Three problems related to engine exhaust system have been reported for the 2004 Ford Excursion. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2004 Ford Excursion based on all problems reported for the 2004 Excursion.
While driving behind this vehicle, it continually emitted dark gray to black smoke upon acceleration at each stop and each traffic light. I wrote down the vehicle license plate only to notice that the expiration date on the tages was April 2010!! this was approximately a 2010 beige Ford Excursion, license plate #5mkh139.
The contact reported that the exhaust is going into the 2004 Ford Excursion. This has been happening for 3 months. When the vehicle is idle or stopped at a light the exhaust comes through the heating grate. The vehicle has 30000 thousand miles on it and had 24000 miles when problem started. The dealer has tried to fix the problem but nothing has worked permanently. They driver is suffering headaches and drowsiness when driving. Updated 01/20/10 the dealer replaced the left exhaust manifold gasket. Updated 01/22/10.
While driving at any speed with the windows down consumer can smell exhaust fumes. Dealership was notified, but did not resolve the problem.