2002 Ford Excursion

129 complaints on file, page 1 of 7.

1. Filed Sep 26, 2023Failure Aug 27, 2023Kalamazoo, MIPower train, Suspension

   As I was driving the transfer case and drive shaft dropped out of truck. Broken bolts and no warning.

   NHTSA complaint 11546512
2. Filed Mar 29, 2021Failure Mar 16, 2021201,352 milesSouth River, NJBody

   LARGE PATCHES OF PAINT TOPCOAT PEELING FROM VEHICLE ROOF, ABSOLUTELY NO EVIDENCE OF PRIMER HAVING BONDED/ ADHERING TO SEPARATED TOPCOAT, PEELED PAINT IS IDENTICAL ON BOTH SIDES, OBVIOUSLY PRIMER INTENDED TO INTEGRATE TOPCOAT WITH SUBSTRATE WAS FAULTY AND NOT ACCEPTABLE.

   NHTSA complaint 11405439
3. Filed Sep 5, 2019Failure Jan 5, 2018210,000 milesKillen, ALEngine

   TL* THE CONTACT OWNS A 2002 FORD EXCURSION. THE CONTACT STATED THAT EACH TIME SHE DROVE THE VEHICLE, IT STALLED WITHOUT WARNING. AFTER THE FAILURES, ALL THE WARNING INDICATORS ILLUMINATED ON THE INSTRUMENT PANEL. THE CONTACT COASTED THE VEHICLE OVER TO THE SIDE OF THE ROAD AND WAITED A MINUTE OR MORE TO RESTART THE VEHICLE. SOMETIMES, IT TOOK UP TO FOUR ATTEMPTS BEFORE THE VEHICLE WOULD RESTART. WHEN THE VEHICLE WAS RESTARTED, IT HESITATED TO MOVE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED, BUT THE TECHNICIAN COULD NOT FIND A FAILURE CODE. THE VEHICLE WAS NOT TAKEN TO A DEALER AND WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURES AND INFORMED THE CONTACT THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 07V553000 (ENGINE AND ENGINE COOLING). NO FURTHER ASSISTANCE WAS OFFERED. THE APPROXIMATE FAILURE MILEAGE WAS 210,000.

   NHTSA complaint 11253362
4. Filed Jun 6, 2019Failure Aug 24, 2017170,000 milesCosta Mesa, CATread/belt

   TL* THE CONTACT OWNS A 2002 FORD EXCURSION EQUIPPED WITH TOYO OPEN COUNTRY R/T TIRES (NA), SIZE: LT285/75/R16. WHILE DRIVING 65 MPH, THE REAR PASSENGER TIRE EXPERIENCED TREAD SEPARATION. PRIOR TO THE FAILURE, THE REAR DRIVER'S TIRE WAS REPLACED BY ALLEN TIRE (LOCATED AT 1725 SUPERIOR AVE, COSTA MESA, CA 92627, (949) 646-5236) DUE TO A BULGE IN THE TIRE. THE CONTACT STATED THAT THERE WAS DAMAGE TO THE VEHICLE. THE SET OF TIRES WERE A REPLACEMENT SET. THE TIRE WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 14T014000 (TIRES). THE MANUFACTURER WAS CONTACTED. THE APPROXIMATE VEHICLE FAILURE MILEAGE WAS 170,000 AND THE TIRE FAILURE MILEAGE WAS 75,000.

   NHTSA complaint 11218329
5. Filed May 25, 2018Failure May 8, 2018136,896 milesBaker, FLWheelsCrash

   HAD A B F GOODRICH LT315/75R16D ALL TERRAIN KO, DOT: BFAUHX111211, FRONT LEFT TIRE EXPLODE WITHOUT ANY WARNING, WAS DRIVING NORTH ON HIGHWAY 65, ABOUT 16 MILES SOUTH OF BRANSON, MO. I WAS TRAVELING AROUND 65 MPH IN THE RIGHT HAND LANE ON A CLEAR DRY DAY WITH MINIMAL TRAFFIC. THE TIRES WERE PURCHASED ON 4-23-11, SAM'S CLUB #6361, VEHICLE HAD 91,461 MILES. THE INCIDENT HAPPENED ON 5-8-18, THE VEHICLE HAD 136,896 MILES. (45,435 MILES). WHEN THE TIRE EXPLODED IT SEVERED THE FRONT LEFT BRAKE LINE RESULTING IN THE LOSS OF CONTROL OF THE VEHICLE, CAUSING MAJOR DAMAGE TO THE VEHICLE, RESULTING IN THE VEHICLE BEING TOTALED.

   NHTSA complaint 11098027
6. Filed Mar 28, 2018Failure Oct 21, 2017Canoga Park, CAElectrical system, Power train

   WAS DRIVING ON HIGHWAY AND VEHICLE ALL OF A SUDDEN LOST POWER KEPT PRESSING THE GAS PEDAL AND IT WOULDN'T GO AS FELT LIKE YOU WANTED TO TURN OFF IT WOULD STALL WE HAVE CHECKED EVERYTHING IN THE TRUCK ENGINE EVERYTHING AND EVERYTHING SEEMS GOOD TRANSMISSION DOES NOT HAVE ANY METAL SHAVINGS I DID NOTICE THAT FOR SOME REASON THE ELECTRICAL PANEL HAVE MELTED IT WAS ALL COMPLETELY MELTED AND THEY BELIEVE THAT THE TRANSMISSION IS ALSO MELTED AND STUCK TOGETHER I'M NOT SURE BECAUSE WE STILL HAVEN'T I MEAN TRANSMISSION HAS NO SIGNS THAT SOMETHING WRONG WITH IT I THINK THIS IS VERY THING I THINK THIS IS VERY DANGEROUS FOR A VEHICLE TO JUST STOP IN THE MIDDLE OF THE FREEWAY AND IMAGINE IF THEY WOULD HAVE BEEN TRAFFIC THANK GOD THAT THERE WASN'T THAT NOBODY WAS RIGHT BEHIND ME CUZ THE TRUCK JUST STOPPED AND IT WAS NOT GOING

   NHTSA complaint 11081775
7. Filed Jan 15, 2018Failure Jan 13, 2018259,000 milesHollywood, MDSteeringCrash

   WHILE BACKING THE VEHICLE I FELT A POP AND THEN THERE WAS NO STEERING CONTROL. I LOOKED UNDER THE VEHICLE AND FOUND THAT THE TIE ROD CONNECTION TO THE PITMAN ARM HAD SNAPPED.

   NHTSA complaint 11062779
8. Filed Jun 27, 2017Failure Jun 21, 2017166,000 milesAdelanto, CATread/belt

   TL* THE CONTACT OWNS A 2002 FORD EXCURSION EQUIPPED WITH SUNFULL MONT-PRO HT781 TIRES, SIZE: LT265/75/16. WHILE DRIVING 65 MPH, THE VEHICLE VIBRATED ABNORMALLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC TO BE DIAGNOSED. THE CONTACT WAS INFORMED THAT THE REAR PASSENGER SIDE TIRE TREAD SEPARATED, WHICH CAUSED A BUBBLE IN THE TIRE. WITHIN LESS THAN A THOUSAND MILES LATER, THE FRONT DRIVER'S TIRE ALSO EXPERIENCED THE FAILURE. THE RETAIL FACILITY WHERE THE TIRES WERE SOLD AND INSTALLED WAS NOT CONTACTED. THE TIRE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS UNKNOWN. THE APPROXIMATE VEHICLE FAILURE MILEAGE WAS 166,000 AND THE TIRE FAILURE MILEAGE WAS APPROXIMATELY 4,999.

   NHTSA complaint 11001709
9. Filed Aug 21, 2016Failure Aug 21, 2016Upper Marlboro, MDEngine

   I HAVE A 2002 FORD EXCURSIONS AND 2 TIME SPARK PLUG EJECTION FROM THE MOTOR.

   NHTSA complaint 10897435
10. Filed Jan 17, 2016Failure Jan 17, 2016167,000 milesMarlette, MIEngine

    I STARTED MY TRUCK AFTER SITTING FOR 36 HOURS AND WHAT SOUNDED LIKE BAD EXHAUST LEAK ..AFTER BEING CHECKED OUT BY MECHANIC FOUND THAT A SPARK PLUG AND COIL HAS BEEN SPIT OUT OF MOTOR ..I HAD THEM REPACE SPARK PLUG AND COIL ON TOP WHICH REPAIRED THE PROBLEM ..TODAY I WAS DRIVING TO TOWN 10 MILES AND AFTER STOPPI G TO GET GAS THE NOISE STARTED AGAIN !

    NHTSA complaint 10820717
11. Filed Nov 14, 2013Failure Jun 1, 2011110,000 milesLeonardtown, MDEngine

    TL* THE CONTACT OWNS A 2002 FORD EXCURSION. THE CONTACT STATED THAT THE VEHICLE BLEW THE NUMBER SIX SPARK PLUG OUT OF THE ENGINE. THE SPARK WAS REPLACED BUT THE FAILURE RECURRED. THE VEHICLE WAS NOT TAKEN TO THE DEALER OR AN INDEPENDENT MECHANIC FOR INSPECTION. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE ISSUE. THE APPROXIMATE FAILURE MILEAGE WAS 110,000.

    NHTSA complaint 10552212
12. Filed Jul 16, 2013Failure Jul 14, 2013176,000 milesScottsdale, AZVehicle speed control

    TL* THE CONTACT OWNS A 2002 FORD EXCURSION. THE CONTACT STATED THAT WHILE DRIVING 70 MPH, SHE APPLIED THE BRAKES TO DISENGAGE THE CRUISE CONTROL AND THE VEHICLE CONTINUED TO ACCELERATE INDEPENDENTLY. THE CONTACT WAS ABLE TO GET THE VEHICLE TO STOP AFTER SEVERAL MINUTES. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 176,000.

    NHTSA complaint 10525170
13. Filed Jun 9, 2013Failure Jun 5, 201386,800 milesPeoria, AZTires

    ON 6/5/2013, I WAS DRIVING ON FREEWAY AT APPROX. 70MPH AND TREAD SEPARATED FROM RT. REAR TIRE CAUSING VEHICLE TO SWERVE INTO ADJACENT LANE. DAMAGE TO QUARTER PANEL AND RUNNING BOARD. THIS IS THE SECOND TIRE FAILURE IN THE PAST 45 DAYS.THE TIRES ARE BFGOODRICH 265/75R/16 COMMERCIAL TA LOAD RANGE E. THE FOUR NEW TIRES WERE INSTALLED ON 2/28/2011 AND HAVE APPROX. 14,300 MILES OF WEAR AT TIME OF FAILURE. THE OTHER TIRE (LEFT FRONT) FAILED ON 4/19/2013. BECAUSE OF STRONG FRONT END VIBRATION, I INSPECTED THE FRONT TIRES. I FOUND THAT IT WAS OUT OF ROUND DUE TO BELT SEPARATION. THE DEALER REPLACED THIS TIRE ALSO. *TR

    NHTSA complaint 10515876
14. Filed May 11, 2013Failure May 11, 201380,000 milesTurlock, CAEngine

    ACCELERATING FROM A STOP, A SPARK PLUG EJECTED FROM THE CYLINDER HEAD. *TR

    NHTSA complaint 10511518
15. Filed Feb 8, 2013Failure Aug 6, 2012Hamlet, NCService brakesFire

    TL* THE CONTACT OWNS A 2002 FORD EXCURSION. THE CONTACT STATED THAT WHILE TRAVELING 55 MPH AND APPLYING THE BRAKES, THERE WAS AN ABNORMAL NOISE HEARD FROM THE BRAKING SYSTEM. THE BRAKE PEDAL BECAME STUCK AND THE VEHICLE WOULD NOT SLOW DOWN. THE CONTACT CONTINUED TO PUMP THE BRAKES AND WAS ABLE TO COAST TO A STOP. THE CONTACT LATER PARKED THE VEHICLE AND NOTICED THAT A FIRE HAD STARTED FROM UNDER THE VEHICLE. THE CONTACT WAS ABLE TO EXTINGUISH THE FIRE HOWEVER, THE TRANSMISSION AND CENTRAL COMPUTER WAS DESTROYED. THE VEHICLE WAS TOWED TO A DEALER WHERE THE TRANSMISSION COMPUTER MODULE, TRANSMISSION AND THE BRAKE BOOSTER WAS REPLACED. THE DEALER ADVISED THAT THE BRAKE BOOSTER LEAKED ONTO THE TRANSMISSION AND THE FRONT DRIVE SHAFT, CAUSING THE VEHICLE TO CATCH ON FIRE. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO THE DEALER THREE WEEKS PRIOR TO FIRE AND THERE WAS NO INDICATION OF A POTENTIAL FAILURE. THE FAILURE MILEAGE WAS UNKNOWN. THE CURRENT MILEAGE WAS 190,000.

    NHTSA complaint 10496815
16. Filed Jun 27, 2012Failure Jun 27, 2012Gilberts, ILEngine

    THE SPARK PLUG BLEW OUT OF THE CYLINDER HEAD (CYL #3), DAMAGING THE THREAD, THE SPARK PLUG, THE SPARK PLUG BOOT AND THE IGNITION COIL. THIS IS THE SECOND TIME THIS HAS OCCURRED IN THIS VEHICLE IN THE LAST TWO YEARS. THE FIRST WAS APPROXIMATELY 2 YEARS AGO AND THAT WAS THE PLUG IN CYLINDER #5. THE SAME DAMAGE OCCURRED. *TR

    NHTSA complaint 10463359
17. Filed Apr 2, 2012Failure Mar 24, 2012Alexandria, VAFuel system, Diesel

    ENGINE PERFORMANCE SUDDENLY BECAME ERRATIC AND VERY ROUGH RUNNING. IMMEDIATELY TURNED AROUND AND WENT HOME/ HAD TOWED TO FORD DEALER. DEALERSHIP RAN $250 DIAGNOSTIC TEST BUT CAME BACK CLEAN. I WAS DIRECTED TO CHANGE ENGINE OIL AS AIR MIGHT HAVE GOTTEN INTO THE FUEL INJECTION LUBING SYSTEM ALONG WITH CHANGING THE FUEL FILTER. ON PERFORMANCE OF FUEL FILTER REPLACEMENT, TECHNICIAN DIRECTED MY ATTENTION TO WHAT APPEARED TO BE SMALL PIECES OF METAL TRAPPED IN AND ON TOP OF FILTER ELEMENT. MECHANIC SAID THIS IS VERY COMMON PROBLEM WITH METAL THE RESULT OF DELAMINATION OF THE INNER LINING OF THE FUEL TANK IN FORD DIESELS. INTERNET RESEARCH REVEALS MANY MANY COMPLAINTS TO BOTH FORD AND NHTSA OVER THIS ISSUE. THIS CREATES A VERY DANGEROUS SITUATION DUE TO LOSS OF POWER STEERING, BRAKES, AND TRAILER BRAKES WHICH COULD EASILY RESULT IN LOSS OF LIVES. I HAVE COMPLAINED TO FORD AND MY COMPLAINT HAS BEEN DULY NOTED AND REGISTERED. *TR

    NHTSA complaint 10453823
18. Filed Jan 31, 2012Failure Oct 13, 2011100,000 milesHouston, TXEngine and engine cooling

    TL* THE CONTACT OWNS A 2002 FORD EXCURSION. THE VEHICLE WAS INCLUDED IN THE RECALL UNDER NHTSA CAMPAIGN ID NUMBER: 07V553000 (ENGINE AND ENGINE COOLING:ENGINE:DIESEL) AND WAS REPAIRED. AFTER THE REPAIR WHILE DRIVING APPROXIMATELY 65 MPH, THE VEHICLE BEGAN TO DECELERATE INDEPENDENTLY. THE VEHICLE WAS TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING WHERE THE TECHNICIAN PERFORMED REPAIRS TO THE VEHICLE BUT THE CONTACT WAS UNAWARE OF THE EXACT REPAIRS. THE FAILURE CONTINUED. THE VEHICLE WAS NOT FURTHER REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 100,000.

    NHTSA complaint 10446030
19. Filed Jan 21, 2012Failure Jan 18, 2012146,000 milesWills Point, TXEngine and engine cooling

    #4 SPARK PLUG BLEW OUT OF ENGINE HEAD, THREADS DESTROYED. FORD DEALER SERVICE DEPARTMENT TOLD ME THIS IS A KNOWN DEFECT IN THE FORD 5.4 TRITON ENGINE HEAD AND THAT FORD IS DOING NOTHING ABOUT IT. *TR

    NHTSA complaint 10444725
20. Filed Jan 18, 2012Failure Jan 5, 201262,550 milesPinson, ALDiesel

    TL* THE CONTACT OWNS A 2002 FORD EXCURSION. THE CONTACT WAS DRIVING 45 MPH WHEN THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS RESTARTED AFTER THE FAILURE AND TAKEN TO A PRIVATE MECHANIC. THE MECHANIC CONFIRMED THAT THE CAMSHAFT SENSOR NEEDED TO BE REPLACED. THE MANUFACTURER WAS CONTACTED AND THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 62,550 AND THE CURRENT MILEAGE WAS 62,600. UPDATED 02/22/12*LJ UPDATED 03/01/12

    NHTSA complaint 10444345