2004 Ford Excursion Problems

RepairPal has identified the most common problems with the 2004 Ford Excursion based on complaints from actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.

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Known Problems

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.

The EGR cooler may leak internally, causing white smoke from the tailpipe.

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

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.

The turbo hose could blow off of the turbo, causing a no boost condition.
The VGT solenoid may fail.
A lack of power may occur if the turbo sticks.