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.
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Newest reported 2002 Ford Excursion problems
High Pressure Diesel Fuel Injection Pump May Fail and Cause "No Start" Condition
The high pressure diesel fuel injection pump may fail, resulting in a "no start" condition.
6 Reports
Oil in fuel system due to injector seal leaks
When changing the fuel filter, if the fuel in the filter bowl looks gray or black, it may be a sign that the fuel injector O-rings are allowing high pressure oil to migrate into the fuel return system. Symptoms of this are rough idle or hard starting.
3 Reports
Inoperative Door Locks Due to Resistance in Circuit
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.
22 Reports
Rough Idle Caused By EGR Sensor Sticking
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.
5 Reports
Hard start due to incorrect engine oil
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.
4 Reports