Ford's largest SUV from 2000 to 2005, the Ford Excursion is a full-sized vehicle designed for buyers who have super-sized interior cargo and towing needs. However, because of its humongous size, it was also labeled as one of TIME Magazine's 50 Worst Cars of all Time. For the consumers, not only is it a challenge for them to drive and park the vehicle, but it was also inconvenient for them to find several faulty components.
One of the bad Ford Excursion parts that owners complained about is the vehicle's set of lower ball joints. It has been reported that this component wears easily, causing a lot of steering problems. These issues include stiff steering, poor steering wheel return, and possible wandering. Owners who encounter this problem are advised to replace it immediately with a set that has grease fitting. Regular lubrication of the replacement part is also recommended.
Repeated heater core failures are common in the Ford Excursion as well. Owners reported related problems including the heater and A/C not working at the front or at the rear. Fixing this issue requires installing redundant electrical system ground connections as well as a restrictor in the heater inlet hose.
Ford Excursion owners also complained that sometimes it was hard to turn the ignition. When it does, sometimes it does not spring back from the start position. Some owners reported that when they turn the ignition, all the dashboard lights come on but the engine doesn't start. While this is an intermittent problem, it could cause a huge inconvenience to those who are in a hurry to leave.
Another problem component, the Ford Excursion spark plug hole threads in the cylinder heads get easily damaged or stripped out when the plugs are removed. This issue is said to be caused by carbon building up on them.
Owners also complained about the spark plugs suddenly blowing out even when the vehicle or the component is still new. While no bulletin has been issued about this yet, prospective buyers of the Ford Excursion should take note of this when shopping around for a new or used truck.