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Resources for the Repair and Maintenance of your 2002 Ford Excursion

2002 Ford Excursion

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2002 Ford Excursion Problems

Miscellaneous -- Verified

One or more of the door locks may become inoperative due to resistance in the circuit. In some cases, replacement of all actuators will be required to correct this issue.

Engine -- Verified

There is a technical service bulletin for the V8 engines regarding a possible problem with the spark plug being ejected from the cylinder head, damaging the threads in the spark plug hole. If the vehicle is under warranty, cylinder head replacement is recommended. If the vehicle is out of warranty, Ford authorized the use of a specific thread insert to repair the head.

Engine -- Verified

The high pressure diesel fuel injection pump may fail, resulting in a "no start" condition.

Exhaust & Emissions -- Verified

Intermittent rough idle may be caused by the EGR sensor sticking, causing the EGR valve to stay slightly open. Our technicians tell us the valve and sensor must be replaced together to correct this concern.

Engine -- Verified

Hard starts, long crank time before the start, rough idle, and loss
of power can be caused by using the wrong type of oil in this motor.
With the engine off, remove the oil dipstick and inspect. If tiny
bubbles are present, then the oil is foaming and unable to maintain
proper operating pressure in the high pressure oil system.

2002 Ford Excursion Recalls (Recent)

Drive Train, August 7, 2006


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Electrical & Lights, July 7, 2011

RepairPal Expert Overview:

An internal fault may develop within the multi-function turn signal switch. This can affect turn signal, tail, hazard, and/or brake light operation. Non-functioning exterior lights could increase the risk of a crash. Dealers will replace the multi-function switch to correct this concern. This recall is scheduled to begin on August 15, 2011. The Ford recall number is 11C18.

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Engine, December 29, 2007


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2002 Ford Excursion Questions and Answers

brucebattlesnake, 2002 Ford Excursion, 7.3L V8 Diesel, Bronx, NY

is there a strainer or screen in the diesel fuel tank. or on the fuel sending unit.

gerald1, 2002 Ford Excursion, 7.3L V8 Diesel, Riverside, CA

getting a bad body shake when braking when weight seems shift to front gets real bad when coming down hill

mx4, 2002 Ford Excursion, Diesel, Lynnwood, WA

What are the possible problems that this indicator could be sensing or is it likely that it's just a sensor?

sclayb, 2002 Ford Excursion, 7.3L V8 Diesel Turbo, Sioux Falls, SD

When I drive my truck on ANY slippery surface, the truck seems to fishtail (slightly). It also feels like only one (rear-right)tire is functioning. I'm wondering what may be the problem and a...

fordman93, 2002 Ford Excursion, 6.8L V10, Oakdale, CA

i need to change my rod bearings and i was wondering if i could do it from the oil pan with the engine still in the vehicle. thanks

Write a Review About Your Car

2002 Ford Excursion Reviews

We have owned this vehicle from mile 1, and since we bought it brand new in 2000, we've put 250,000 Miles on our 2001 Ford Excursion, and it's still running like new. I've kept track of everything we've done to it in the 1/4 million miles that we've owned it, down to the light bulbs, and I have to say that the reliability is impressive. This is by far the best heavy duty SUV ever made. The 7.3 diesel engine has plenty of power to pull anything, and still gets 15-18 MPG. The interior is spacious, plenty of room for all seven kids and all of their luggage. It holds up well and stays together considering the abuse it gets from the youngsters. The driver seat seam on the left recently opened as is slowly growing, and the rear seats and showing some wear and age. The third rear seat gets a little uncomfortable after a while, but I've still fallen asleep in it. The body has no rust on it, and no paint chips. Going on vacation and being able to pull the 10,000 lb. camper without a sweat, and at the same time have room for everyone inside is easily achieved with this vehicle. The ride isn't the smoothest, but hey, it's a 1 ton SUV! In fact, put a heavy trailer on the back and the ride actually gets smoother! Being able to remove the rear third seat and fold the middle seats creates an enormous amount of room inside the vehicle for almost anything.

Reliability is the best part of this vehicle, especially when you have the 7.3 diesel. The injectors and injector pump are original, and the only things we have replaced on the engine are all 8 glow plugs, injector/glow plug wiring harnesses, glow plug control module, water pump, drive belt tensioner, fuel filter bowl valve (due to the change to ultra low sulfur diesel) and the camshaft position sensor, which was recalled anyway. Other than that, absolutely nothing has been done to the engine besides oil changes. It doesn't even burn or leak a drop of oil either.

The transmission did go out at 104,000 and was replaced, and the additional cooler and inline filter was added to prevent the new transmission from overheating. Haven't had any problems since the replacement, and the fluid hasn't darkened at all.

A brake caliper slide pin did seize up and was replaced. The rear A/C evaporator was replaced due to a leak. Both front hub bearings developed play and have been replaced. All of the door lock actuators slowly quit working and have been replaced, even the rear one. The outer plastic grip on the shifter did break, and has been replaced. The auto darkening mirror did malfunction and darkened 3/4 of the mirror all the time, and has been replaced. A running board light socket was replaced due to water contamination. Even though not a single bulb has burnt out in the front of the vehicle until a side marker bulb just burnt out today, both rear brake lights, reverse lights, and top third brake lamp bulbs have been replaced three times. The top rear door support shocks/struts weakened and were replaced. Both lower ball joints were replaced after play developed. An interior bulb was replaced. Just recently the tape player quit playing any tapes and just ejects them saying "Tape Error".

We recently hit a full size deer at 60 MPH while pulling a trailer, and I have to say I was glad I hit it in this vehicle instead of one of our small cars. The only damage to the truck was a broken grille and a dented bumper. That's it. They really built this truck tough!

We also have modified the transmission slightly, added a power chip, K&N intake, and Silverline 4" turbo back exhaust, and have since then picked up another 2-3 MPG and 100 HP, which was well worth every penny of it.

If only all vehicles were built like the Ford Excursion. This is truly one of Ford's best vehicles ever made, and it's a shame they discontinued it. Even though the kids are growing up and moving on, my Ford Excursion will be my daily driver 'till the day I die.

I turned my truck on today and a gas can with water above it showed up on my dash.. what does this mean? looked in the manual and no picture showing this.. any help would be greatly appreciated!!
lost in vegas

This is the best Truck ever made period


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