The 2002 Excursion is Ford's largest SUV built on Super Duty truck bones. Engine choice matters enormously—the 7.3L Power Stroke is legendary for longevity, the 5.4L Triton has spark plug and cam phaser issues, and the 6.8L V10 suffers catastrophic spark plug ejection. All share the 4R100 transmission's oil cooler failure problem.
4R100 Transmission Internal Oil Cooler Failure
Common · high severityTypical onset: 100,000-150,000 mi
Symptoms: Transmission fluid in coolant (strawberry milkshake appearance in overflow), Coolant in transmission pan, Transmission slipping or delayed engagement, Engine overheating in some cases
Fix: Internal cooler in radiator fails, mixing fluids and destroying transmission. Requires radiator replacement, transmission flush or full rebuild if contamination went unnoticed. Complete job with transmission rebuild: 12-16 hours labor. Preventive external cooler install: 2-3 hours.
Estimated cost: $3,500-6,500
5.4L Triton Spark Plug Ejection and Cam Phaser Failure
Common · high severityTypical onset: 80,000-130,000 mi
Symptoms: Loud rattling on cold start (cam phasers), Sudden loss of power with hissing sound (blown plug), Misfires and rough idle, Check engine light with misfire codes
Fix: Two-valve 5.4L ejects spark plugs due to inadequate thread engagement (8 threads vs. 4). Requires thread repair inserts (TimeSert kit). Cam phasers rattle due to low oil pressure or wear—requires front cover removal, timing chains, phasers, tensioners. Plug repair per hole: 1-2 hours. Cam phaser job: 10-14 hours.
Estimated cost: $400-800 per plug ejection; $2,200-3,800 cam phasers
6.8L V10 Spark Plug Blowout
Common · high severityTypical onset: 60,000-100,000 mi
Symptoms: Loud pop or bang under acceleration, Immediate misfire on one cylinder, Visible damage to plug wire/coil boot, Loss of compression on affected cylinder
Fix: V10 has same 4-thread spark plug design as 5.4L but under higher cylinder pressures—plugs literally shoot out of heads. Must install thread repair inserts (HeliCoil or TimeSert). If caught early: 1.5-2.5 hours per hole. If aluminum head damage is severe, may require head removal or replacement: 12-18 hours.
Estimated cost: $350-700 per cylinder; $3,000-5,000 if head replacement needed
7.3L Power Stroke Injector O-Ring Leaks
Occasional · medium severityTypical onset: 150,000-250,000 mi
Symptoms: Hard starting when engine is hot, White smoke on startup, Fuel smell in oil (check dipstick), Rough idle that smooths out after warmup
Fix: Injector sleeve O-rings harden and leak, allowing fuel into crankcase or combustion chamber. Requires valve cover removal, injector extraction with slide hammer, new sleeves and O-rings. Best done as complete set. 8-12 hours labor for all eight injectors.
Estimated cost: $1,800-2,800
Front Hub Bearing Failures
Common · medium severityTypical onset: 80,000-120,000 mi
Symptoms: Grinding or humming noise that increases with speed, Vibration through steering wheel, ABS light intermittently (speed sensor integrated), Wheel play when jacked up
Fix: Dana 50/60 front axle uses unit bearings that fail from weight and stress. Bearings are relatively cheap but require hub socket and torque to 221 ft-lbs. 2-3 hours per side. Related recall issued for hub assemblies.
Estimated cost: $400-700 per side
Ball Joint Wear (Front Axle)
Common · high severityTypical onset: 70,000-110,000 mi
Symptoms: Clunking over bumps, Wandering or loose steering feel, Uneven tire wear on inside edges, Visual play when prying with bar
Fix: Upper and lower ball joints wear rapidly with Excursion's 7,000+ lb curb weight. Uppers fail first typically. Requires press or ball joint service tool, alignment after. Both sides, all four joints: 6-8 hours.
Estimated cost: $1,200-1,800
Exhaust Manifold Studs (5.4L/6.8L)
Occasional · medium severityTypical onset: 90,000-140,000 mi
Symptoms: Ticking noise on cold start that fades when warm, Exhaust leak smell in cabin, Visible soot around manifold-to-head junction, Loss of power under load
Fix: Manifold studs break in aluminum heads due to thermal cycling. Requires manifold removal, stud extraction (often heads come off if studs snap flush), re-tap or HeliCoil inserts. Per side: 4-6 hours if studs extract clean; 10-14 hours if heads come off.
Estimated cost: $800-1,400 per side; $2,500-4,000 if heads removed
Buy the 7.3L diesel without hesitation if maintained; avoid 5.4L/6.8L gas engines unless seller proves plug threads have been repaired and transmission cooler bypassed—otherwise you're buying someone else's $8,000 problem.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.