Owners have filed 150 complaints
about the 2002 Ford Excursion with NHTSA between 2002 and 2023.
The largest single group is the engine & cooling.
Across this model's run it ranks 4 of 7 worst.
The letter says how bad. This says what kind — whether this year drew
an unusual number of complaints, unusually dangerous
ones, or failures that arrived unusually early.
The dashed ring is 50 — the national norm. Further out is worse.
Complaint volume — 38
Against the median year of the Ford Excursion. 50 means typical for this
model; 100 means roughly double.
Severity — 100
21.3% of these complaints
involved a crash, fire, injury or death, against a national rate of
9.7%.
Early failure — 41
24% of failures with a mileage on record happened under
36,000 miles, against a national rate of
29%.
NHTSA files every complaint against a named sub-assembly, not just a
system. This is the difference between knowing it was "the engine" and
knowing which part of it — the list to hand a mechanic.
Odometer readings owners gave when they filed. About half of all
complaints include one.
1,000 – 9,999 miles
44.2%
10,000 – 24,999 miles
44.2%
25,000 – 49,999 miles
2829.2%
50,000 – 74,999 miles
1818.8%
75,000 – 99,999 miles
1717.7%
100,000 – 149,999 miles
1515.6%
150,000+ miles
1010.4%
NHTSA crash tests
The agency crash-tested this model year itself. These are its own
photographs and star ratings.
These stars come from the pre-2011 crash test programme. NHTSA
rebuilt the programme for the 2011 model year and states that
ratings either side of that change are not comparable — so do
not read these against a 2011-or-newer car's stars.
Configuration
Overall
Front
Side
Rollover
2002 Ford Excursion 4-DR
—
—
—
—
When owners complained
A spike years after the car went on sale usually means a part wearing
out on schedule across the whole fleet — the kind of pattern no single
owner can see from inside their own car.
Feb 2002peak 9Sep 2023
NHTSA investigations into the 2002 Ford Excursion
An investigation is the step before a recall: the agency has seen enough
complaints to look into a pattern itself. An open one means it thinks
something may be wrong and nothing has been fixed yet.
DP05005Opened 22 Sep 2005Closed 4 Jan 2006ENGINE AND ENGINE COOLING:ENGINE
SPARK PLUG EJECTION FROM CYLINDER HEAD
ON SEPTEMBER 6, 2005, ODI RECEIVED A PETITION REQUESTING THAT THE AGENCY INVESTIGATE ALLEGATIONS OF ENGINE SPARK PLUG EJECTION IN CERTAIN MODEL YEAR 1997 THROUGH 2004 FORD VEHICLES WITH TRITON V-8 AND V-10 ENGINES.ODI RECEIVED A TOTAL OF 474 NON-DUPLICATIVE COMPLAINTS ON THE SUBJECT VEHICLES WHERE THE COMPLAINANT, OR THE DEALER REPAIRING THE VEHICLE, REPORTED THAT A SPARK PLUG DETACHED FROM THE CYLINDER AND/OR EJECTED FROM THE ENGINE.AS OF DECEMBER 8, 2005, ODI IS NOT AWARE OF ANY ALLEGATIONS WHERE THE ALLEGED DEFECT RESULTED IN A LOSS OF VEHICLE CONTROL, A CRASH, AN INJURY, OR A FATALITY IN A...
EA05005Opened 22 Mar 2005Closed 2 Aug 2006ELECTRICAL SYSTEM
ENGINE COMPARTMENT FIRES
EA05-005 IS CLOSED WITH FORD?S ACTIONS IN RECALLS 05V-017, 05V-388, AND 06V-286, RECALLING APPROXIMATELY 6.7 MILLION VEHICLES EQUIPPED WITH TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCHES (SCDS).THE BRAKE SYSTEMS IN THESE RECALLED VEHICLES GENERATE A VACUUM THAT CAN POTENTIALLY CAUSE THE SCDS TO FAIL AND, IN CERTAIN SWITCH INSTALLATION ORIENTATIONS, CATCH FIRE.FORD IS ALSO INCLUDING THE ENTIRE POPULATION OF 1998 EXPLORERS.FORD HAS INFORMED ODI THAT TESTING TO DETERMINE THE CAUSE OF FAILURES IN THE 1998 EXPLORERS WILL CONTINUE AFTER THIS INVESTIGATION IS CLOSED.ODI BELIEVES THAT THE VEHIC...
EA04006Opened 23 Feb 2004Closed 10 Feb 2005VEHICLE SPEED CONTROL:ACCELERATOR PEDAL
ACCELERATOR PEDAL SENSOR (ETC)
FAILURE COUNTS FROM ODI?S ANALYSIS ARE STATED ABOVE; SEE THE ADDITIONAL PROBLEM EXPERIENCE DISCUSSION IN THE SUMMARY REPORT.FORD DATA CONTAINED DUPLICATIVE REPORTS FOR 4 ODI COMPLAINTS AND 1 CRASH.THREE CRASHES WERE ALLEGEDLY DUE TO INTERMITTENT OPERATION OF THE ELECTRONIC THROTTLE CONTROL (ETC) PEDAL, ONE CRASH OCCURRED WHEN AN ETC DISABLED VEHICLE WAS STRUCK BY ANOTHER MOTORIST, ONE REPORT CONTAINED NO DETAIL.THE INJURIES WERE MINOR.AN ISSUE INVOLVING FIXED ETC PEDALS WAS INVESTIGATED ALSO, HOWEVER FAILURE REPORTS AND POPULATIONS ARE NOT SHOWN ABOVE; SEE SUMMARY REPORT FOR DETAIL.ALTHOUGH FO...
PE03044Opened 26 Sep 2003Closed 18 Feb 2004VEHICLE SPEED CONTROL:ACCELERATOR PEDAL
ACCELERATOR PEDAL SENSOR FAILURE (ETC)
THE SUBJECT VEHICLES FOR THIS INVESTIGATION INCLUDE MODEL YEAR 2002 AND 2003 EXCURSION AND F SUPER DUTY TRUCKS EQUIPPED WITH 7.3L DIESEL ENGINES AND AN OPTIONAL POWER ADJUSTABLE PEDAL (PAP) FEATURE.THE SUBJECT VEHICLES UTILIZE AN ELECTRONIC THROTTLE CONTROL (ETC) SYSTEM TO CONTROL ENGINE SPEED AND POWER.THE ACCELERATOR PEDAL POSITION SENSOR OF THE ETC SYSTEM WAS REPLACED UNDER FORD'S FIELD SERVICE ACTION (FSA) 03B03 (ANNOUNCED IN FEBRUARY 2003) DUE TO CONCERNS THAT IT MAY NOT OPERATE AS DESIGNED AND AS A RESULT, MAY CAUSE THE VEHICLE TO CONTINUE TO IDLE OR UNEXPECTEDLY SLOW WHEN THE ACCELERATO...
Recalls on the 2002 Ford Excursion
A complaint is one owner's allegation. A recall is the point at which
the manufacturer or a regulator agreed the defect is real and dangerous
enough to fix for free — however old the car is.
United States — NHTSA
11V352000
EXTERIOR LIGHTING:TAIL LIGHTS
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.
Risk: NON-FUNCTIONING LIGHTS COULD INCREASE THE RISK OF A CRASH.
09V399000
VEHICLE SPEED CONTROL
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.
Risk: A VEHICLE FIRE COULD OCCUR WITH OR WITHOUT THE ENGINE RUNNING.
07E106000
WHEELS:HUB
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.
Risk: WHEEL SEPARATION CAN RESULT IN A VEHICLE CRASH.
07V553000
ENGINE AND ENGINE COOLING:ENGINE:DIESEL
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.
Risk: IN THE EVENT OF AN ENGINE STALL, A CRASH COULD RESULT WITHOUT WARNING.
06V286000
VEHICLE SPEED CONTROL
ON CERTAIN TRUCKS EQUIPPED WITH SPEED CONTROL, GASOLINE OR NATURAL GAS ENGINES, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT.
Risk: OVERHEATING COULD RESULT IN SMOKE OR BURN AND AN UNDERHOOD FIRE.
Canada — Transport Canada
Canada runs its own recall programme, and its campaigns do not
always mirror the American ones.
Recall 20112515,815 units in Canada
Lights And Instruments
On certain 2011 Ranger vehicles, the multi-function switch, installed during vehicle assembly, could malfunction and fail. Additionally, other vehicle models may have received the affected switch as a replacement part during service, and are therefore also involved in this campaign. Failure of the multi-function switch could result in a loss of turn signal, tail lamp, hazard warning signal flasher and/or stop lamp function. Failure of these lighting components to illuminate may result in the following road users being unaware of the driver's intentions, as well as reducing vehicle conspicuity during hours of darkness, which could increase the risk of a crash causing property damage and/or personal injury. Correction: Dealers will inspect and, if necessary, replace the multi-function switch.
Recall 2009292492,877 units in Canada
Other
On certain vehicles, the speed control deactivation switch may overheat, smoke, or burn, potentially resulting in an underhood fire. The condition may occur either when the vehicle is parked or when it is in operation. Correction: Dealers will install a new switch or fused wiring harness. Note: This is an expansion of recall 2005028 (05S28) for vehicles not previously included in the campaign.
Recall 200740395,484 units in Canada
Engine
On certain vehicles equipped with a 7.3L diesel engine, the camshaft position sensor may fail, causing the engine to stall. Engine stalling would result in lost propulsion which, in conjunction with traffic and road conditions, and the driver's reactions, could increase the risk of a crash. Correction: Dealers will inspect and, if required, replace the camshaft position sensor.
Recall 2005028304,417 units in Canada
Electrical
On certain vehicles, the speed control deactivation switch may overheat, smoke, or burn, potentially resulting in an underhood fire. The condition may occur either when the vehicle is parked or when it is in operation. Correction: Initially as an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available, owners will be instructed to return to the dealers for installation of a new switch or fused wiring harness.
Reports where the owner recorded a crash, a fire, an injury or a death.
at 136,896 milesBaker, FLCrash
WHEELS
HAD A B F GOODRICH LT315/75R16D ALL TERRAIN KO, DOT: BFAUHX111211, FRONT LEFT TIRE EXPLODE WITHOUT ANY WARNING, WAS DRIVING NORTH ON HIGHWAY 65, ABOUT 16 MILES SOUTH OF BRANSON, MO. I WAS TRAVELING AROUND 65 MPH IN THE RIGHT HAND LANE ON A CLEAR DRY DAY WITH MINIMAL TRAFFIC. THE TIRES WERE PURCHASED ON 4-23-11, SAM'S CLUB #6361, VEHICLE HAD 91,461 MILES. THE INCIDENT HAPPENED ON 5-8-18, THE VEHICLE HAD 136,896 MILES. (45,435 MILES). WHEN THE TIRE EXPLODED IT SEVERED THE FRONT LEFT BRAKE LINE RESULTING IN THE LOSS OF CONTROL OF THE VEHICLE, CAUSING MAJOR DAMAGE TO THE VEHICLE, RESULTING IN THE VEHICLE BEING TOTALED.
NHTSA complaint #11098027 — an unverified report by a vehicle owner.
at 259,000 milesHollywood, MDCrash
STEERING
WHILE BACKING THE VEHICLE I FELT A POP AND THEN THERE WAS NO STEERING CONTROL. I LOOKED UNDER THE VEHICLE AND FOUND THAT THE TIE ROD CONNECTION TO THE PITMAN ARM HAD SNAPPED.
NHTSA complaint #11062779 — an unverified report by a vehicle owner.
Hamlet, NCFire
SERVICE BRAKES
TL* THE CONTACT OWNS A 2002 FORD EXCURSION. THE CONTACT STATED THAT WHILE TRAVELING 55 MPH AND APPLYING THE BRAKES, THERE WAS AN ABNORMAL NOISE HEARD FROM THE BRAKING SYSTEM. THE BRAKE PEDAL BECAME STUCK AND THE VEHICLE WOULD NOT SLOW DOWN. THE CONTACT CONTINUED TO PUMP THE BRAKES AND WAS ABLE TO COAST TO A STOP. THE CONTACT LATER PARKED THE VEHICLE AND NOTICED THAT A FIRE HAD STARTED FROM UNDER THE VEHICLE. THE CONTACT WAS ABLE TO EXTINGUISH THE FIRE HOWEVER, THE TRANSMISSION AND CENTRAL COMPUTER WAS DESTROYED. THE VEHICLE WAS TOWED TO A DEALER WHERE THE TRANSMISSION COMPUTER MODULE, TRANSMISSION AND THE BRAKE BOOSTER WAS REPLACED. THE DEALER ADVISED THAT THE BRAKE BOOSTER LEAKED ONTO THE TRANSMISSION AND THE FRONT DRIVE SHAFT, CAUSING THE VEHICLE TO CATCH ON FIRE. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO THE DEALER THREE WEEKS PRIOR TO FIRE AND THERE WAS NO INDICATION OF A POTENTIAL FAILURE. THE FAILURE MILEAGE WAS UNKNOWN. THE CURRENT MILEAGE WAS 190,000.
NHTSA complaint #10496815 — an unverified report by a vehicle owner.
at 110,000 milesPort Townsend, WAFire
VEHICLE SPEED CONTROL
TL* THE CONTACT OWNS A 2002 FORD EXCURSION. THE VEHICLE WAS PARKED IN THE CONTACTS DRIVEWAY AND CAUGHT ON FIRE. THE VEHICLE WAS TOWED TO THE DEALER WHERE THEY REPLACED THE VEHICLE SPEED CONTROL SWITCH BUT THEY REFUSED TO COVER THE POWER DISTRIBUTION JUNCTION BOX, WHERE THE FIRE ORIGINATED. THE CONTACT STATED THAT THE ENTIRE WIRING FUSE BOX WAS MELTED. THE DEALER ADVISED THAT THE REPLACEMENT PARTS WOULD BE AT THE CONTACTS EXPENSE. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 110,000.
NHTSA complaint #10364978 — an unverified report by a vehicle owner.
Levittown, PACrash
TRAILER HITCHES
2002 FORD EXCURSION, THE HITCH ON THE VEHICLE BROKE, CAUSING IT TO JACK KNIFE, GO OFF THE RIGHT SIDE OF THE ROADWAY AND STRIKE THE MEDIAN WALL. *BF (OHIO TRAFFIC CRASH REPORT # 10-0368-91)
NHTSA complaint #10345517 — an unverified report by a vehicle owner.
at 82,000 milesAustin, TXFire
ENGINE AND ENGINE COOLING:ENGINE
TL*THE CONTACT OWNS A 2002 FORD EXCURSION. WHILE THE VEHICLE WAS PARKED IN THE DRIVEWAY, IT BURST INTO FLAMES WITHOUT WARNING. THE VEHICLE WAS COMPLETELY DESTROYED. THE FIRE DEPARTMENT WAS CALLED TO THE SCENE AND A REPORT WAS FILED. THE REPRESENTATIVE STATED THAT THE FAILURE ORIGINATED FROM THE ENGINE. THE VIN WAS UNKNOWN. THE FAILURE AND CURRENT MILEAGES WERE 82,000.
NHTSA complaint #10237328 — an unverified report by a vehicle owner.
The most recent complaints
In the owners' own words, exactly as filed with NHTSA.
Kalamazoo, MI
POWER TRAIN
As I was driving the transfer case and drive shaft dropped out of truck. Broken bolts and no warning.
NHTSA complaint #11546512 — an unverified report by a vehicle owner.
Kalamazoo, MI
SUSPENSION
As I was driving the transfer case and drive shaft dropped out of truck. Broken bolts and no warning.
NHTSA complaint #11546512 — an unverified report by a vehicle owner.
at 201,352 milesSouth River, NJ
STRUCTURE:BODY
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.
NHTSA complaint #11405439 — an unverified report by a vehicle owner.
at 210,000 milesKillen, AL
ENGINE
TL* THE CONTACT OWNS A 2002 FORD EXCURSION. THE CONTACT STATED THAT EACH TIME SHE DROVE THE VEHICLE, IT STALLED WITHOUT WARNING. AFTER THE FAILURES, ALL THE WARNING INDICATORS ILLUMINATED ON THE INSTRUMENT PANEL. THE CONTACT COASTED THE VEHICLE OVER TO THE SIDE OF THE ROAD AND WAITED A MINUTE OR MORE TO RESTART THE VEHICLE. SOMETIMES, IT TOOK UP TO FOUR ATTEMPTS BEFORE THE VEHICLE WOULD RESTART. WHEN THE VEHICLE WAS RESTARTED, IT HESITATED TO MOVE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED, BUT THE TECHNICIAN COULD NOT FIND A FAILURE CODE. THE VEHICLE WAS NOT TAKEN TO A DEALER AND WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURES AND INFORMED THE CONTACT THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 07V553000 (ENGINE AND ENGINE COOLING). NO FURTHER ASSISTANCE WAS OFFERED. THE APPROXIMATE FAILURE MILEAGE WAS 210,000.
NHTSA complaint #11253362 — an unverified report by a vehicle owner.
at 170,000 milesCosta Mesa, CA
TIRES:TREAD/BELT
TL* THE CONTACT OWNS A 2002 FORD EXCURSION EQUIPPED WITH TOYO OPEN COUNTRY R/T TIRES (NA), SIZE: LT285/75/R16. WHILE DRIVING 65 MPH, THE REAR PASSENGER TIRE EXPERIENCED TREAD SEPARATION. PRIOR TO THE FAILURE, THE REAR DRIVER'S TIRE WAS REPLACED BY ALLEN TIRE (LOCATED AT 1725 SUPERIOR AVE, COSTA MESA, CA 92627, (949) 646-5236) DUE TO A BULGE IN THE TIRE. THE CONTACT STATED THAT THERE WAS DAMAGE TO THE VEHICLE. THE SET OF TIRES WERE A REPLACEMENT SET. THE TIRE WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 14T014000 (TIRES). THE MANUFACTURER WAS CONTACTED. THE APPROXIMATE VEHICLE FAILURE MILEAGE WAS 170,000 AND THE TIRE FAILURE MILEAGE WAS 75,000.
NHTSA complaint #11218329 — an unverified report by a vehicle owner.
at 136,896 milesBaker, FLCrash
WHEELS
HAD A B F GOODRICH LT315/75R16D ALL TERRAIN KO, DOT: BFAUHX111211, FRONT LEFT TIRE EXPLODE WITHOUT ANY WARNING, WAS DRIVING NORTH ON HIGHWAY 65, ABOUT 16 MILES SOUTH OF BRANSON, MO. I WAS TRAVELING AROUND 65 MPH IN THE RIGHT HAND LANE ON A CLEAR DRY DAY WITH MINIMAL TRAFFIC. THE TIRES WERE PURCHASED ON 4-23-11, SAM'S CLUB #6361, VEHICLE HAD 91,461 MILES. THE INCIDENT HAPPENED ON 5-8-18, THE VEHICLE HAD 136,896 MILES. (45,435 MILES). WHEN THE TIRE EXPLODED IT SEVERED THE FRONT LEFT BRAKE LINE RESULTING IN THE LOSS OF CONTROL OF THE VEHICLE, CAUSING MAJOR DAMAGE TO THE VEHICLE, RESULTING IN THE VEHICLE BEING TOTALED.
NHTSA complaint #11098027 — an unverified report by a vehicle owner.
Canoga Park, CA
POWER TRAIN
WAS DRIVING ON HIGHWAY AND VEHICLE ALL OF A SUDDEN LOST POWER KEPT PRESSING THE GAS PEDAL AND IT WOULDN'T GO AS FELT LIKE YOU WANTED TO TURN OFF IT WOULD STALL WE HAVE CHECKED EVERYTHING IN THE TRUCK ENGINE EVERYTHING AND EVERYTHING SEEMS GOOD TRANSMISSION DOES NOT HAVE ANY METAL SHAVINGS I DID NOTICE THAT FOR SOME REASON THE ELECTRICAL PANEL HAVE MELTED IT WAS ALL COMPLETELY MELTED AND THEY BELIEVE THAT THE TRANSMISSION IS ALSO MELTED AND STUCK TOGETHER I'M NOT SURE BECAUSE WE STILL HAVEN'T I MEAN TRANSMISSION HAS NO SIGNS THAT SOMETHING WRONG WITH IT I THINK THIS IS VERY THING I THINK THIS IS VERY DANGEROUS FOR A VEHICLE TO JUST STOP IN THE MIDDLE OF THE FREEWAY AND IMAGINE IF THEY WOULD HAVE BEEN TRAFFIC THANK GOD THAT THERE WASN'T THAT NOBODY WAS RIGHT BEHIND ME CUZ THE TRUCK JUST STOPPED AND IT WAS NOT GOING
NHTSA complaint #11081775 — an unverified report by a vehicle owner.
Canoga Park, CA
ELECTRICAL SYSTEM
WAS DRIVING ON HIGHWAY AND VEHICLE ALL OF A SUDDEN LOST POWER KEPT PRESSING THE GAS PEDAL AND IT WOULDN'T GO AS FELT LIKE YOU WANTED TO TURN OFF IT WOULD STALL WE HAVE CHECKED EVERYTHING IN THE TRUCK ENGINE EVERYTHING AND EVERYTHING SEEMS GOOD TRANSMISSION DOES NOT HAVE ANY METAL SHAVINGS I DID NOTICE THAT FOR SOME REASON THE ELECTRICAL PANEL HAVE MELTED IT WAS ALL COMPLETELY MELTED AND THEY BELIEVE THAT THE TRANSMISSION IS ALSO MELTED AND STUCK TOGETHER I'M NOT SURE BECAUSE WE STILL HAVEN'T I MEAN TRANSMISSION HAS NO SIGNS THAT SOMETHING WRONG WITH IT I THINK THIS IS VERY THING I THINK THIS IS VERY DANGEROUS FOR A VEHICLE TO JUST STOP IN THE MIDDLE OF THE FREEWAY AND IMAGINE IF THEY WOULD HAVE BEEN TRAFFIC THANK GOD THAT THERE WASN'T THAT NOBODY WAS RIGHT BEHIND ME CUZ THE TRUCK JUST STOPPED AND IT WAS NOT GOING
NHTSA complaint #11081775 — an unverified report by a vehicle owner.
at 259,000 milesHollywood, MDCrash
STEERING
WHILE BACKING THE VEHICLE I FELT A POP AND THEN THERE WAS NO STEERING CONTROL. I LOOKED UNDER THE VEHICLE AND FOUND THAT THE TIE ROD CONNECTION TO THE PITMAN ARM HAD SNAPPED.
NHTSA complaint #11062779 — an unverified report by a vehicle owner.
at 166,000 milesAdelanto, CA
TIRES:TREAD/BELT
TL* THE CONTACT OWNS A 2002 FORD EXCURSION EQUIPPED WITH SUNFULL MONT-PRO HT781 TIRES, SIZE: LT265/75/16. WHILE DRIVING 65 MPH, THE VEHICLE VIBRATED ABNORMALLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC TO BE DIAGNOSED. THE CONTACT WAS INFORMED THAT THE REAR PASSENGER SIDE TIRE TREAD SEPARATED, WHICH CAUSED A BUBBLE IN THE TIRE. WITHIN LESS THAN A THOUSAND MILES LATER, THE FRONT DRIVER'S TIRE ALSO EXPERIENCED THE FAILURE. THE RETAIL FACILITY WHERE THE TIRES WERE SOLD AND INSTALLED WAS NOT CONTACTED. THE TIRE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS UNKNOWN. THE APPROXIMATE VEHICLE FAILURE MILEAGE WAS 166,000 AND THE TIRE FAILURE MILEAGE WAS APPROXIMATELY 4,999.
NHTSA complaint #11001709 — an unverified report by a vehicle owner.
Upper Marlboro, MD
ENGINE
I HAVE A 2002 FORD EXCURSIONS AND 2 TIME SPARK PLUG EJECTION FROM THE MOTOR.
NHTSA complaint #10897435 — an unverified report by a vehicle owner.
at 167,000 milesMarlette, MI
ENGINE
I STARTED MY TRUCK AFTER SITTING FOR 36 HOURS AND WHAT SOUNDED LIKE BAD EXHAUST LEAK ..AFTER BEING CHECKED OUT BY MECHANIC FOUND THAT A SPARK PLUG AND COIL HAS BEEN SPIT OUT OF MOTOR ..I HAD THEM REPACE SPARK PLUG AND COIL ON TOP WHICH REPAIRED THE PROBLEM ..TODAY I WAS DRIVING TO TOWN 10 MILES AND AFTER STOPPI G TO GET GAS THE NOISE STARTED AGAIN !
NHTSA complaint #10820717 — an unverified report by a vehicle owner.
at 110,000 milesLeonardtown, MD
ENGINE
TL* THE CONTACT OWNS A 2002 FORD EXCURSION. THE CONTACT STATED THAT THE VEHICLE BLEW THE NUMBER SIX SPARK PLUG OUT OF THE ENGINE. THE SPARK WAS REPLACED BUT THE FAILURE RECURRED. THE VEHICLE WAS NOT TAKEN TO THE DEALER OR AN INDEPENDENT MECHANIC FOR INSPECTION. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE ISSUE. THE APPROXIMATE FAILURE MILEAGE WAS 110,000.
NHTSA complaint #10552212 — an unverified report by a vehicle owner.
at 176,000 milesScottsdale, AZ
VEHICLE SPEED CONTROL
TL* THE CONTACT OWNS A 2002 FORD EXCURSION. THE CONTACT STATED THAT WHILE DRIVING 70 MPH, SHE APPLIED THE BRAKES TO DISENGAGE THE CRUISE CONTROL AND THE VEHICLE CONTINUED TO ACCELERATE INDEPENDENTLY. THE CONTACT WAS ABLE TO GET THE VEHICLE TO STOP AFTER SEVERAL MINUTES. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 176,000.
NHTSA complaint #10525170 — an unverified report by a vehicle owner.
at 86,800 milesPeoria, AZ
TIRES
ON 6/5/2013, I WAS DRIVING ON FREEWAY AT APPROX. 70MPH AND TREAD SEPARATED FROM RT. REAR TIRE CAUSING VEHICLE TO SWERVE INTO ADJACENT LANE. DAMAGE TO QUARTER PANEL AND RUNNING BOARD. THIS IS THE SECOND TIRE FAILURE IN THE PAST 45 DAYS.THE TIRES ARE BFGOODRICH 265/75R/16 COMMERCIAL TA LOAD RANGE E. THE FOUR NEW TIRES WERE INSTALLED ON 2/28/2011 AND HAVE APPROX. 14,300 MILES OF WEAR AT TIME OF FAILURE. THE OTHER TIRE (LEFT FRONT) FAILED ON 4/19/2013. BECAUSE OF STRONG FRONT END VIBRATION, I INSPECTED THE FRONT TIRES. I FOUND THAT IT WAS OUT OF ROUND DUE TO BELT SEPARATION. THE DEALER REPLACED THIS TIRE ALSO.
NHTSA complaint #10515876 — an unverified report by a vehicle owner.
at 80,000 milesTurlock, CA
ENGINE
ACCELERATING FROM A STOP, A SPARK PLUG EJECTED FROM THE CYLINDER HEAD.
NHTSA complaint #10511518 — an unverified report by a vehicle owner.
Hamlet, NCFire
SERVICE BRAKES
TL* THE CONTACT OWNS A 2002 FORD EXCURSION. THE CONTACT STATED THAT WHILE TRAVELING 55 MPH AND APPLYING THE BRAKES, THERE WAS AN ABNORMAL NOISE HEARD FROM THE BRAKING SYSTEM. THE BRAKE PEDAL BECAME STUCK AND THE VEHICLE WOULD NOT SLOW DOWN. THE CONTACT CONTINUED TO PUMP THE BRAKES AND WAS ABLE TO COAST TO A STOP. THE CONTACT LATER PARKED THE VEHICLE AND NOTICED THAT A FIRE HAD STARTED FROM UNDER THE VEHICLE. THE CONTACT WAS ABLE TO EXTINGUISH THE FIRE HOWEVER, THE TRANSMISSION AND CENTRAL COMPUTER WAS DESTROYED. THE VEHICLE WAS TOWED TO A DEALER WHERE THE TRANSMISSION COMPUTER MODULE, TRANSMISSION AND THE BRAKE BOOSTER WAS REPLACED. THE DEALER ADVISED THAT THE BRAKE BOOSTER LEAKED ONTO THE TRANSMISSION AND THE FRONT DRIVE SHAFT, CAUSING THE VEHICLE TO CATCH ON FIRE. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO THE DEALER THREE WEEKS PRIOR TO FIRE AND THERE WAS NO INDICATION OF A POTENTIAL FAILURE. THE FAILURE MILEAGE WAS UNKNOWN. THE CURRENT MILEAGE WAS 190,000.
NHTSA complaint #10496815 — an unverified report by a vehicle owner.
Gilberts, IL
ENGINE
THE SPARK PLUG BLEW OUT OF THE CYLINDER HEAD (CYL #3), DAMAGING THE THREAD, THE SPARK PLUG, THE SPARK PLUG BOOT AND THE IGNITION COIL. THIS IS THE SECOND TIME THIS HAS OCCURRED IN THIS VEHICLE IN THE LAST TWO YEARS. THE FIRST WAS APPROXIMATELY 2 YEARS AGO AND THAT WAS THE PLUG IN CYLINDER #5. THE SAME DAMAGE OCCURRED.
NHTSA complaint #10463359 — an unverified report by a vehicle owner.
Alexandria, VA
FUEL SYSTEM, DIESEL
ENGINE PERFORMANCE SUDDENLY BECAME ERRATIC AND VERY ROUGH RUNNING. IMMEDIATELY TURNED AROUND AND WENT HOME/ HAD TOWED TO FORD DEALER. DEALERSHIP RAN $250 DIAGNOSTIC TEST BUT CAME BACK CLEAN. I WAS DIRECTED TO CHANGE ENGINE OIL AS AIR MIGHT HAVE GOTTEN INTO THE FUEL INJECTION LUBING SYSTEM ALONG WITH CHANGING THE FUEL FILTER. ON PERFORMANCE OF FUEL FILTER REPLACEMENT, TECHNICIAN DIRECTED MY ATTENTION TO WHAT APPEARED TO BE SMALL PIECES OF METAL TRAPPED IN AND ON TOP OF FILTER ELEMENT. MECHANIC SAID THIS IS VERY COMMON PROBLEM WITH METAL THE RESULT OF DELAMINATION OF THE INNER LINING OF THE FUEL TANK IN FORD DIESELS. INTERNET RESEARCH REVEALS MANY MANY COMPLAINTS TO BOTH FORD AND NHTSA OVER THIS ISSUE. THIS CREATES A VERY DANGEROUS SITUATION DUE TO LOSS OF POWER STEERING, BRAKES, AND TRAILER BRAKES WHICH COULD EASILY RESULT IN LOSS OF LIVES. I HAVE COMPLAINED TO FORD AND MY COMPLAINT HAS BEEN DULY NOTED AND REGISTERED.
NHTSA complaint #10453823 — an unverified report by a vehicle owner.
at 100,000 milesHouston, TX
ENGINE AND ENGINE COOLING
TL* THE CONTACT OWNS A 2002 FORD EXCURSION. THE VEHICLE WAS INCLUDED IN THE RECALL UNDER NHTSA CAMPAIGN ID NUMBER: 07V553000 (ENGINE AND ENGINE COOLING:ENGINE:DIESEL) AND WAS REPAIRED. AFTER THE REPAIR WHILE DRIVING APPROXIMATELY 65 MPH, THE VEHICLE BEGAN TO DECELERATE INDEPENDENTLY. THE VEHICLE WAS TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING WHERE THE TECHNICIAN PERFORMED REPAIRS TO THE VEHICLE BUT THE CONTACT WAS UNAWARE OF THE EXACT REPAIRS. THE FAILURE CONTINUED. THE VEHICLE WAS NOT FURTHER REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 100,000.
NHTSA complaint #10446030 — an unverified report by a vehicle owner.
at 146,000 milesWills Point, TX
ENGINE AND ENGINE COOLING
#4 SPARK PLUG BLEW OUT OF ENGINE HEAD, THREADS DESTROYED. FORD DEALER SERVICE DEPARTMENT TOLD ME THIS IS A KNOWN DEFECT IN THE FORD 5.4 TRITON ENGINE HEAD AND THAT FORD IS DOING NOTHING ABOUT IT.
NHTSA complaint #10444725 — an unverified report by a vehicle owner.
at 62,550 milesPinson, AL
ENGINE AND ENGINE COOLING:ENGINE:DIESEL
TL* THE CONTACT OWNS A 2002 FORD EXCURSION. THE CONTACT WAS DRIVING 45 MPH WHEN THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS RESTARTED AFTER THE FAILURE AND TAKEN TO A PRIVATE MECHANIC. THE MECHANIC CONFIRMED THAT THE CAMSHAFT SENSOR NEEDED TO BE REPLACED. THE MANUFACTURER WAS CONTACTED AND THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 62,550 AND THE CURRENT MILEAGE WAS 62,600. UPDATED 02/22/12*LJ UPDATED 03/01/12
NHTSA complaint #10444345 — an unverified report by a vehicle owner.
at 160,000 milesSevierville, TN
VEHICLE SPEED CONTROL
TL* THE CONTACT OWNS A 2002 FORD EXCURSION. WHILE DRIVING APPROXIMATELY 65 MPH, THE VEHICLE BEGAN TO DECELERATE WHILE THE CONTACT WAS DEPRESSING THE ACCELERATOR PEDAL. THE CONTACT RELEASED THE ACCELERATOR BUT WAS ABLE TO REGAIN ACCELERATION ONCE DEPRESSED AGAIN. THE FAILURE RECURRED INTERMITTENTLY AT VARIOUS SPEEDS TRAVELED. THE VEHICLE WAS TAKEN TO THE DEALER TWICE FOR DIAGNOSTIC TESTING. THE TECHNICIANS WERE ABLE TO DUPLICATE THE FAILURE BUT COULD NOT DIAGNOSE THE CAUSE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 160,000.
NHTSA complaint #10440983 — an unverified report by a vehicle owner.
at 183,000 milesHailey, ID
TIRES
WHILE DRIVING ON I-84 EAST BOUND, BETWEEN THE DALLES AND PENDLETON OREGON, OUR 2002 FORD EXCURSION EXPERIENCED A TIRE TREAD SEPARATION ON THE RIGHT REAR. WE EXPERIENCED A RECURRING POPPING SOUND JUST PRIOR TO THE TREAD SEPARATION. WE WERE PULLING A LIGHT TRAILER. TREAD SEPARATED BUT TIRE REMAINED INFLATED. I WAS ABLE TO SEE THE TREAD LEAVE THE TIRE IN MY RIGHT MIRROR AS IT HAPPENED. WE WERE TRAVELING UP HILL AT THE TIME SO SPEED WAS APPROXIMATELY 63MPH. DRY ROADS AND 93 DEGREES.
NHTSA complaint #10424129 — an unverified report by a vehicle owner.
at 110,000 milesLakeside, CA
ENGINE AND ENGINE COOLING
WAS STARTING FROM A STOP TO MAKE A LEFT TURN WHEN DRIVER HEARD A LOUD POP. THERE WAS A SUDDEN LOSS OF POWER AND SOME SMOKE. THE VEHICLE WAS TOWED AND DIAGNOSED. THE #3 PLUG ON THE RIGHT BANK HAS BLOWN COMPLETELY OUT AND DAMAGED THE COIL PACK. A PHONE CALL TO THE DEALER YIELDED NO HELP OTHER THAN WE CAN HAVE IT TOWED THERE TO BE REPAIRED, AS IT LIKELY NEEDS A NEW HEAD. SOME INTERNET RESEARCH AND TALKING TO OTHER FORD OWNERS DEFINITELY SUGGEST THAT THIS IS A DESIGN PROBLEM WITH THE ALUM HEADS BLOWING OUT SPARK PLUGS, AND THE #3 R PLUG SEEMS TO BE COMMON. THIS COULD CAUSE FUEL/VAPORS TO BE EXHAUSTED AND SPRAYED ON A HOT MANIFOLD AND CAUSE A FIRE. IT SOUNDS LIKE THERE MAY HAVE ALREADY BEEN SOME FIRES ATTRIBUTED TO THIS PROBLEM. THIS SOUND LIKE A CASE WHERE THE DEALER/FORD REFUSES TO ADMIT THAT IT IS A PROBLEM AND FIX IT FOR OWNERS. BEFORE THERE ARE SERIOUS INJURIES FROM A CRASH OR A FIRE, FORD SHOULD BE COMPELLED TO FIX THIS ISSUE. ITS UNLIKELY THAT FORD WILL ANSWER THE CALL WITHOUT PRESSURE FROM NHTSA. THERE SEEM TO BE FAR TOO MANY OF THE SAME TYPE OF PROBLEMS WITH THIS 5.4L MOTOR FOR IT TO BE A COINCIDENCE.
NHTSA complaint #10407829 — an unverified report by a vehicle owner.