One problem related to manifold/header/muffler/tail pipe has been reported for the 2003 Ford Excursion. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2003 Ford Excursion based on all problems reported for the 2003 Excursion.
Faulty exhaust manifold bolts break off and cause excessive noise, exhaust enters the drivers cabin, vehicle will not pass emissions inspection and is expensive to repair. I have 4 Ford vehicles with this problem. First incident was at around 50,000 miles and 48 months after purchase. Ford refused to make repairs under any portion of the factory warranty. They claim lifetime emissions warranty doesn't cover it, nor the 100,000 powertrain warranty. I have spent over $8000. 00 making repairs to these exhaust manifolds. Triton v-10 gas engine.