VehicleVerdict

2004 Ford Excursion problems

Verdict · NHTSA data

Worth extra scrutiny

The 2004 Ford Excursion sits mid-pack among Excursion years: 125 NHTSA complaints against a model median of roughly 104, with 2 recalls and 3 closed investigations.

No single system dominates the record — complaints spread across engine (30), electrical system (24), and fuel system (12), which usually points to general build quality rather than one defect.

125

NHTSA complaints

2

Recalls

3

Investigations

6

Crash-involved

3

Fires reported

7

Injuries

0

Deaths

—

NCAP overall

How does 2004 compare to other Excursion years?

Excursion NHTSA complaints by model year, 2004 highlighted635 complaints1997: 1 complaints1998: 0 complaints1999: 10 complaints2000: 635 complaints2001: 240 complaints2002: 150 complaints2003: 139 complaints2004: 125 complaints2005: 84 complaints2010: 1 complaints
Excursion NHTSA complaints by model year, 2004 highlighted. Red bars are years to avoid.

See all Excursion years to avoid →

What are the most common 2004 Ford Excursion problems?

ComponentComplaintsShare
Engine3024%
Electrical System2419%
Fuel System1210%
Speed Control97%
Transmission76%
Tires & Wheels65%
Brakes65%
Visibility & Wipers54%
Airbags32%
Latches & Locks32%
Lighting32%
Seats32%
Steering32%
Body & Structure32%
Suspension32%
Seat Belts22%
Other22%
Climate Control (A/C & Heat)11%

Does the 2004 Ford Excursion have recalls?

2 NHTSA recall campaigns on file. Recall repairs are free at franchised dealers.

11V352000LightingJuly 13, 2011 · 26,715 units

Defect

FORD IS RECALLING CERTAIN MODEL YEAR 2011 RANGER TRUCKS BUILT FROM JANUARY 25, 2011, THROUGH APRIL 25, 2011 AT THE TWIN CITIES ASSEMBLY PLANT, AND SERVICE PARTS DISTRIBUTED TO DEALERS FOR CERTAIN 2004 THROUGH 2011 MODEL YEAR RANGER TRUCKS, 2002 THROUGH 2005 MODEL YEAR EXCURSION VEHICLES, AND 2002 THROUGH 2007 MODEL YEAR F-250, F-350, F-450, AND F-550 TRUCKS FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THE MULTI-FUNCTION SWITCH WAS SHIPPED WITH A SUBCOMPONENT (SLIDER) THAT MAY EXPERIENCE DEFORMATION. A MULTI-FUNCTION SWITCH WITH A DEFORMED SLIDER MAY MALFUNCTION CAUSING THE TURN SIGNAL, TAIL LIGHTS, HAZARD WARNING SIGNAL FLASHERS AND/OR BRAKE LIGHTS NOT TO ACTIVATE.

Consequence

NON-FUNCTIONING LIGHTS COULD INCREASE THE RISK OF A CRASH.

Remedy

DEALERS WILL REPLACE THE SWITCHES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 15, 2011. OWNERS MAY CONTACT FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.

05V270000Electrical SystemJune 10, 2005 · 180,104 units

Defect

CERTAIN PICKUP TRUCKS, SPORT UTILITY VEHICLES AND VANS EQUIPPED WITH 6.0L DIESEL ENGINES MAY EXPERIENCE STALLING WITHOUT WARNING WHILE DRIVING AND MAY OR MAY NOT RESTART.

Consequence

SHOULD THE ENGINE STALL, A VEHICLE CRASH COULD OCCUR.

Remedy

DEALERS WILL UPGRADE THE FUEL INJECTION CONTROL MODULE (FICM) WIRE HARNESS OR REPLACED, AND/OR HAVE A NEW INJECTION CONTROL PRESSURE (ICP)) SENSOR CONNECTOR INSTALLED FREE OF CHARGE. THE RECALL BEGAN ON JULY 22, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673.

Consumer complaints filed with NHTSA

Representative excerpts, cleaned of personal information. These are consumer statements, not verified defects.

“TL* THE CONTACT OWNS A 2004 FORD EXCURSION. WHILE HAVING THE VEHICLE SERVICED FOR ROUTINE MAINTENANCE AT AN INDEPENDENT REPAIR SHOP, HE WAS INFORMED WATER WAS LEAKING AROUND THE EGR COOLER AND ANTI FREEZE WAS LEAKING INTO THE EXHAUST SYSTEM. THE VEHICLE WAS NOT REPAIRED AND THE FAILURE CONTINUES.…”

Complaint filed with NHTSA · Engine · July 15, 2010

“WHILE DRIVING 35 MPH, A FIRE STARTED UNDER THE HOOD. CONSUMER MANAGED TO PULL OVER , AND PUT OUT THE FIRE. HAD THE VEHICLE TOWED. DEALERSHIP WAS NOTIFIED, BUT DID NOT RESOLVE THE PROBLEM. *AK”

Complaint filed with NHTSA · Electrical System · February 2, 2005 · fire

“TL* THE CONTACT OWNS A 2004 FORD EXCURSION. THE CONTACT STATED THAT THE VEHICLE FAILED TO START. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE THE TECHNICIAN DIAGNOSED THAT THE FUEL INJECTOR CONTROL MODULE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE…”

Complaint filed with NHTSA · Fuel System · May 25, 2014

“TL*THE CONTACT OWNS A 2004 FORD EXCURSION. IN JULY OF 2009 THE VEHICLE WAS TAKEN TO THE DEALER FOR RECALL 09V399000 VEHICLE SPEED CONTROL; HOWEVER, THE REPAIR DIDN'T CORRECT THE FAILURE. ON JULY 30, 2010 WHILE DRIVING THE CONTACT NOTICED SMOKE UNDER THE HOOD. THE VEHICLE WAS TOWED TO A LOCAL…”

Complaint filed with NHTSA · Speed Control · July 30, 2010 · crash

“DT: VEHICLE WAS INVOLVED N AN ACCIDENT DUE TO BRAKE FAILURE. THE ABS WENT OUT. WHEN OPENED THE HOOD FOR INVESTIGATION THE MASTER CYCLINDER SEPARTED FROM THE BRAKE BOOSTER CYLINDER. NO LOCK ON BOLT AND THE NUT SHEARED ITSELF OFF. CALLED FORD AND LEFT MESSAGE. HAD TO PUT NEW TRANSMISSION AT 16,000…”

Complaint filed with NHTSA · Transmission · May 29, 2005 · crash

2004 Ford Excursion — common questions

Is the 2004 Ford Excursion reliable?

It is close to typical for the Excursion: 125 NHTSA complaints, 2 recalls, and 3 investigations on file.

What are the most common 2004 Excursion problems?

According to NHTSA complaint data, the leading problem areas are engine (30 complaints), electrical system (24 complaints), fuel system (12 complaints).

Does the 2004 Ford Excursion have recalls?

Yes — NHTSA lists 2 recall campaigns affecting the 2004 Ford Excursion. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Is the 2004 Ford Excursion under NHTSA investigation?

NHTSA opened 3 investigations into this model year; all are now closed.

Which Ford Excursion years should you avoid?

Based on complaint rates and open investigations, the Excursion years to avoid are 2000, 2001. The cleanest record among Excursion years belongs to 1998.

Related

Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.

Compiled by Sharon Ben-Moshe, Founder.