The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate when reading these PIDs and cannot display quickly enough to validate a concern. The PCM automatically monitors these inputs more accurately and will set diagnostic trouble codes (DTCs) when appropriate. Using these PIDs for diagnostics will lead to inaccurate results and improper ETB replacements. If a concern is intermittent and no DTCs are present, refer to historical DTCs and the PC/ED, Section 3 No DTCs Present Index chart for further information.
full bulletin at NHTSA ↗2005 Ford Excursion engine problems
severe 19 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
19
Recalls
0
Avg fix
$3,100
1fire
When does it fail?
Of the 19 engine complaints filed for the 2005 Ford Excursion, here's the actual mileage breakdown — failures cluster heaviest at 0-25,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Engine accounts for 29% of all owner complaints filed against this vehicle, across 6 categories tracked.
No new NHTSA engine complaint has been filed on this vehicle in over 16 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering engine on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
FORD: ON SOME TRUCKS, THERE IS A NO CRANK SITUATION AND IF VOLTAGE ON TRANSMISSION RANGE SENSOR AT PIN 21, IS LESS THAN 5 VOLTS, DISCONNECT THE ENGINE COOLING FAN CLUTCH, ELECTRONICALLY, AND RECHECK VOLTAGE. MODEL 2003-2007 F SUPER DUTY, 2004-2010 E SERIES, 2003-2005 EXCURSION.
full bulletin at NHTSA ↗FORD: SOME VEHICLES WITH DIESEL ENGINES MAY EXPERIENCE NO STARTS, HARD STARTS OR ROUGH RUNNING WHEN COLD AND MAY BE ACCOMPANIED WITH DIAGNOSTIC TROUBLE CODES (DTCS) P0611, P1378 AND/OR ALL 8 INJECTOR CIRCUIT CODES.
full bulletin at NHTSA ↗FORD: SOME VEHICLES EQUIPPED WITH 6.0L DIESEL ENGINE MAY EXHIBIT ANY ONE OR COMBINATION OF THE FOLLOWING CONCERNS-LACK OF POWER, WHITE/BLACK SMOKE OR A SURGE.
full bulletin at NHTSA ↗FORD TRUCKS: MISFIRE, LACK OF POWER, BUCK/JERK, EXCESSIVE SMOKE, CRANK/NO START-DIAGNOSTICS FOR FUEL SYSTEM. THERE ARE SEVERAL POTENTIAL CAUSES FOR THESE SYMPTOMS.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners of 2005 Ford Excursion 6.0L diesels describe a cascade of engine failures. The most common complaint is the head gaskets blowing out from head bolts stretching—a dealer even told one owner this was so routine he'd need aftermarket ARP Racing head bolts ($600) to prevent recurrence.
EGR coolers fail and rupture repeatedly, with one owner replacing the same cooler twice before resorting to an aftermarket unit. Another owner faced a $4000 bill out of warranty, only to discover the design itself is flawed.
Stalling while driving is widespread and dangerous. Vehicles shut down at highway speeds (70 mph, 65 mph, 40 mph) with zero warning, robbing owners of power brakes and steering. Some stall up to nine times in a single day. Dealers spent weeks troubleshooting without fixing it; one owner dropped $1800 on diagnostics with no resolution.
Spark plugs eject from the cylinder head on factory-installed plugs. One owner noted research showing plugs can rupture the fuel line above them, igniting fires. A dealer refused warranty coverage, blaming loose plugs on the owner despite factory installation.
EGR valve sticking causes repeated roadside failures. One owner had it serviced five times and crashed into his trailer when the truck died and killed his power steering. Turbochargers fail within weeks of replacement. Wiring harness defects cause stalling that resurface days after repair.
Fuel delivery problems persist despite five replacements of the fuel pedal assembly. Throughout, owners report Ford knew about these defects but offered little support outside the initial warranty window.
Failure modes owners describe
Head gasket failure
Head gaskets blow out, typically after head bolts stretch. Occurs under towing load and high operating temperatures. Owners report dealers acknowledging this as common on 6.0L diesel engines.
When: Early in ownership; one owner experienced failure again at higher mileage
Symptoms owners cite: Engine overheating; Loss of coolant; White smoke from exhaust
Repairs/costs cited: Ford replaced under warranty in early years; owner upgraded to ARP Racing head bolts ($600) to prevent recurrence. Later failures out of warranty reported as $4000+ repairs.
Recalls/TSBs owners mention: Early warranty repairs; dealer acknowledged design issue and head bolt stretch as root cause
EGR cooler rupture
EGR cooler and oil cooler assembly ruptures repeatedly. Owners found the cooler design itself to be fundamentally flawed. Multiple owners required replacement; one replaced twice and eventually installed aftermarket unit.
When: 2008 at 106,000+ miles; recurred within years on same vehicles
Symptoms owners cite: Coolant leaks; Engine overheating
Repairs/costs cited: Warranty covered first failures; out-of-warranty repairs reported as $4000. One owner installed aftermarket cooler with no further problems.
Recalls/TSBs owners mention: Covered under warranty initially; offered no assistance out of warranty despite known design flaw
Engine stalling while driving
Vehicle shuts off without warning while driving at various speeds (5 mph to 70 mph). Occurs repeatedly and unpredictably, sometimes 9 times in one day. Owners lose power steering and brakes when stalling occurs, creating safety hazard. Multiple service attempts fail to resolve.
When: Throughout vehicle ownership; one owner had issue at 41,000 miles, another at 125,165 miles
Symptoms owners cite: Unannounced engine shutdown; Loss of power steering; Loss of power brakes; No restart capability initially
Repairs/costs cited: One replacement of high-volume oil pressure pump performed with temporary resolution; other cases remained undiagnosed despite dealer and independent shop troubleshooting. One owner spent over $1,800 on diagnostics without resolution.
Recalls/TSBs owners mention: Limited; some dealers unable to diagnose; manufacturer provided no repair guidance on unresolved cases
Spark plug ejection from cylinder head
Spark plugs blow out or detach from cylinder head. Factory-installed plugs loosen, creating ejection hazard. Owner reports research showing instances of spark plugs rupturing fuel lines above spark plug and igniting fires.
When: Occurs at various mileages; one reported at 140,000 miles
Symptoms owners cite: Check engine light; Spark plugs detaching or being expelled; Potential for fire if fuel line ruptures
Codes mentioned: Check engine light illuminated
Repairs/costs cited: Helicoil installation attempted; spark plugs replaced. Recurred after repair on at least one vehicle.
Recalls/TSBs owners mention: Dealer denied warranty coverage, claiming loose plugs are owner fault despite factory installation
EGR valve malfunction
EGR valve sticks or fails, causing repeated roadside breakdowns. Owner reports replacing and cleaning valve five times. One owner experienced white smoke and loss of power while backing down driveway.
When: Throughout ownership; one owner had five service events over vehicle ownership period
Symptoms owners cite: Vehicle stalls on highway; White smoke from exhaust; Engine surging; Loss of power and braking when stalled; Check engine light
Repairs/costs cited: Multiple replacements and cleanings performed (5 times on one vehicle). One owner crashed into trailer during stall event.
Recalls/TSBs owners mention: Ford aware of issue; documented in ambulance industry; provided minimal support
FICM module failure
Fuel injection control module malfunctions, causing engine light and running issues. Owners report this is subject to recall on similar vehicles but not their specific VINs.
When: 2009 and later; varies by vehicle
Symptoms owners cite: Check engine light illumination; Fuel delivery issues
Codes mentioned: Recall #05V27 referenced but not applicable to all vehicles
Repairs/costs cited: Replacement part cost $700 plus labor when out of warranty. One owner had fuel pedal module assembly replaced 5 times without resolution.
Recalls/TSBs owners mention: Recall #05V27 exists but does not cover all vehicles; manufacturer offered no assistance to excluded VINs
Fuel system failure to start
Vehicle occasionally fails to start despite engine turning over. No fuel reaches engine. Owner reports replacement of fuel pedal assembly multiple times without resolution.
When: Recurring throughout ownership
Symptoms owners cite: Engine cranks but will not start; No fuel delivery to engine
Repairs/costs cited: Fuel pedal assembly and module replaced 5 times with problem persisting
Turbocharger failure
Turbocharger quits working while driving, requiring replacement. Recurrence within weeks of first repair.
When: May 2007 on one vehicle; recurred June 2007
Symptoms owners cite: Loss of boost pressure
Repairs/costs cited: Turbo replaced May 2007; failed again in June 2007
Wiring harness failure
Wiring harness defect causes vehicle stalling while driving on freeway. Replacement did not fully resolve stalling issues on that vehicle.
When: July 2007 on one vehicle
Symptoms owners cite: Vehicle stalls while driving on freeway
Repairs/costs cited: Wiring harness replaced; vehicle stalled again 3 days after repair
EGR/exhaust regulator failure with head gasket damage
Exhaust regulator fails, emitting heavy white smoke. Extended driving allows water and gasoline to enter engine, damaging head gaskets through overheating.
When: 163,000 miles on reported vehicle
Symptoms owners cite: Heavy white smoke from tailpipe; Engine overheating; Head gasket failure
Repairs/costs cited: Dealer identified as known problem but did not repair vehicle
Recalls/TSBs owners mention: Dealer acknowledged this as known problem
Synthesized from 19 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 5 most recent
My vehicle randomly experiences engine stalls while driving. It has stalled while traveling up to 40 MPH in traffic. When it stalls I lose power brakes and steering. I've had the vehicle at the dealer off and on for approximately two months and they are unable to fix the problem. *tr
I am so disappointed in purchasing this Ford truck....I have had this vehicle for 5 years and it has been in the shop on several occasions for the same reason...EGR valve gets stuck and I'm stuck on side the highway....I cannot trust this vehicle to get me to the corner store let alone a long distance trip. Although I loved my truck...the cost of these repairs have just been astronomical, not to…
Tl* the contact owns a 2005 Ford excursion. While driving approximately 10 MPH, the check engine warning light illuminated and the spark plugs detached from the cylinder head. The vehicle was taken to an independent mechanic. The helicoil was installed and the spark plugs were replaced. The vehicle was repaired, but the failure recurred. The manufacturer was notified of the failure. The…
Tl* the contact owns a 2005 Ford excursion. The contact stated that the exhaust regulator was failing. This failure would cause a heavy white smoke to emit from the tail pipe and if the vehicle was driven for long periods of time, the head gasket would overheat and allow water and gasoline into the engine. The dealer inspected the vehicle and stated that the failure was a known problem on the…
While towing a camper, the engine overheated about 4 hours into the trip. The truck and trailer had to be towed home. The truck was brought to Ford and it was determined that the head gaskets blew out. The dealer said this was common with the 6.0 diesel engines. He stated that it was caused by the head bolts stretching. He repaired it, but, told me I would be back again unless I purchased…
Had engine trouble with your 2005 Ford Excursion?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the engine problem on the 2005 Ford Excursion?
It's a meaningful issue. 19 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $3,100.
At what mileage does the engine typically fail?
Across the 19 complaints that reported odometer mileage, most engine failures cluster between 55,000 and 135,000 miles, with the median around 87,000. A quarter of owners report trouble before 55,000; a quarter make it past 135,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $3,100 for engine repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to engine?
No active recalls currently cover engine issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2005/Ford/Excursion.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.