Fuel System complaints by model year
Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
What owners report
While driving the truck the accelerator becomes nonresponsive and soon after the truck shuts down, complete power loss. Very difficult to steer and brake. It will start back up most of the time, but on occasion it will take 20 to 30 minutes to re-start. Ford has a recall for this # 05s34. My VIN indicates that my Excursion isn't under this recall, but this is exactly what is happening. This event happens on city streets and highways, while driving or sitting at a stop sign or stop light. This event has become more frequent as my wife will no longer drive it do to the vehicles handling/breaking issues without power so I only drive it on weekends. It happens at least once a day sometimes repeatedly within seconds after restarting and sometimes never again during the weekend. It also is not time or distance related. …
Tl* the contact owns a 2005 Ford Excursion. The contact stated that the vehicle stalled without warning while driving 70 MPH. The contact was able restart the engine. The vehicle was taken to an independent mechanic who stated that the failure could be related to the fuel injector. The vehicle was not repaired. The vehicle was previously serviced under NHTSA campaign number: 05V270000 (electrical system). The manufacturer was notified of the failure. The VIN was not available. The failure mileage was 146,000.
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.
Tl contact owns a 2004 Ford Excursion. The contact stated that while driving at an unknown speed, the vehicle failed to accelerate without warning. The vehicle was taken to an independent mechanic. The technician diagnosed that the fuel injection control module needed to be replaced. No repairs were made to the vehicle. The manufacturer was made aware of the failure. The failure mileage was 24,096.
My 2003 Excursion had a major turbo failure while traveling on I-10 on 12-26-03. My family and myself were traveling to houston. The vehicle only had a total of 1,049 life to date miles. While on the interstate for about 30 to 45 minutes we hear a larger pop noise and a large drop in the engine power. I only had a flash of a dash light and it went right back off. I was trying to get off the interstate. Was driving about 25 to 35 MPH trying to get to the next exit. Notice large volume of smoke coming from the rear of the vehicle. I pulled over asap after seeing this. The smoke came into the cab from the ventilation system (A/C). Pulled my daughter from the vehicle, also had my wife get out of the vehicle. At this point released the hood lock, checking the heat on the hood first. Raised the hood found fire coming from exhaust pipe from the turbo. …
My 2003 Ford Excursion with a 6.0l diesel has been surging and will stall suddenly and without warning. It has caused several near collisions. The dealer had to replace the icp sensor. Apparently this was recalled in 2004 models and newer but not the 2003 model. I feel that I have fallen through the cracks because Ford didn't start installing the 6.0l in the 2003 model until late in the model years. Seems like they forgot about me and my truck has the exact same dangerous condition as the 2004 models.
Tl contact owns a 2002 Ford Excursion. While parked, the vehicle accelerated without warning and crashed into the front of another vehicle. The dealer was unable to diagnose the cause of failure. The vehicle was taken to a second dealer who replaced the throttle cable. The failure has not occurred since the replacement was made. The current mileage is 95,000 and failure mileage was 94,300. The consumer provided an eyewitness statement, freeport police repor, various articles pertaining to the defect, and the repair invoice. The dealer stated there is a strong smell of fuel, passenger door does not lock with remote, and customer overhead door is broken. Updated 08/27/07
Tl contact owns a 2002 Ford Excursion. The contact stated that after opening the hood there was gasoline fumes coming from the engine and fuel was spraying all over the engine. The fuel continued to spray throughout the engine while the vehicle was on; however, when the vehicle was turned off there was a puddle of fuel under it. The dealer observed the fuel leak while performing an additional recall repair and refused to address or repair the fuel leak unless the contact paid $200 for the repair. The manufacturer stated that the fuel leak was not a part of the recall. There was routine maintenance performed on the vehicle prior to the failure. The failure mileage was 40,000.
Frequently asked questions
Which Ford Excursion years have fuel system problems?
By NHTSA complaints, the 2004 (12), 2005 (12), 2003 (9), 2000 (7) and 2001 (5) model years. Fuel System complaints make up 13% of all complaints for the 2004.
Is there a recall for Ford Excursion fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for any Ford Excursion model year. A widespread problem may still be covered by an extended warranty or a manufacturer service bulletin, so ask a dealer.
At what mileage do Ford Excursion fuel system problems start?
Across all years, half of the complaints with a recorded mileage happened before about 79,000 miles; 31% happened before 50,000 miles.
What part fails most often?
Owners most often name the storage › tank assembly (4 mentions), followed by the fuel injection system (3).
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.