2,000 miles) up to about 200,000 miles, with many between roughly 25,000 and 100,000 miles.

   Recall 09V399000Recall 07V5530006 related service bulletins

   What to check: Ask for service records on injectors, the ICP sensor and the camshaft position sensor, and confirm whether the speed control switch recall and any diesel-related campaigns were completed. A long test drive from cold, including idle and light-throttle cruise, is worth doing.

   2 excerpts from owner complaints in NHTSA records

   “My 2003 Ford Excursion with a 6.0l diesel has been surging and will stall suddenly and without warning. It has caused several near collisions. The dealer had to replace the icp sensor. Apparently this was recalled in 2004 models and newer but not the 2003 model. I feel that I have fallen through the cracks because Ford didn't start installing the 6.0l in the 2003 model until late in the model years. Seems like they forgot about me and my truck has the exact same dangerous condition as the 2004 models.”

   NHTSA complaint #10274336, filed 2009-06, 98,000 miles

   “While driving about 25 MPH, the engine stalled and I lost steering control. Luckily no other cars were approaching because I was making a left turn on to a busy street. Very dangerous. The stall has also occurred at least 5 other times, usually when decelerating when coming to a stop light. Today, the ABS light came on, then I heard a click and all the gauges lost power, the radio display went out. I could not restart the vehicle - only heard a click sound. After waiting an hour, the vehicle started. …”

   NHTSA complaint #10227686, filed 2008-05, 110,000 miles
2. 2
   Electrical system

   Gauge, battery and charging electrical faults

   • 23 complaints (22%)
   • median 83,474 mi at 5.6 yrs old (21 state mileage)
   • 7 mention a crash, fire or injury
   • filed 2003–2017

   Complaints describe instrument gauges swinging or failing, dash lights flickering, and loss of power to electrical systems, sometimes followed by a no-start with only a click. Owners report repeated battery replacement, alternator and harness work, and in a few cases an engine-bay fire. Some mention power-adjustable pedals and seat controls stopping together. Mostly reported between roughly 25,000 and 100,000 miles, with a few cases lower and higher.

   Recall 04V327000Recall 09V399000

   What to check: Check that all gauges and interior electronics work, and ask whether the battery, alternator and charging harness have been serviced. Confirm whether the battery ground stud and speed control switch recalls were completed.

   2 excerpts from owner complaints in NHTSA records

   “While driving on hwy 210 my ABS light came on then my interior lights went dim my head lights started to flicker then the dash board was like christmas everything started to blink fuel like miles to empty seatbelt ect.. Then loss all power steering wheel locked I had my four children in the car when we flipped in to a ditch after hitting some mail boxes.. Wth I see some of the same reports why hasn't Ford fixed this problem!!!”

   NHTSA complaint #10390143, filed 2011-03, 204,000 miles

   “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.”

   NHTSA complaint #10055646, filed 2004-01, 15,000 miles
3. 3
   Suspension

   Wandering, popping and worn front ball joints

   Mentioned in 8 of 60 sampled complaints

   Complaints describe the truck wandering across lanes, poor steering return, pulling to one side, and a popping or rattling noise from the front end. Several owners say dealers replaced upper and lower ball joints, in some cases more than once, and one report notes the joints failed again within about 17,000 miles. Others mention a broken leaf spring and abnormal noise over bumps. Mostly reported between about 48,000 and 95,000 miles, with a few at very low mileage.

   What to check: Have the front end inspected for ball joint play and uneven tire wear before buying, and ask whether ball joints or steering components have been replaced and when.

   2 excerpts from owner complaints in NHTSA records

   “I have a 2003 Ford Excursion with the triton v10 gas engine. I was driving on the highway and heard an exhaust sound. I drove directly to pasadena Ford and as I drove in a salesman told me that it was the #3 cylinder and that the spark plug had blown out of the head. He stated that it was common and he saw it all the time. I proceeded to drop off the truck and my service tech called me back and indeed the spark plug had blown out and stripped the head. He told me the repairs would cost $4,000.00. …”

   NHTSA complaint #10155464, filed 2006-04, 86,000 miles

   “2003 Ford Excursion lost control under normal highway driving conditions swerving into both left and right lanes barely missing other vehicles. I returned vehicle to dealership with complaint. They had no explanation or solution. I contacted Ford and was told it was up to the dealership to rectify problem. I was not willing to wait and see if it would happen again considering the safety of my family. We were left with no option from the dealership other than to trade vehicle in with great financial loss. …”

   NHTSA complaint #10061869, filed 2004-03, 2,500 miles
4. 4
   Brakes

   Brake pull, grabbing and pedal problems

   • 15 complaints (14%)
   • median 57,000 mi at 4.0 yrs old (13 state mileage)
   • 2 mention a crash, fire or injury
   • filed 2003–2020

   Owners report the vehicle pulling left or right when braking, sometimes violently, and pedal kickback or a pedal that sticks near the floor. Some describe repeated rotor replacement, ABS module replacement that did not resolve the pull, and loss of power assist after an engine stall. A few report hydro-boost or master cylinder failure. Spread from under 2,000 miles to about 160,000 miles, with many between roughly 25,000 and 65,000 miles.

   1 related service bulletin

   What to check: Test braking at moderate speed on a straight, empty road for pull or vibration, and check pedal feel and travel. Ask about rotor, ABS module and brake booster service history.

   2 excerpts from owner complaints in NHTSA records

   “Pavement was wet...cit was dark ....a car suddenly stopped in the roadway..my anti lock brakes locked up causing me to skid into the car in front of me..causing rear damage to it...my airbag also did not deploy..was going about 25mph..but seemed to increase in speed skidding on the pavement it caused me to lose my safe driving discount on my istate farm insurance...had to pay a higher premium for 3yrs because of it..I have recently gotten my safe driver discount back can get statefarm documentation later if needed”

   NHTSA complaint #11298486, filed 2020-01, 160,000 miles

   “Vehicle experienced a problem with the front ball joints. This vehicle had 60,000 miles on it. Owner took the vehicle to the dealer for a check up on the brakes when it was discovered that the ball joints had worn out, and there was plenty of movement with in the wheel. Dealer replaced left front lower ball joint. And machined the front rotors.”

   NHTSA complaint #10111475, filed 2005-03, 60,011 miles
5. 5
   Engine cooling

   Gas engine power loss, misfire and blown spark plugs

   • 17 complaints (16%)
   • median 25,286 mi at 3.5 yrs old (17 state mileage)
   • owner-quoted repair $4,000 (median of 5 quotes)
   • filed 2003–2017

   Owners of the V10 and V8 gas engines describe a miss or light-throttle hesitation, loss of power, and a sudden loud exhaust noise when a spark plug comes out of the cylinder head and strips the threads. Some report broken exhaust manifold bolts causing noise and exhaust smell in the cabin, and a few describe valvetrain noise leading to engine replacement. Complaints say dealers acknowledged the patterns but often declined warranty coverage. Reported from a few thousand miles up to about 235,000 miles, with several cases around 40,000-90,000 miles.

   1 related service bulletin

   What to check: Listen for exhaust ticking or a miss on a cold start, and check whether plug thread inserts or head work have been done. Ask for records of exhaust manifold bolt or spark plug repairs.

   2 excerpts from owner complaints in NHTSA records

   “Faulty exhaust manifold bolts break off and cause excessive noise, exhaust enters the drivers cabin, vehicle will not pass emissions inspection and is expensive to repair. I have 4 Ford vehicles with this problem. First incident was at around 50,000 miles and 48 months after purchase. Ford refused to make repairs under any portion of the factory warranty. They claim lifetime emissions warranty doesn't cover it, nor the 100,000 powertrain warranty. I have spent over $8000.00 making repairs to these exhaust manifolds. Triton v-10 gas engine.”

   NHTSA complaint #11046166, filed 2017-11, 40,000 miles

   “When driving the vehicle stalls and also occasionally losses turbo power. Has stalled at stop signs and when pulling into parking spaces. At this time you lose brakes and steering, very dangerous!! When loses turbo, it takes about a minute or two for it to kick back on.”

   NHTSA complaint #10068409, filed 2004-05, 11,000 miles

Buying note. Which engine the vehicle has matters most here, so ask for records of injector, sensor and plug or head work and have the front end and brakes inspected before purchase. A pre-purchase inspection that includes a cold start and a highway test drive is worthwhile.

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.