2004 Ford Excursion Engine cooling Problems
- Complaints
- 22about this part
- Share
- 23%of 95 total for the year
- Median mileage
- 61,000miles
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
NHTSA recorded 22 complaints about the engine cooling of the 2004 Ford Excursion, 23% of the 95 complaints for this model year. Where a mileage was given, the median is 61,000 miles.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“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.”
NHTSA complaint #10290540, filed 2009-11, 74,231 miles“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.”
NHTSA complaint #10242858, filed 2008-09, 110,000 miles“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. 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.”
NHTSA complaint #10101818, filed 2004-12, 13,000 miles“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 .”
NHTSA complaint #10455772, filed 2012-04, 74,000 miles“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.”
NHTSA complaint #10120501, filed 2005-05, 11,000 milesRelated service bulletins
- 10109070Sep 21, 2016The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to…
- 10055629Feb 1, 2014Ford: on some trucks, there is a no crank situation and if voltage on transmission range sensor at pin 21, is less than 5 volts, disconnect the engine cooling fan clutch…
- 10030848Dec 9, 2009Ford: some vehicles equipped with the 6.0l engine may experience a p006a, p132, p0401 or p0402 diagnostic trouble code (dtc) with a lack of power condition, surge, or…
- 10028826Jun 1, 2009Ford: some vehicles with diesel engines may experience no starts, hard starts or rough running when cold and may be accompanied with diagnostic trouble codes (dtcs) p0611, p1378…
- 10028730May 1, 2009Ford: some vehicles equipped with 6.0l diesel engine may exhibit any one or combination of the following concerns-lack of power, white/black smoke or a surge.
- 10028284Mar 20, 2009Ford trucks: misfire, lack of power, buck/jerk, excessive smoke, crank/no start-diagnostics for fuel system. There are several potential causes for these symptoms.
- 10028125Mar 4, 2009Ford: vehicles may exhibit fuel in the engine coolant, due to leaks in the cylinder head fuel injector area. Symptoms may include fuel in engine coolant and coolant expulsion…
- 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…
- 10024325Mar 1, 20086.0l turbocharger carbon deposit diagnostics and service tips. *nj updated 5/29/08.
- 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…
Engine cooling: other model years
Other parts of the 2004 Ford Excursion
21 complaintsFuel system
12 complaintsVehicle speed control
9 complaintsEngine
7 complaintsTransmission and drivetrain
7 complaintsTires
6 complaintsBrakes
5 complaintsVisibility (wipers, defrost, mirrors)
5 complaintsAir bags
3 complaintsExterior lighting
3 complaintsLatches, locks and linkages
3 complaintsSeats
3 complaints
← All problems reported for the 2004 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