The 2000 Excursion is a truck-based SUV built on the Super Duty frame. The 7.3L Power Stroke is the most durable engine; the 5.4L and 6.8L Triton gas engines are plagued by spark plug and piston issues that can grenade motors if neglected.
5.4L/6.8L Triton Spark Plug Ejection and Blown Spark Plugs
Common · high severity
Typical onset: 80,000-150,000 mi
Symptoms: rough idle or misfire, Check Engine Light with P030x codes, loud popping noise from engine bay, loss of power
Fix: Early 2-valve Tritons have inadequate thread engagement for spark plugs. Plugs can blow out of the head, stripping threads, or break off during removal. Prevention: replace plugs every 60k with anti-seize. Repair requires HeliCoil inserts (1.5-2 hrs per hole) or cylinder head removal if severely damaged (8-12 hrs per head).
Estimated cost: $300-600 per plug if caught early; $2,500-4,500 if head removal needed
5.4L/6.8L Triton Piston Slap and Ring Land Failure
Occasional · high severity
Typical onset: 120,000-180,000 mi
Symptoms: loud knocking on cold start that fades when warm, excessive oil consumption (1+ qt per 1000 mi), white or blue smoke from exhaust, loss of compression
Fix: Poor piston skirt design causes slap; worn rings or cracked ring lands lead to catastrophic oil consumption. Once knocking is persistent hot, engine is toast. Requires complete engine rebuild or replacement (20-30 hrs labor for long block swap).
Estimated cost: $4,500-8,000
4R100 Transmission Overheating and Internal Cooler Failure
Common · high severity
Typical onset: 100,000-150,000 mi
Symptoms: transmission slipping or delayed engagement, burnt transmission fluid smell, check transmission light, coolant in transmission fluid or vice versa
Fix: Internal transmission cooler inside radiator can rupture, cross-contaminating coolant and ATF—destroys transmission quickly. Install external trans cooler as prevention. If cooler fails, requires transmission rebuild (12-16 hrs) plus radiator replacement (3 hrs). Flush cooling system thoroughly.
Estimated cost: $2,800-4,500
7.3L Power Stroke Fuel Bowl Heater O-Ring Failure
Common · medium severity
Typical onset: Any mileage, age-related
Symptoms: hard starting or no-start when cold, diesel fuel smell in cab or under hood, visible fuel leak on top of engine, loss of prime
Fix: O-rings under fuel bowl heater (top of engine) dry out and leak, causing air intrusion into fuel system. Simple fix but often misdiagnosed. Replace O-rings and refill fuel filter bowl (1-1.5 hrs).
Estimated cost: $150-300
7.3L Power Stroke Injector Stiction and Failure
Occasional · medium severity
Typical onset: 150,000-250,000 mi
Symptoms: rough idle especially when cold, extended cranking before start, black smoke on acceleration, loss of power, hard start after sitting overnight
Fix: HEUI injectors develop sticky solenoids or internal seal wear. Often starts with one or two injectors causing misfire codes. Individual injector replacement requires valve cover removal and special tools (2-3 hrs per injector). All 8 is 10-14 hrs labor.
Estimated cost: $400-700 per injector; $3,500-5,500 for all eight
Front Hub Bearing and Locking Hub Failure
Common · medium severity
Typical onset: 80,000-140,000 mi
Symptoms: grinding or humming from front end, wheel play when jacked up, ABS light, 4WD won't engage or stuck engaged
Fix: Unit bearings fail from weight and exposure. Manual locking hubs (if equipped) wear internally, causing vacuum leaks or mechanical failure. Replace hub bearings as pairs (2.5-3 hrs per side). Locking hubs are 1 hr per side.
Estimated cost: $600-1,200 for both hub bearings; $300-500 for both locking hubs
Fix: Heavy truck with heavy loads accelerates front-end wear. Upper and lower ball joints require press work (3-4 hrs per side for uppers/lowers). Tie rod ends are 2 hrs total. Alignment required after.
Estimated cost: $800-1,500 for ball joints both sides; $300-500 for tie rods
Exhaust Manifold Studs and Bolts Breaking (7.3L Power Stroke)
Occasional · low severity
Typical onset: 100,000+ mi
Symptoms: loud ticking from engine bay, exhaust smell in cab, sooty residue on manifold, loss of boost pressure if turbo side affected
Fix: Manifold studs corrode and snap due to heat cycling. Common on passenger side rear and driver side front. Requires manifold removal and stud extraction (4-6 hrs per side). Use ARP studs on reinstall.
Estimated cost: $600-1,200 per side
Owner tips
7.3L buyers: check for fuel bowl leaks, test drive for injector stiction at cold start, add aftermarket transmission cooler immediately
5.4L/6.8L buyers: verify spark plug change history—if none documented past 100k, budget for potential head work or walk away
All models: inspect frame and body mounts for rust (especially northern trucks), and test 4WD engagement in all modes
Change transmission fluid every 30k with Mercon V, not 'lifetime' fluid—4R100 cannot handle neglect at this weight
Front suspension wears fast—budget $1,500-2,000 for front end refresh if buying high-mileage
Buy the 7.3L diesel version under 200k miles with service records and walk away from any 5.4L or 6.8L with unknown plug history—those are grenades with pins pulled.
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.
Fitment notes: Heavy-duty battery required for V10 engine; located under hood on passenger side
As an Amazon Associate and Autel/ANCEL partner, OLP earns from qualifying purchases — how we link. This never changes the specs we publish.
Control Modules — 2000 Ford Excursion
Every control module on the 2000-2005 Ford Excursion — where it lives, replacement time, and what it takes to program a replacement. Modules marked dealer / factory tool won't work after a part swap alone — budget for programming.
📍 4R100 transmission: integrated into valve body inside transmission; TorqShift 5R110W (2003-2005 diesel): external on driver side of transmission case
🔧 Ford NGS/IDS + Service Function Card
⚠️ 4R100 requires transmission pan removal; TorqShift external module is easier access but still requires VIN programming and adaptive relearn
Transfer Case Control Module (TCCM)1.8 hr R&Rrelearn only +0.3 hr4WD models with electronic shift▸ programming details
📍 attached to transfer case on driver side
🔧 scan tool for shift relearn
⚠️ Controls electronic shift motor; requires shift pattern relearn after replacement; 2WD models have no transfer case
📍 integrated within PCM and GEM/SJB; no standalone module
🔧 Ford NGS/IDS
⚠️ Key programming requires both PCM and GEM/SJB communication; minimum two programmed keys required for self-programming additional keys
Aftermarket tool coverage varies by software version and vehicle build — treat "aftermarket tool" rows as "usually possible" and verify against your tool maker's coverage list before promising a customer. Spot a wrong location or hour? Tell us — corrections ship fast here.
FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002 MERCURY MOUNTAINEER, 1995-1997 AND 2001-2003 RANGER, AND 1994 F53 VEHICLES EQUIPPED WITH THE TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCH (SCDS). THE SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
Consequence: A VEHICLE FIRE COULD OCCUR WITH OR WITHOUT THE ENGINE RUNNING.
Remedy: FORD WILL NOTIFY OWNERS THAT DEALERS WILL INSTALL A FUSED WIRING HARNESS IN LINE WITH THE SCDS. ON 1999-2003 WINDSTAR VEHICLES WITH A LEAKING SCDS, DEALERS WILL ALSO INSPECT THE ABS CONTROL MODULE CONNECTOR AND REPAIR AS NECESSARY. REPAIRS WILL BE COMPLETED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON OCTOBER 27, 2009. OWNERS MAY CONTACT FORD AT 1-888-222-2751.
WHEELS:HUB · 07E106000
2007-12-17
CERTAIN FEDERAL-MOGUL REPLACEMENT WHEEL HUB ASSEMBLIES WITH THE BRAND NAMES: NATIONAL, CARQUEST P/NOS. 515020, 515021, 515025, 515053, 515054, 515059, AND 515060, SHIPPED BETWEEN JANUARY 23, 2006, AND DECEMBER 20, 2007, SOLD FOR LIGHT DUTY AND MEDIUM DUTY TRUCKS. THE INBOARD RETENTION NUT USED TO MAINTAIN HUB BEARING ASSEMBLY CAN LOOSEN RESULTING IN AN ABS LIGHT INDICATION, NOISE, AND/OR WHEEL SEPARATION.
Consequence: WHEEL SEPARATION CAN RESULT IN A VEHICLE CRASH.
Remedy: FEDERAL-MOGUL WILL NOTIFY CUSTOMERS AND WILL REPLACE THE HUB ASSEMBLY FREE OF CHARGE. THE RECALL BEGAN ON FEBRUARY 7, 2008. OWNERS CAN CONTACT FEDERAL-MOGUL TOLL-FREE AT 877-489-6659.
ENGINE AND ENGINE COOLING:ENGINE:DIESEL · 07V553000
2007-12-05 · EA06012
ON CERTAIN HEAVY DUTY TRUCKS EQUIPPED WITH 7.3L DIESEL ENGINES, THE CAMSHAFT POSITION SENSOR LOCATED ON THE ENGINE OF THE VEHICLE MAY FUNCTION INTERMITTENTLY, POSSIBLY RESULTING IN AN ENGINE STALL.
Consequence: IN THE EVENT OF AN ENGINE STALL, A CRASH COULD RESULT WITHOUT WARNING.
Remedy: DEALERS WILL INSPECT THE SENSOR AND REPLACE IT WITH AN IMPROVED CAMSHAFT POSITION SENSOR FREE OF CHARGE. THE RECALL BEGAN ON DECEMBER 29, 2007. OWNERS MAY CONTACT FORD AT 1-866-436-7332.
VEHICLE SPEED CONTROL · 06V286000
2006-08-01 · EA05005
ON CERTAIN TRUCKS EQUIPPED WITH SPEED CONTROL, GASOLINE OR NATURAL GAS ENGINES, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT.
Consequence: OVERHEATING COULD RESULT IN SMOKE OR BURN AND AN UNDERHOOD FIRE.
Remedy: DEALERS WILL INSTALL A FUSED WIRING HARNESS INTO THE SPEED CONTROL SYSTEM FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 7, 2006. OWNERS MAY CONTACT FORD AT 1-866-436-7332. (NOTE: ALSO SEE RECALLS 05V017 AND 05V388)
VEHICLE DESCRIPTION: PASSENGER CARS, SPORT UTILITY VEHICLES, AND LIGHT AND MEDIUM DUTY PICKUP TRUCKS. A SWITCH LOCATED IN THE PLASTIC COVER OF THE WIPER MOTOR GEAR CASE COULD MALFUNCTION AND OVERHEAT, POTENTIALLY RESULTING IN LOSS OF INTERMITTENT WIPER FUNCTION, LOSS OF WIPER PARK FUNCTION, COMPLETE LOSS OF WIPER FUNCTION, OR IGNITION OF THE PLASTIC COVER MATERIAL. SWITCH MALFUNCTION IS MOST LIKELY TO OCCUR WHEN THE INTERMITTENT SETTING OF THE WIPERS IS BEING USED, OR WHEN SNOW OR ICE OBSTRUCTS THE BLADES FROM RETURNING TO THE "PARKED" POSITION AT THE BOTTOM OF THE WINDSHIELD. THESE VEHICLES WERE BUILT AT THE FOLLOWING ASSEMBLY PLANTS: ATLANTA PLANT FROM 2/11/00 THROUGH 7/31/00; CHICAGO PLANT FROM 2/14/00 THROUGH 8/4/00; KANSAS CITY PLANT FROM 2/26/00 TO 9/4/00; KENTUCKY TRUCK PLANT FROM 2/18/00 TO 8/31/00; MICHIGAN TRUCK PLANT FROM 2/23/00 THROUGH 8/3/00; NORFOLK PLANT FROM 2/21/00 THROUGH 7/27/00; WAYNE STAMPING AND ASSEMBLY PLANT FROM 2/25/00 THROUGH 8/15/00; AND WIXOM PLANT FROM 2/15/00 THROUGH 8/8/00.
Consequence: LOSS OF VISIBILITY WHILE DRIVING INCREASES THE RISK OF A CRASH.
Remedy: DEALERS WILL INSPECT THE DATE CODE ON THE WIPER MOTOR. MOTORS BUILT WITH THE SUSPECT TIME FRAME WILL HAVE THE WIPER MOTOR GEAR CASE COVER REPLACED. OWNER NOTIFICATION BEGAN AUGUST 20, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-866-436-7332.
EXTERIOR LIGHTING:HEADLIGHTS:SWITCH · 01V075000
2001-03-12
VEHICLE DESCRIPTION: PASSENGER AND SPORT UTILITY VEHICLES. DUE TO THE USE OF INCORRECT MATERIAL BY A SUPPLIER, THE HEADLAMP SWITCH KNOB CAN FRACTURE AND SEPARATE FROM THE HEADLAMP SWITCH.
Consequence: THIS WOULD CAUSE DIFFICULTY FOR THE DRIVER TO ACTIVATE THE HEADLAMPS, WHICH COULD AFFECT DRIVER VISIBILITY, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL REPLACE THE HEADLAMP SWITCH KNOB. OWNER NOTIFICATION BEGAN APRIL 9, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-800-392-3673.
Vehicle Info — 2000 Ford Excursion
Performance
Horsepower
310hp
Torque
425lb-ft
0–60 mph
10.8sec
Quarter mile
18.2sec
Top speed
105mph
Capability & size
Towing capacity
11,000lb
Payload
1,920lb
Curb weight
7,200lb
Wiper blades
First year of Excursion production. Large SUV with rear wiper standard.
Size-standard part numbers — verify your connector type before buying. Rear blades are model-specific; check the package's vehicle list.
Fuel economy figures are EPA data via fueleconomy.gov (median across matching trims). Performance figures are compiled estimates for the 2000 Ford Excursion 6.8L V10 Triton and can vary by trim.
🔧 Built by master technician Chris Hackleman · Master Technician · 20+ years.