2004 Ford Excursion Engine Problems

REPEATEDLY EJECTS SPARK PLUGS FROM CYLINDER HEAD. *TR

ON 11/26/13 DRIVING BACK FROM ATLANTA HEADING SOUTH LEAVING THE FLORIDA WELCOME CENTER ON I-75, 4 MILES NORTH OF JENNINGS ON I-75 SOUTH JENNINGS. LEAVING THE WELCOME CENTER THE VEHICLES ENGINE LOST POWER WHILE TRYING TO MERGE BACK INTO TRAFFIC WITHOUT ANY PRIOR INDICATION OF A PROBLEM. THE LOSS OF POWER CAUSED US TO HAVE TO DIVERT FROM THE LANE UNTIL WE COULD GAIN MORE SPEED. THE VEHICLE HAD NO ACCELERATING POWER ABOVE 40 MPH EVEN WITH THE GAS PEDAL DEPRESSED ALL THE WAY TO THE FLOOR. THERE WERE NO CHECK ENGINE LIGHTS ON OR ANY ABNORMAL INDICATORS. I CALLED THE FORD CUSTOMER CARE CENTER ON 12/12/13 AND THEY ACKNOWLEDGE THEY HAVE A PROBLEM WITH THE ERG FAILING DUE TO COLLECTING CARBON AND SOOT BUILD UP. THEY HAVE NOT ISSUED ANY SERVICE BULLETINS TO OWNERS LETTING THEM KNOW THERE IS AN ISSUE OR HAVE ISSUED A MAINTENANCE PROGRAM TO TRY TO PREVENT THIS FROM OCCURRING. 1)FORD DESIGNED THE ENGINE TO PASS SOOT AND CARBON BACK THRU THE ERG VALVE. IT IS A BAD DESIGN SINCE IT CAUSES EVERY ENGINE TO EVENTUALLY FAIL. 2)FORD DOES NOT WARRANTY THE EGR VALVE OR ANY COMPONENT IF SOOT OR CARBON STICKS TO THE VALVE OR COMPONENT, EVEN THOUGH IT IS DESIGNED TO DO SO. 3)FORD KNOWS THERE IS AN ISSUE WITH THE EGR FAILING WHICH DEPOSITS SOOT AND CARBON IN THE INTAKE OF THE ENGINE WHICH CAUSES THE ENGINE TO LOSE POWER AND OR ULTIMATELY QUIT WITHOUT WARNING. 4)NO SERVICE BULLETINS WERE ISSUED TO OWNERS WARNING THEM OF THIS SAFETY PROBLEM. 5)CLEANING THE EGR VALVE IS NOT LISTED IN THE ISSUED SERVICE MANUAL. 6)NO PREVENTATIVE MAINTENANCE SERVICE WAS OFFERED TO PREVENT THIS FAILURE FROM OCCURRING. 7)DEALERS ENJOY THIS FAILURE SINCE IT IS A HIGH LABOR REVENUE GENERATOR FOR THEM TO TEAR DOWN THE ENGINE TO REPLACE OR CLEAN THE INTAKE MANIFOLD. 8)THE REPAIR COST WAS APPROXIMATELY $3319.90 THE VEHICLE IS CURRENTLY UNDER THE HIGHEST FORD PREMIUM CARE WARRANTY. *TR

TL* THE CONTACT OWNS A 2004 FORD EXCURSION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 30 TO 45 MPH, THE VEHICLE STALLED WITHOUT ANY WARNING. THE VEHICLE WAS LATER TOWED TO A DEALER. AFTER DIAGNOSIS, THE CONTACT WAS INFORMED THAT THE PROBLEM MAY BE THE FUSE NEAR THE TRANSMISSION. THE VEHICLE WAS REPAIRED. APPROXIMATELY THREE MONTHS LATER, THE FAILURE RECURRED. THE VEHICLE WAS TAKEN BACK TO THE DEALER. AFTER DIAGNOSIS, THEY ADVISED HER THAT THE FUSE FAILED AGAIN DUE TO THE BRACKET CHAFING THE WIRES. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS CONTACTED AND THEY OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 89,000. THE CURRENT MILEAGE WAS APPROXIMATELY 90,000. THE VIN WAS UNAVAILABLE.

VEHICLE ENGINE EJECTS SPARK PLUG FROM CYLINDER HEAD. *TR

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". *JS

TL* THE CONTACT OWNS A 2004 FORD EXCURSION. THE CONTACT STATED THAT UPON STARTING THE VEHICLE, A LARGE CLOUD OF SMOKE EMITTED FROM THE TAIL PIPE. THE FAILURE RECURRED ON AN INTERMITTENT BASIS. THE CONTACT ALSO STATED THAT THE ENGINE FAN WOULD INTERMITTENTLY CREATE A VERY LOUD NOISE. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND THE CONTACT WAS INFORMED THAT COOLANT WAS LEAKING INTO THE ENGINE. THE CONTACT WAS INFORMED THAT THE ENGINE WOULD NEED TO BE REBUILT. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE, BUT OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS 81,000. UPDATED 11/01/11*LJ THE CONSUMER STATED THE ENGINE EGR COOLER FAILURE RESULTED IN A SUDDEN LOSS OF COOLANT AND THERE WAS NO WARNING ON THE DASHBOARD FROM THE SERVICE ENGINE LIGHT. WHITE CLOUDS EMITTED FROM THE TAILPIPE AND AUXILIARY FAN ACTIVATION, WHICH WERE BOTH INTERMITTENT AND INCONSISTENT. THE FAILURE OCCURRED OVER A ONE WEEK PERIOD. WHEN THE CONSUMER STARTED THE VEHICLE HE NOTICED A BILLOWING OF WHITE CLOUDS COMING FROM THE TAILPIPE. THE BILLOWING CLOUDS STOPPED AS THE CONSUMER CONTINUED TO DRIVE, ONLY TO REAPPEAR INTERMITTENTLY OVER THE NEXT WEEK.

TL* THE CONTACT OWNS A 2004 FORD EXCURSION. THE CONTACT STATED WHEN DRIVING AT 50 MPH, THE VEHICLE WOULD SPORADICALLY STALL WITHOUT WARNING. THE CONTACT WAS ABLE TO RESTART THE VEHICLE AFTER SEVERAL ATTEMPTS. THE DEALER WAS UNABLE TO DUPLICATE THE FAILURE. THE MANUFACTURER ADVISED THE VEHICLE WAS NOT UNDER RECALL AND WOULD NOT PROVIDE ANY FURTHER ASSISTANCE. THE FAILURE AND CURRENT MILEAGES WERE 100,000.

TL* THE CONTACT OWNS A 2004 FORD EXCURSION. WHILE HAVING THE VEHICLE SERVICED FOR ROUTINE MAINTENANCE AT AN INDEPENDENT REPAIR SHOP, HE WAS INFORMED WATER WAS LEAKING AROUND THE EGR COOLER AND ANTI FREEZE WAS LEAKING INTO THE EXHAUST SYSTEM. THE VEHICLE WAS NOT REPAIRED AND THE FAILURE CONTINUES. THE FAILURE AND CURRENT MILEAGES WERE 95,000.

2004 FORD EXCURSION DIESEL WITH 6.0 ENGINE. THE ENGINE IS CRAP. THE FUEL INJECTORS ARE BAD IT'S A KNOWN PROBLEM. I WAS IN AN INTERSECTION WHILE MAKING A LEFT TURN WITH AN ON COMING VEHICLE WHEN I HAD NO ACCELERATION AND BLACK EXHAUST WAS COMING OUT OF THE TAIL PIPE. I HAD MY 3YR OLD DAUGHTER ON THAT SIDE OF THE VEHICLE. THIS ISN'T THE FIRST PROBLEM WE HAVE HAD WITH THIS ENGINE AS HAS ALMOST EVERYONE ELSE THAT OWNS IT. IT NEEDS TO BE RECALLED. IT SCARED ME SO BAD I CRIED. I HAVE CALLED THE FORD CONSUMER NUMBER THEY DID NOTHING. I AM PAYING FORD $1,500.00 TO FIX THE PROBLEM THAT I WAS TOLD WOULD CONTINUE TO HAPPEN BECAUSE IT'S A DEFECT IN THIS PARTICULAR ENGINE. IN THE WORDS OF ONE OF FORDS MECHANICS "HE WOULDN'T OWN ONE, THEY ARE CRAP" I'M SCARED TO DRIVE IT EVEN AFTER IT GETS FIXED KNOWING ANOTHER MAY GO SOON OR THE SAME ONE. *TR

TL*THE CONTACT OWNS A 2004 FORD EXCURSION. THE CONTACT STATED THAT THE TURBO CHARGER ON THE DIESEL ENGINE BROKE. THIS WAS CAUSED BY A MALFUNCTION WITHIN THE ENGINE. THERE WAS A 100,000 MILE WARRANTY ON THE VEHICLE AND THE FORD MANUFACTURER WOULD NOT HONOR IT. THE FAILURE MILEAGE WAS 78,318.

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. *TR

TL* THE CONTACT REPORTED THAT THE EXHAUST IS GOING INTO THE 2004 FORD EXCURSION. THIS HAS BEEN HAPPENING FOR 3 MONTHS. WHEN THE VEHICLE IS IDLE OR STOPPED AT A LIGHT THE EXHAUST COMES THROUGH THE HEATING GRATE. THE VEHICLE HAS 30000 THOUSAND MILES ON IT AND HAD 24000 MILES WHEN PROBLEM STARTED. THE DEALER HAS TRIED TO FIX THE PROBLEM BUT NOTHING HAS WORKED PERMANENTLY. THEY DRIVER IS SUFFERING HEADACHES AND DROWSINESS WHEN DRIVING. UPDATED 01/20/10 *BF THE DEALER REPLACED THE LEFT EXHAUST MANIFOLD GASKET. UPDATED 01/22/10. *JB

MY 2004 FORD EXCURSION JUST EJECTED A SPARK PLUG AND IT'S THREADED BUSHING. THIS IS A FACTORY DEFECT AND SHOULD BE ADDRESSED BY FORD AND/OR YOUR OFFICE. *TR

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. *TR

THIS VEHICLE HAS BEEN SERVICED COUNTLESS TIMES FOR STALLING. EACH TIME THE DEALER HAS REPLACED THE EGR VALVE AND OTHER ITEMS BECAUSE OF FAILURE CODES. EACH TIME THE EGR VALVE HAS FAILED. THE DEALER IS "REPAIRING" THE VEHICLE AND GIVING IT BACK TO ME. WITHIN 5 MINUTES AFTER RECEIVING THE VEHICLE FROM THE SERVICE DEPARTMENT, IT STALLS AGAIN. THE VEHICLE WILL STALL AT LEAST 3 TIMES DURING A 30 MINUTE DRIVE. IT STALLS ON THE FREEWAY, ON RESIDENTIAL STREETS, STARTING FROM A DEAD STOP, AND IF IT IS DRIVING AT A CONSTANT SPEED. THIS VEHICLE IS NOT FIXED AND IT IS OBVIOUS THE DEALER CANNOT FIX IT! IT IS GOING IN TOMORROW FOR THE 3RD TIME THIS MONTH FOR THE SAME PROBLEM. I HAVE ALMOST GOTTEN IN AN ACCIDENT FROM IT STALLING, AND I HAVE HAD MANY TIMES WHERE I HAVE BEEN IN A DANGEROUS SITUATION FROM IT STALLING. THE DEALER CANNOT FIX IT, I CANNOT SALE IT TO ANOTHER PERSON IN THIS CONDITION, AND FORD WON'T DO ANYTHING TO HELP ME. I AM DRIVING A VERY DANGEROUS VEHICLE AND HAVE NO WAY TO FIX IT. WHAT CAN I DO? PLEASE GIVE ME A SUGGESTION. DO I HAVE ANY RIGHTS IF THE VEHICLE CANNOT BE FIX? *TR

TL*THE CONTACT OWNS A 2004 FORD EXCURSION. WHILE DRIVING APPROXIMATELY 25 MPH, IDLING, OR PARKED, THE RPM'S BEGIN TO INCREASE FROM 2,000 TO 3,000 AUTOMATICALLY AND THE VEHICLE WILL OCCASIONALLY STALL. WHEN DRIVING AT LOW SPEEDS, THE RPM'S WILL INCREASE FROM 2,000 TO 5,000. THE VEHICLE HAS BEEN DIAGNOSED BY THE DEALER SEVERAL DIFFERENT TIMES, BUT THE FAILURE STILL PERSISTS. NHTSA CAMPAIGN ID NUMBER 05V270000 (ELECTRICAL SYSTEM:WIRING) WAS REFERENCED. THE CURRENT MILEAGE WAS 48,000 AND FAILURE MILEAGE WAS 15,000.

TL*THE CONTACT OWNS A 2004 FORD EXCURSION. WHILE DRIVING BETWEEN 35-40 MPH, THE VEHICLE STALLED AND THEN SHUT OFF. THE VEHICLE WAS TOWED TO A MECHANIC AND THEY REPLACED THE NUMBER 1 AND NUMBER 3 FUEL INJECTORS. THE DEALER STATED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER 05V270000 (ELECTRICAL SYSTEM:WIRING). THE CURRENT MILEAGE WAS 130,994 AND FAILURE MILEAGE WAS 108,480. UPDATED 09/10/08 *BF THE ALTERNATOR, CONTROL MODULE FOR THE HEATING AND AC SYSTEM, AND COOLING SYSTEM WERE REPLACED. UPDATED 09/19/08. *JB

DT*: THE CONTACT STATED WHILE DRIVING VARIOUS SPEEDS, THE ENGINE STALLED WITHOUT WARNING. THE VEHICLE WAS MANEUVERED OFF THE ROAD AND RESTARTED. THE VEHICLE WAS DRIVEN TO THE DEALER ON SEVERAL OCCASIONS FOR THE PROBLEM WHERE A TURBO AND A SENSOR WERE REPLACED. ALTHOUGH THE PROBLEM PERSISTED, THE DEALER WAS UNABLE TO DUPLICATE THE PROBLEM. UPDATED 1/10/2007 - *NM

MY VEHICLE'S ENGINE WILL SURGE AND STALL. SOMETIMES BOTH THINGS WILL HAPPEN ON A GIVEN DAY OR JUST ONE. I HAVE HAD MY VEHICLE STALL COMING TO A STOP AND OR DRIVING. MY VEHICLE'S ENGINE HAS SURGED AND CAUSED MY CAR TO MOVE EVEN WITH MY FOOT ON THE BRAKE. THIS HAS BEEN A ONGOING PROBLEM THAT FORD CAN NOT FIX. *AK

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.