Which parts fail
Components named in complaints (battery, alternator, wiring, ignition, instrument cluster, infotainment).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Ford Excursion owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl* the contact owns a 2004 Ford Excursion. While driving, the vehicle stalled without warning. The contact placed the gear into neutral, while in traffic, and restarted the vehicle. Afterwards, the vehicle was able to drive normally. The vehicle was taken to future Ford Lincoln (located at 650 automall dr, roseville, ca 95661, [phone]) where a wiggle test was performed because a failure code could not be found. The injection control pressure was replaced with a used part. The contact stated that the vehicle was worse after the replacement of the used part and the steering wheel became difficult to steer. The vehicle was taken back to the same dealer who stated that a wire harness was needed to repair the vehicle. The vehicle was not repaired. …
Tl contact owns a 2004 Ford Excursion. After the vehicle had been parked for eight hours, the contact smelled something burning when it was restarted. He noticed smoke coming from the engine compartment and the vehicle burst into flames two minutes later. The fire burned through the air conditioner hose and erupted. The eruption also extinguished the fire. The contact is a mechanic and he inspected the vehicle. He was able to start the vehicle and drove to the dealer. The dealer stated that the failure was caused by a loose wire. The manufacturer stated that the VIN was not included in NHTSA campaign id number 04V327000 (electrical system:battery) for the 2003 models. The current and failure mileages were 56,880. Updated 03-04-08 the consumer believed the problem he experienced was related to the recall. Updated
Total loss of engine power massive amount black soot exiting exhaust while driving recall # 05V270000 was not performed on vehicle ( I am the original owner) never received notice in mail and dealer somehow missed this "work" and Ford should have followed through on this situation. Other repairs done to this vehicle to "fix" this problem was to drain the fuel tank (algae in fuel was the excuse-no algae) fuel pump and filter rail (not problem) two turbochargers were replaced due to excessive sooting (one warranty one at my expense) EGR valves and a cam sensor (Ford knows the problems exist because Ford discountinued the 6.0 litre motor) this problem has occured multiple times over my ownership.
I own a 2004 Ford Excursion which has on two occasions failed to start and was towed to fairview Ford. The first occurrence the dealer replaced the camshaft sensor and reflashed the computer. The second incident the car was also towed by roadside assistance from my driveway. The tow truck driver was also unable to start the vehicle. I was contacted later in the day by my service advisor saying that the vehicle started fine and they were unable to duplicate the problem. On a third occurrence the vehicle stalled in a parking lot and would not restart for my wife. After shopping for approximately 45 minutes my wife returned and was able start the vehicle and it was driven strait to the dealer. The dealer was again unable to duplicate the problem. …
Tl* the contact owns a 2004 Ford Excursion. The contact was stopped at a light when the vehicle attempted to accelerate forward. The contact stated that the brakes were applied during the failure. The following day, the vehicle failed to start and was towed to an authorized dealer. The dealer advised him that the vehicle would need a new injection control pressure sensor and a fuel injection control module. The vehicle was not repaired. The contact referenced NHTSA campaign id number: 05v27000 (electrical system: wiring) and was advised by the dealer and the manufacture that his VIN was not included in the recall. The approximate failure mileage was 82,300 and the approximate current mileage was 82,400. Updated 02/03/11 updated 02/11/11
Tl contact owns a 2004 Ford Excursion. The contact was driving approximately 25 MPH, the engine stalled without any warning lights illuminating on the instrument panel. The engine restarted momentarily and the vehicle resumed as normal. The vehicle was taken to an authorized dealer and diagnosed. The failure was related to the injection control sensor. There was a recall related to the defect under NHTSA campaign id number 05V270000 (electrical system: wiring). The VIN was not included in the recall. The vehicle was currently being repaired. The manufacturer was made aware that the failure occurred intermittently. The failure mileage was 97,000. The VIN was unavailable. Updated 09/07/2011
Tl contact owns a 2004 Ford Excursion. While driving between 25 and 65 MPH, the vehicle stalled. The vehicle also failed to accelerate when the pedal was depressed. After being parked for 3-4 hours, the vehicle would operate normally for thirty minutes before the stalling began. The check engine light illuminated after the failure, but dimmed when the vehicle was restarted. The contact took the vehicle to the dealer twice and to a mechanic another two times. On one occasion, he was informed that the fuel filter was clogged. NHTSA campaign id number 05V270000 (electrical system:wiring) was referenced. The current mileage was 75,100 and failure mileage was 68,000.
Dt: the caller had recall work done on his vehicle and it is running worse than before. Received recall 05s34 concerning injection control pressure sensor and wiring harness. Now, the vehicle has problems that it did not have before the recall. Vehicle stalls when engine is cold/hesitates and surges while accelerating. Took vehicle to the dealer 4 times since July 19, 2005, and is now was taking it to them again. Manufacturer can not be reached. The dealer's service manager told the consumer that he May have to live with the engineering change Ford made to the engine when recall 05s34 was completed on July 19, 2005.
While driving the vehicle, it will go into a reduce power mode or sometimes stall. This has happened at various speeds, from around town to highway driving. Very dangerous condition when trying to make left turns and power is lost or engine stalls. Also engine fails to start or starts and stalls right away on occasion. Call Ford customer relations and dealer and they tell me my VIN is not covered under the recall. I am experiencing the same symptoms but I am not covered. Don't want to spend more money at dealer if they don't know what is happening and how to fix it.
Tl contact owns a 2000 Ford Excursion. The contact stated the engine was turned off, and failed to restart. A certified technician replaced the fuse relay. Seven months later, the identical failure recurred and the fuse relay was replaced a second time. Most recent, the fuse relay was replaced each time the engine was turned off in order for the vehicle to restart normally. The vehicle was taken to an independent mechanic who was unable to duplicate the failure. The manufacturer was made aware of the failure. The approximate failure mileage was 120,000.
Related recalls
Electrical system › Wiring
Certain pickup trucks, sport utility vehicles and vans equipped with 6.0l diesel engines May experience stalling without warning while driving and May or May not restart.
Remedy: Dealers will upgrade the fuel injection control module (ficm) wire harness or replaced, and/or have a new injection control pressure (icp)) sensor connector installed free of charge. The recall began on July 22, 2005.
NHTSA investigations
Engine stalling
In a June 7, 2005 letter, Ford notified odi that it would be conducting a safety recall of approximately 180,000 Ford f-super duty, excursion and e-series vehicles equipped with 6.0l diesel engines to correct two wiring related conditions that could result in engine stall (NHTSA recall no. 05v-270, Ford no.
Electrical complaints in other Excursion years
Frequently asked questions
How common are electrical problems on the 2004 Ford Excursion?
NHTSA has 21 complaints about the electrical system of the 2004 Ford Excursion, 22% of the model year's 95 complaints. The component named most often is wiring (8 mentions).
Is there a recall for 2004 Ford Excursion electrical problems?
Yes — NHTSA recall 05V-270 (wiring, Jun 10, 2005). Recall repairs are free at authorized dealers.
At what mileage do 2004 Ford Excursion electrical problems start?
Half of the complaints with a recorded mileage happened before about 95,000 miles, and 11% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 2 fires and 0 injuries to electrical system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.