2005 Ford Excursion Problems

What owners report

Owners of this model year most often describe the engine quitting without warning while driving, which also takes away power steering and power brakes; many link it to the 05V270000 wiring/FICM recall and say their vehicle's identification number was not covered. A second common theme is 6.0L diesel trouble — rough cold starts, white or black smoke, loss of power, EGR and cooler work — along with occasional fuel odors after filling the tank and worn front-end steering parts. Reported mileages vary widely, from a few thousand to well past 150,000.

1. 1
   Electrical system

   Engine stalls while driving, sometimes will not restart

   • 30 complaints (46%)
   • median 83,800 mi at 6.6 yrs old (29 state mileage)
   • 1 mention a crash, fire or injury
   • filed 2007–2018

   Complaints describe the engine shutting off without warning at speeds from about 5 to 75 mph, with power steering and power brakes going away at the same time; some vehicles restart, others need towing. Several owners point to the fuel injection control module or wiring harness, and some were told the repair would cost thousands. Others say the dealer could not reproduce or diagnose the stall, and repeated attempts at repair did not stop it. Some owners report that the manufacturer told them their vehicle was not included in the recall for this symptom. Scattered from roughly 25,000 to 190,000 miles, with many reports between 55,000 and 120,000 miles.

   Recall 05V2700001 related service bulletin

   What to check: Ask whether the 05V270000 recall or any later reflash of the injection control module was performed, and if possible have a diesel shop scan for stored codes and check the module and harness connectors before purchase.

   2 excerpts from owner complaints in NHTSA records

   “My vehicle randomly experiences engine stalls while driving. It has stalled while traveling up to 40 MPH in traffic. When it stalls I lose power brakes and steering. I've had the vehicle at the dealer off and on for approximately two months and they are unable to fix the problem.”

   NHTSA complaint #10295117, filed 2009-12, 87,000 miles

   “While driving the truck the accelerator becomes nonresponsive and soon after the truck shuts down, complete power loss. Very difficult to steer and brake. It will start back up most of the time, but on occasion it will take 20 to 30 minutes to re-start. Ford has a recall for this # 05s34. My VIN indicates that my Excursion isn't under this recall, but this is exactly what is happening. This event happens on city streets and highways, while driving or sitting at a stop sign or stop light. …”

   NHTSA complaint #10926037, filed 2016-11, 88,000 miles
2. 2
   Engine

   6.0L diesel rough running, smoke and power loss

   • 11 complaints (17%)
   • median 62,158 mi at 5.6 yrs old (11 state mileage)
   • 2 mention a crash, fire or injury
   • filed 2007–2018

   Owners describe hard or no starts when cold, running rough enough to shake the truck, excessive white or black exhaust, surging and a lack of power, in some cases stalling after a cold start. Repairs mentioned include injectors, injector pressure components, the EGR valve and cooler, the turbocharger, and head gaskets on a vehicle that overheated while towing. Several complaints say the same symptom returned after repair, or that the dealer could not identify a cause. Commonly reported between roughly 55,000 and 145,000 miles; the cold-start complaints cluster in winter months.

   7 related service bulletins

   What to check: Have the engine checked cold: look for hard starting, white or black smoke and rough idle, and ask for service records covering injectors, the EGR system and any head gasket work.

   2 excerpts from owner complaints in NHTSA records

   “Vehicle was backing down the driveway and the motor started surging and blowing white smoke. I lost all power and slammed into my trailer. This is a known failure of the EGR valve I have had it replaced and cleaned five times. The truck loose all braking power and steering power when the truck dies. They have had many known and documented issues in the ambulance industry.”

   NHTSA complaint #10298991, filed 2010-01, 62,158 miles

   “I am so disappointed in purchasing this Ford truck....I have had this vehicle for 5 years and it has been in the shop on several occasions for the same reason...EGR valve gets stuck and I'm stuck on side the highway....I cannot trust this vehicle to get me to the corner store let alone a long distance trip. Although I loved my truck...the cost of these repairs have just been astronomical, not to mention the inconvenience of constant towing and days spent in the Ford service department. …”

   NHTSA complaint #10437952, filed 2011-12, 55,000 miles
3. 3
   Steering

   Steering wander, play and vibration

   • 7 complaints (11%)
   • median 69,430 mi at 9.0 yrs old (6 state mileage, few)
   • filed 2005–2025

   Complaints describe the vehicle wandering or pulling to one side, heavy steering play that requires constant correction to stay in a lane, and in one case the wheel jerking and wobbling at speed with no cause found by a mechanic. One owner also noted power steering fluid leaking at the hydroboost connection. Remedies in the complaints are limited, with some vehicles not diagnosed or repaired. Mostly reported between about 68,000 and 90,000 miles, with other reports at higher mileage.

   1 related service bulletin

   What to check: On a test drive, check for steering play, wander and vibration at highway speed, and inspect the power steering lines and hydroboost area for fluid seepage.

   2 excerpts from owner complaints in NHTSA records

   “While merging onto 75mph highway, without warning, vehicle lost all power making steering nearly impossible. We were able to move onto shoulder just at the point where highway and on ramp met. We could not restart vehicle and had we made it onto highway, could have very easily been rear ended by oncoming traffic. This is the second time we have lost complete power with this vehicle. We had same situation in july and had paid over two thousand dollars to have fuel system repaired. …”

   NHTSA complaint #10485907, filed 2012-11, 106,000 miles

   “Several times I’ll be driving and the steering wheel will jerk in one direction and wobble violently I will grab it to correct it and basically fight to keep it in the lane so I have to pull over and try again. I checked all steering components had it looked at by a mechanic and cannot figure out what could be the issue. It is very dangerous and terrifying to drive since it happens out of nowhere at random.”

   NHTSA complaint #11680694, filed 2025-08
4. 4
   Fuel system

   Fuel smell after filling the tank

   • 6 complaints (9%)
   • median 85,900 mi at 6.5 yrs old (6 state mileage, few)
   • filed 2007–2016

   Owners describe a strong gasoline smell after filling the tank halfway or more, noticed around the driver's side and rear of the vehicle. Other fuel-related complaints center on loss of throttle response and stalling, with repairs such as the injection pressure regulator and fuel pump mentioned. Fuel in the engine coolant due to injector-area leaks is described in a service bulletin for the diesel engine. Reported from about 84,000 to 97,000 miles in the sampled complaints.

   3 related service bulletins

   What to check: After a fill-up, check for fuel odor around the filler neck and under the vehicle, and ask whether the fuel system or injectors have had prior repairs.

   2 excerpts from owner complaints in NHTSA records

   “In december after I filled up my gas tank about 3/4 of the way. I drove home, and when I stepped out of my vehicle I started to smell a strong gas odor. Every time I fill up my gas tank half way or more, then drive any. I start smelling a strong gas odor. The smell seems to be coming from between the front of the left side passenger door , and the back left side wheel.”

   NHTSA complaint #10504634, filed 2013-03, 97,425 miles

   “We have had numerous incidents with our Excursion dating back to one week after we purchased it used from a local Ford dealership in july 2009 until now - sept. 2012. We began experiencing acceleration issues after the first week. We returned the vehicle to the dealership for a diagnostic evaluation. They replaced the ipr and fuel pump. This seemed to fix the problem until january 2011. In january 2011, the accelerator began failing again. It would just stop working. …”

   NHTSA complaint #10474336, filed 2012-09, 83,800 miles

Buying note. Look for records of the 05V270000 recall work and of diesel injector, EGR and head gasket repairs, and have a diesel-capable shop inspect the injection control module and cooling system. A careful highway test drive and an exterior-light check will show whether steering and lighting concerns are present.

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.