2004 Ford Excursion Technical Service Bulletins

86 technical service bulletins (TSBs) are on record for the 2004 Ford Excursion. TSBs are notes manufacturers send to dealers about repair procedures for issues seen in the field. They are not recalls and do not by themselves mean a vehicle has a fault.

• 10243490Sep 7, 2023Transmission and drivetrain. When performing any transmission fluid changes or topoffs involving MERCON SP, MERCON LV has replaced all versions of MERCON SP and can be used going forward. Mixing MERCON LV and MERCON SP in the same transmission is acceptable. After 30-Jun-2023, MERCON SP ATF will no longer be manufactured and will only be available until inventory depletes.
• 10189008Feb 10, 2021Transmission and drivetrain. This SKU is a Transmission Line. The customer communication requested return of unsold inventory to inspect the connector. The transmission line connector may have an incorrect thread size, which will prevent it from being installed.
• 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. Excessive friction in the ball joint assembly may cause a perceptible increase in steering effort.
• 10109070Sep 21, 2016Engine cooling, Engine. The 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 diagnose possible ETB concerns. The IDS has a limited refresh rate when reading these PIDs and cannot display quickly enough to validate a concern. The PCM automatically monitors these inputs more accurately and will set diagnostic trouble codes…
• 10056196May 1, 2014Transmission and drivetrain. Ford: when shifting between park, reverse and/or during 2-3 shift, an intermittent clunk occurs with a torqshift transmission. Model 2003-2014 f-super duty, e series, excursion, f-53 motorhome chassis, low cab forward.
• 10055629Feb 1, 2014Engine cooling, Transmission and drivetrain. Ford: 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, electronically, and recheck voltage. Model 2003-2007 f super duty, 2004-2010 e series, 2003-2005 excursion.
• 10034571Jun 11, 2010Fuel system. Ford: runs rough, lacks power, hard start, no start. Some vehicles and trucks equipped with 6.0l engine may exhibit a runs rough, lacks power, hard to start, no start concern with or without diagnostic trouble code (dtc) p0611 code or various injector circuit codes.
• 10030848Dec 9, 2009Engine cooling. Ford: 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 turbocharger flutter after performing field service action (fsa) 06e17, or after recalibrating the vehicle with the inferred exhaust pressure (ebp) strategy.
• 10030836Aug 1, 2009Transmission and drivetrain. Ford: multiple vehicles with a torq shift transmission intermittent clunk when shifting between drive, reverse and park and/or during 2-3 upshift. Models f super duty; e series; excursion; f53 motorhome chassis and low cab forward.
• 10028826Jun 1, 2009Engine cooling, Fuel system. Ford: 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 and/or all 8 injector circuit codes.
• 10028730May 1, 2009Engine cooling. Ford: 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, 2009Engine cooling. Ford 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, 2009Engine cooling. Ford: 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 from the degas bottle. *pe updated 3/20/09.
• 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 vehicles, model years 2002-2005. Updated 10/24/08. *pe csc letter was received. Updated 10/27/08.
• 10024325Mar 1, 2008Engine cooling. 6.0l turbocharger carbon deposit diagnostics and service tips. *nj updated 5/29/08.
• 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 chassis. Updated 2/23/10.
• 10023855Oct 1, 2007Engine cooling. 6.0l--mil on--p0401, p0402, p0404, p1335--lack of power or surge with some 2003-2007 f-super duty, 2003-2005 excursion and 2004-2008 e-series vehicles.
• 10022675Sep 19, 2007Brakes. Brake booster system may exhibit a brake pedal kickback and/or grabbing condition when applying the brakes.
• 10022295Jul 25, 2007Engine cooling. Dtc's p006a or p132b - lacks power, surge, or flutter after field service action 06e17.
• 10022293Jul 25, 2007Engine cooling. 6.0l diesel engine - oil leak or boost pressure leak at hot side charge air cooler duct.
• 10021464Apr 27, 2007Engine cooling. 6.0l oil seep or boost pressure leak at hot side charge air cooler duct.
• 10021462Apr 27, 2007Engine cooling. Cold start driveability - white smoke, lacks power, exhaust odor, surges, runs, rough, or no start.
• 10021236Mar 23, 2007Engine cooling. Lack of cooling fan operation.
• 10021232Mar 23, 2007Engine cooling. 6.0l turbocharger carbon deposit diagnostics and service tips - lack of power, white or black smoke, surge, p0238, p0299, p0404, p2262, and/or p2263.
• 10021619Feb 1, 2007Engine cooling. Air filter water ingestion / snow packing with codes p0103.
• 10020675Dec 20, 2006Fuel system. Water in the fuel. Lamp is one and flickering.
• 10020673Dec 20, 2006Engine cooling. 6.0l turbocharger carbon deposit diagnostics and service tips, lack of power, white or black smoke, surge, p0238, p0299, p0404, p0478, p0478, p2262, and/or p2263. *kb updated 11/05/07.
• 10021229Sep 1, 2006Engine cooling. Watch for oil flow from the base engine oil pump. Vehicles equipped with a 6.0l diesel engine.
• 10021174Sep 1, 2006Engine cooling. Driveability issues and/or dtc p132b, p006a immediately after reprogramming.
• 10021173Jun 1, 2006Engine cooling. Oil flow from the base engine oil pump.
• 10020150Jun 1, 2006Engine cooling. Repeat turbocharger or vgt replacement.
• 10019808Apr 29, 2006Transmission and drivetrain. Exhaust pressure sensor input no longer used if pcm is reprogrammed - service tip.
• 10019795Apr 28, 2006Electrical system. P0404 SERVICE TIP.
• 10019945Apr 1, 2006Engine cooling. Voluntary emission recall 06e17 supplement #1: control module recalibration. Corrosion may exist at the electrode surface on the exhaust pressure (ep) sensor; fuel delivery timing during cold weather may not be optimal; and/or exhaust gas recirculation (egr) system operation at idle may not be optimal.
• 10019380Mar 13, 2006Engine cooling. White smoke, lacks power, exhaust odor, surges, runs rough, or no start - 6.0l.
• 10020069Jan 1, 2006Engine cooling. Misfire, lack of power, buck/jerk, excessive smoke or crank/no start.
• 10019949Jan 1, 2006Electrical system. Water-in-fuel (wif) lamp on.
• 10019385Jan 1, 2006Engine cooling. Coolant degas bottle overflow - 6.0l.
• 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.
• 10017806Oct 31, 2005Engine cooling. Buck/jerk or surge - 6.0l vehicles built before 8/22/2005.
• 10018067Oct 7, 2005Visibility (wipers, defrost, mirrors). Vacuum pump inoperative or runs continuously - climate control defaults to defrost mode.
• 10018062Oct 7, 2005Engine cooling. Coolant degas bottle overflow.
• 10018060Oct 7, 2005Transmission and drivetrain. Diagnostic trouble code p0488 and/or p1334 with no driveability symptoms, harsh shift and/or transmission engagements.
• 10018054Oct 7, 2005Visibility (wipers, defrost, mirrors). Service kit available for wiper motor wiring.
• 10018073Sep 1, 2005Engine cooling. Flutter noise on deceleration.
• 10018070Sep 1, 2005Transmission and drivetrain. Torqshift transmission - intermittent clunk when shifting from reverse gear or drive gear to park. Multiple vehicles. Ford oasis. To include 2006 ford f-53.
• 10017996Aug 18, 2005Engine cooling. Voluntary emission recall 05e15 - supplement #2. Exhaust pressure sensor replacement, on-board diagnostic system and engine control module recalibrations.
• 10012944Aug 18, 2005Transmission and drivetrain. Low/reverse gear set pinion shaft(s) that may walk out, causing metallic particle contamination. Customer satisfaction program 04b24. Transmission reverse planet replacement. *tt supplement #1 and #2. *tt supplement #3.
• 10016823Aug 17, 2005Equipment. Customer satisfaction program 05b29: supplement#3. Charge air cooler duct replacement.

← All problems reported for the 2004 Ford Excursion