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 severity
Typical 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 severity
Typical 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 severity
Typical 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 severity
Typical 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 severity
Typical 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 severity
Typical 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 severity
Typical 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
Owner tips
Install auxiliary transmission cooler IMMEDIATELY if buying any gas model—bypasses the deadly internal radiator cooler
If purchasing 5.4L or 6.8L, budget for spark plug thread repair as preventive maintenance—replace plugs every 60k with anti-seize and proper torque
7.3L Power Stroke: change oil every 5k miles with Motorcraft or Rotella T6, fuel filters every 15k—this engine will outlast the truck
Grease front end every oil change—Dana axle ball joints and tie rods need it with this much weight
Check transmission fluid color every month—catch the strawberry milkshake early and you might save $4,000
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.
Fitment notes: Heavy-duty application for full-size SUV; located under hood on passenger side
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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 CERTAIN MODEL YEAR 2011 RANGER TRUCKS BUILT FROM JANUARY 25, 2011, THROUGH APRIL 25, 2011 AT THE TWIN CITIES ASSEMBLY PLANT, AND SERVICE PARTS DISTRIBUTED TO DEALERS FOR CERTAIN 2004 THROUGH 2011 MODEL YEAR RANGER TRUCKS, 2002 THROUGH 2005 MODEL YEAR EXCURSION VEHICLES, AND 2002 THROUGH 2007 MODEL YEAR F-250, F-350, F-450, AND F-550 TRUCKS FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THE MULTI-FUNCTION SWITCH WAS SHIPPED WITH A SUBCOMPONENT (SLIDER) THAT MAY EXPERIENCE DEFORMATION. A MULTI-FUNCTION SWITCH WITH A DEFORMED SLIDER MAY MALFUNCTION CAUSING THE TURN SIGNAL, TAIL LIGHTS, HAZARD WARNING SIGNAL FLASHERS AND/OR BRAKE LIGHTS NOT TO ACTIVATE.
Consequence: NON-FUNCTIONING LIGHTS COULD INCREASE THE RISK OF A CRASH.
Remedy: DEALERS WILL REPLACE THE SWITCHES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 15, 2011. OWNERS MAY CONTACT FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.
VEHICLE SPEED CONTROL · 09V399000
2009-10-13 · EA08021
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)
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 2002 Ford Excursion 5.4L V8 Triton and can vary by trim.
🔧 Database maintained under the daily editorial review of Chris Hackleman · Master Technician · 20+ years and Jeff Moore · Master Lexus & Toyota Mechanic · 20+ years.