There are 4 owner-reported body & structure complaints for the 2002 Ford Excursionin NHTSA's database. These are unverified consumer reports and may not reflect confirmed defects.
LARGE PATCHES OF PAINT TOPCOAT PEELING FROM VEHICLE ROOF, ABSOLUTELY NO EVIDENCE OF PRIMER HAVING BONDED/ ADHERING TO SEPARATED TOPCOAT, PEELED PAINT IS IDENTICAL ON BOTH SIDES, OBVIOUSLY PRIMER INTENDED TO INTEGRATE TOPCOAT WITH SUBSTRATE WAS FAULTY AND NOT ACCEPTABLE.
MY 2002 FORD EXCURSION HAD A TOTAL BRAKE FAILURE RESULTING IN A NEAR FATAL SITUATION. WHEN THE VEHICLE WAS TOWED TO THE FORD DEALERSHIP, THEY FOUND A MANUFACTURING DEFECT. THE PLASTIC WHEEL WELL LINER ON THE FRONT LEFT WHEEL WAS POSITIONED AGAINST THE METAL BRAKE LINE FROM THE ABS PUMP AND FROM THE VEHICLE MOTION THE LINER HAD WORN A HOLE IN THE METAL LINE CAUSING TOTAL FAILURE OF THE BRAKE SYSTEM. THIS IS A VERY SERIOUS DESIGN DEFECT THAT NEEDS IMMEDIATE ATTENTION. *JB
2002 FORD EXCURSION. REAR GLASS SHATTERED AND FELL ON THE GROUND WHEN OUR CHILD ATTEMPTED TO CLOSE THE REAR GLASS AND THE TWO REAR GATES IN THE INCORRECT ORDER. THIS IS A DESIGN DEFECT AND POSES A SIGNIFICANT RISK TO HUMANS SHOULD THE REAR GLASS FALL ONTO A PERSON WHILE ATTEMPTING TO CLOSE THE REAR GLASS AND GATES. THE DEFECT IS THAT THE REAR GLASS AND THE LOWER GATES ARE DESIGNED SUCH THAT IF THEY ARE OPERATED IN THE INCORRECT FASHION, WITH THE UPPER GLASS LOWERED FIRST AND THEN THE LOWER GATES ATTEMPTED TO BE SWUNG CLOSED, THE LOWER GATES IMPINGE WITH A VERY LONG TORQUE ARM ON THE GLASS OF THE UPPER WINDOW, AND THE RESULTANT FORCE LITERALLY CAUSES THE UPPER GLASS TO SHATTER. THE SHATTERED "SAFETY GLASS" THEN FALLS ON THE GROUND AT THE OPERATOR'S FEET, OR WORSE, SOME OF THE SMALL AND VERY SHARP GLASS FRAGMENTS FLY HORIZONTALLY AND LAND ON THE OPERATOR OR OCCUPANTS. IN OUR CASE, A ADOLESCENT CHILD WAS THE OPERATOR, AND LUCKILY AVOIDED INJURY. THERE WERE THREE OTHER CHILDREN INSIDE THE REAR COMPARTMENT OF THE VEHICLE, AND GLASS SHOWERED INTO THE COMPARTMENT AND ONTO THEIR LEGS, BUT NO INJURIES WERE SUSTAINED. THE MANUFACTURER HAS BEEN CONTACTED, BUT THERE IS NO RECOURSE AT THIS POINT. THE MANUFACTURER HAS NO RECALL IN EFFECT. CURIOUSLY, I PERSONALLY KNOW OF FOUR OTHER SUCH INCIDENTS IN THE TOWN IN WHICH I LIVE, AND THOSE FOLKS ALSO FOUND NO RECOURSE WITH THE FORD DEALER OR THE MANUFACTURER.*AK
WHILE DRIVING 70 MPH CONSUMER ACTIVATED BOTH REAR WINDOWS, AS SOON AS THE WINDOWS WERE LOWERED, THE VEHICLE STARTED TO SHAKE VIOLENTLY, IT WAS DIFFICULT TO CONTROL VEHICLE, WHEN THE WINDOWS WERE CLOSED THE SHAKING STOPPED.*AK. CONSUMER CONTACTED THE MANUFACTURE AND WAS INFORMED THAT ALL THE EXCURSIONS ARE THAT WAY.*JB
Complaints are unverified consumer reports submitted to NHTSA. A high complaint count may reflect vehicle popularity, not defect severity. Data sourced from NHTSA public records.
Data synced from NHTSA on May 4, 2026