Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2005 Ford Excursion owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl* the contact owns 2005 Ford Excursion diesel. The contact stated that while driving 60 MPH, the vehicle began smoking and stalled. The contact attempted to restart the vehicle but to no avail. The vehicle was taken into a local repair shop and diagnosed as a faulty engine. The vehicle was repaired. In addition, the contact stated that every time the heater or air conditioner was activated, fumes would emit into the vehicle. The failure mileage was 176,000 and the current mileage was 179,000. Updated 2/28/11 updated 04/29/11
Tl* the contact owns a 2005 Ford Excursion. The contact stated that the vehicle stalled without warning. After several attempts, the vehicle was able to restart, but the failure recurred. The vehicle was not included in NHTSA campaign number: 05V270000 (electrical system). The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The approximate failure mileage was 150,000. ....updated 07/22/15 the consumer stated after the vehicle was repaired the failure recurred. Updated 9/22/2015
Tl* the contact owns a 2005 Ford Excursion. While driving at an unknown speed, the vehicle stalled, shut off, and the check engine warning indicator illuminated. The vehicle was towed to the contact's residence. The dealer was contacted (buss Ford, in mchenry, il) who stated that there was no recall. The manufacturer was made aware of the failure and stated that there was no recall. The failure was not diagnosed. The failure mileage was approximately 120,000.
Tl* the contact owns a 2005 Ford Excursion. While undergoing routine service by an independent mechanic, the technician noticed that the coolant leaking through the engine cylinder and the head gaskets needed to be replaced. The vehicle was not repaired. The vehicle was not taken to a dealer. The manufacturer informed the contact that the VIN was not included in a recall. The approximate failure mileage was 135,000. The VIN was not available.
Tl* the contact owns a 2005 Ford Excursion. While driving 65 MPH, the vehicle stalled without warning. The vehicle was taken to an independent mechanic. The contact called a local dealer (chapman Ford, 9371 roosevelt blvd, philadelphia, pa 19114) and was advised to schedule a service appointment. The vehicle was not diagnosed or repaired. The manufacturer was notified and referred the contact to NHTSA. The failure mileage was 192,000.
While towing a camper, the engine overheated about 4 hours into the trip. The truck and trailer had to be towed home. The truck was brought to Ford and it was determined that the head gaskets blew out. The dealer said this was common with the 6.0 diesel engines. He stated that it was caused by the head bolts stretching. He repaired it, but, told me I would be back again unless I purchased arp racing head bolts($600). I researched it online and found he was correct. I provided the bolts and Ford did the repair under warranty. In 2008, the EGR cooler/oil cooler ruptured and had to be replaced (under warranty). In 2009, the ficm module malfunctioned. Since the truck was now out of warranty, Ford wanted $700 for the part, plus labor. In 2010, the EGR cooler/oil cooler ruptured again. Since the truck was out of warranty, I was told it would be $4000 to repair. …
Spark plug blown out of head of vehicle, brought to dealer and was told it was not covered by warranty because the plug had loosened ,these plugs were factory installed therefore it should be considered defective workmanship and should be covered under warranty. This problem is a common occurrence with Ford motors as I have been made aware. I have also reviewed many articles relating to this several of which are quite disturbing mainly the fact that there have been instances of spark plugs ejecting and rupturing the fuel line which sits directly above the spark plug causing a fire and engulfing the vehicles in flames. Being as I have a large family we have a Ford Excursion and we have children strapped in car seats I am quite concerned that this is even a remote possibility and I feel that this should be a grave concern for your organization as well. …
I am so disappointed in purchasing this Ford truck....I have had this vehicle for 5 years and it has been in the shop on several occasions for the same reason...EGR valve gets stuck and I'm stuck on side the highway....I cannot trust this vehicle to get me to the corner store let alone a long distance trip. Although I loved my truck...the cost of these repairs have just been astronomical, not to mention the inconvenience of constant towing and days spent in the Ford service department. I've done some research on this problem and found that Ford company is more than aware of the problems with the 6.0-liter diesel engines and has done little to nothing to help its consumers. My husband and I loved Ford trucks, but this will certainly be the last time I purchase anything from this company or its brands. In fact, it is in the shop again!!!!! As I type this complaint.
While merging onto 75mph highway, without warning, vehicle lost all power making steering nearly impossible. We were able to move onto shoulder just at the point where highway and on ramp met. We could not restart vehicle and had we made it onto highway, could have very easily been rear ended by oncoming traffic. This is the second time we have lost complete power with this vehicle. We had same situation in July and had paid over two thousand dollars to have fuel system repaired. Ford had recall on this but our truck's VIN did not fall under recall. However, have concerns for others who have vehicles whose vins are not part of the recall. Another family May not be as fortunate as we were yesterday. Ford is aware of these issues and I hope Ford does not wait until lives are lost due to their faulty vehicles!
2005 6.0 diesel Excursion has had many motor issues and lots of parts already replaced by Ford up to this date. Turbo quit working while driving and had to be replaced in May, 2007. In June, 2007, vehicle has more turbo issues and EGR cooler assembly is replaced. On July 4th, 2007, vehicle starts stalling while driving down freeway and wiring harness had to be replaced. On July 16th, 2007, (3 days home from shop), stalls again while driving down freeway. Dealership cannot determine problem yet refuses to buy back defective vehicle. It's been over 60 days in shop since bought brand new in 2005. Oasis report is 6 pages long already.
Engine complaints in other Excursion years
Frequently asked questions
How common are engine problems on the 2005 Ford Excursion?
NHTSA has 23 complaints about the engine & cooling of the 2005 Ford Excursion, 35% of the model year's 65 complaints. The component named most often is engine › diesel (5 mentions).
Is there a recall for 2005 Ford Excursion engine problems?
No. NHTSA lists no engine & cooling recall for the 2005 Ford Excursion, though it has 2 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2005 Ford Excursion engine problems start?
Half of the complaints with a recorded mileage happened before about 106,000 miles, and 5% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 0 injuries to engine & cooling 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.