The Ford Excursion, a behemoth of an SUV, holds a special place in automotive history. Discontinued after the 2005 model year, it remains a popular choice for those needing serious towing capacity, ample passenger space, and rugged durability. Choosing the right year, however, is crucial to avoid potential problems and maximize your investment. This guide will walk you through the best and worst years for the Ford Excursion, helping you make an informed decision.

Ford Excursion Model Years: A Quick Reference Table

Model Year Key Features & Common Issues Recommendation
2000 First year of production; 7.3L Power Stroke common, some early production quirks. Proceed with Caution: Thorough inspection crucial. Look for rust and previous maintenance records.
2001 Minor improvements over 2000; 7.3L Power Stroke still available. Consider: Better than 2000, but still requires careful inspection.
2002 7.3L Power Stroke phased out mid-year; introduction of 6.8L V10 and 5.4L V8; 4R100 transmission issues possible. Proceed with Caution: Transmission health is paramount. Inspect for leaks and smooth shifting.
2003 Introduction of the 6.0L Power Stroke diesel; known for EGR cooler and head gasket issues; updated interior. Avoid (Generally): Unless extensively bulletproofed (EGR delete, head studs, etc.). High risk of expensive repairs.
2004 Continued use of the problematic 6.0L Power Stroke; some minor improvements. Avoid (Generally): Similar issues as 2003. Requires extensive pre-purchase inspection and confirmation of repairs.
2005 Last year of production; some argue minor improvements to the 6.0L, but still prone to issues; updated front end. Proceed with Caution: Potentially slightly better than 2003/2004, but the 6.0L concerns remain. Check for documented repairs.

Detailed Explanations of Model Years and Associated Issues

2000: The inaugural year for the Excursion, the 2000 model is highly sought after for its availability with the venerable 7.3L Power Stroke diesel engine. However, being the first year, it may have some early production quirks and potentially more wear and tear due to its age. Rust is a significant concern, especially in regions with harsh winters.

2001: The 2001 model year offered minor improvements over the 2000 model while still retaining the desirable 7.3L Power Stroke. While generally considered a better option than the 2000, the same precautions regarding rust and thorough inspection apply. The 7.3L is known for its reliability, but age-related issues can still occur.

2002: 2002 marked a significant transition year. The 7.3L Power Stroke was phased out mid-year, replaced by the 6.8L V10 and 5.4L V8 gasoline engines. The 4R100 transmission, used behind the 7.3L and some of the gasoline engines, can be prone to issues, especially with heavy towing. Check the transmission fluid condition and test for smooth shifting.

2003: The introduction of the 6.0L Power Stroke diesel engine in 2003 brought a host of problems. This engine is notorious for EGR cooler failures, leading to coolant entering the engine, and head gasket issues, resulting in costly repairs. While some 2003 Excursions have been "bulletproofed" (upgraded with stronger components), most remain a high-risk purchase.

2004: The 2004 model year continued the use of the problematic 6.0L Power Stroke. While some minor improvements were made, the core issues persisted. Potential buyers should be extremely cautious and only consider a 2004 Excursion if there's documented proof of extensive repairs and upgrades addressing the 6.0L's inherent weaknesses.

2005: As the final year of production, the 2005 Excursion saw some argue for minor improvements to the 6.0L Power Stroke, but the underlying problems remained a concern. The updated front-end styling is a visual cue for this model year. While potentially slightly better than the 2003 and 2004 models, the 6.0L's reputation precedes it, and thorough inspection and repair documentation are crucial.

Engine Options: A Deeper Dive

7.3L Power Stroke Diesel: This engine is widely considered the most reliable option for the Excursion. Its robust design and relatively simple construction contribute to its longevity. However, even the 7.3L is subject to age-related issues, such as injector problems, fuel pump failures, and worn turbochargers.

6.0L Power Stroke Diesel: As mentioned above, this engine is the source of many Excursion owners' headaches. Its design flaws, including the EGR cooler and head gasket issues, can lead to significant repair costs. "Bulletproofing" the 6.0L (replacing the problematic components with upgraded versions) can mitigate these risks, but it's an expensive endeavor.

6.8L V10 Gasoline: A powerful gasoline option, the 6.8L V10 provides ample horsepower and torque for towing and hauling. While generally more reliable than the 6.0L diesel, it's less fuel-efficient. Potential issues include exhaust manifold leaks and spark plug problems.

5.4L V8 Gasoline: The smallest engine option, the 5.4L V8, offers adequate power for everyday driving but may struggle with heavy loads. Fuel economy is still not great, given the size and weight of the Excursion. Common issues include spark plug ejection and timing chain problems.

Transmission Considerations

The Ford Excursion primarily used two main transmissions:

  • 4R100: This 4-speed automatic transmission was used behind the 7.3L Power Stroke and some of the gasoline engines. It's generally a robust transmission, but it can be prone to issues with heavy towing, especially if not properly maintained. Look for smooth shifting and check the transmission fluid for a burnt smell or discoloration.

  • 5R110W (TorqShift): This 5-speed automatic transmission was used behind the 6.0L Power Stroke. While a more advanced transmission than the 4R100, it can also experience problems, particularly with the 6.0L's problematic torque output.

What to Look For When Buying a Used Ford Excursion

  • Rust: Rust is a major concern, especially in areas with road salt. Pay close attention to the undercarriage, rocker panels, and wheel wells.
  • Engine Condition: If considering a 7.3L, listen for unusual noises and check for excessive smoke. For a 6.0L, look for signs of coolant leaks, oil leaks, and head gasket issues.
  • Transmission Health: Test drive the vehicle and ensure smooth shifting. Check the transmission fluid for a burnt smell or discoloration.
  • Maintenance Records: Ask for maintenance records to see how well the vehicle has been cared for.
  • Towing History: Inquire about the vehicle's towing history, as heavy towing can accelerate wear and tear on the engine and transmission.
  • Aftermarket Modifications: Be cautious of heavily modified Excursions, as modifications can sometimes introduce new problems.
  • Professional Inspection: Before making a purchase, have a qualified mechanic inspect the vehicle.

Frequently Asked Questions

  • Which Ford Excursion year is the most reliable? The 2000-2001 models with the 7.3L Power Stroke are generally considered the most reliable, although age-related issues can still occur.

  • Is the 6.0L Power Stroke engine worth the risk? Generally, no. Unless the engine has been extensively "bulletproofed" and you have documented proof, the risk of expensive repairs is too high.

  • What is "bulletproofing" a 6.0L Power Stroke? Bulletproofing refers to replacing the problematic components of the 6.0L (EGR cooler, head studs, oil cooler, etc.) with upgraded, more durable versions.

  • How much should I expect to pay for a used Ford Excursion? Prices vary widely depending on the year, condition, mileage, and engine. Expect to pay anywhere from $15,000 to $40,000+ for a well-maintained Excursion.

  • Are the gasoline engines in the Excursion reliable? The 6.8L V10 and 5.4L V8 are generally more reliable than the 6.0L diesel, but they're less fuel-efficient and may not offer the same towing capacity.

  • What are the common problems with the 7.3L Power Stroke? Common issues include injector problems, fuel pump failures, worn turbochargers, and rust.

Conclusion

Choosing the right Ford Excursion requires careful consideration and thorough inspection. While the 2000-2001 models with the 7.3L Power Stroke are generally the most reliable, even they require scrutiny due to their age. The 2003-2005 models with the 6.0L Power Stroke should be approached with extreme caution, unless extensively bulletproofed.