Four problems related to gas recirculation valve (egr valve) 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.
Total loss of engine power massive amount black soot exiting exhaust while driving recall # 05v270000 was not performed on vehicle ( I am the original owner) never received notice in mail and dealer somehow missed this "work" and Ford should have followed through on this situation. Other repairs done to this vehicle to "fix" this problem was to drain the fuel tank (algae in fuel was the excuse-no algae) fuel pump and filter rail (not problem) two turbochargers were replaced due to excessive sooting (one warranty one at my expense) egr valves and a cam sensor (Ford knows the problems exist because Ford discountinued the 6. 0 litre motor) this problem has occured multiple times over my ownership.
On 11/26/13 driving back from atlanta heading south leaving the florida welcome center on I-75, 4 miles north of jennings on I-75 south jennings. Leaving the welcome center the vehicles engine lost power while trying to merge back into traffic without any prior indication of a problem. The loss of power caused us to have to divert from the lane until we could gain more speed. The vehicle had no accelerating power above 40 mph even with the gas pedal depressed all the way to the floor. There were no check engine lights on or any abnormal indicators. I called the Ford customer care center on 12/12/13 and they acknowledge they have a problem with the erg failing due to collecting carbon and soot build up. They have not issued any service bulletins to owners letting them know there is an issue or have issued a maintenance program to try to prevent this from occurring. 1)Ford designed the engine to pass soot and carbon back thru the erg valve. It is a bad design since it causes every engine to eventually fail. 2)Ford does not warranty the egr valve or any component if soot or carbon sticks to the valve or component, even though it is designed to do so. 3)Ford knows there is an issue with the egr failing which deposits soot and carbon in the intake of the engine which causes the engine to lose power and or ultimately quit without warning. 4)no service bulletins were issued to owners warning them of this safety problem. 5)cleaning the egr valve is not listed in the issued service manual. 6)no preventative maintenance service was offered to prevent this failure from occurring. 7)dealers enjoy this failure since it is a high labor revenue generator for them to tear down the engine to replace or clean the intake manifold. 8)the repair cost was approximately $3319. 90 the vehicle is currently under the highest Ford premium care warranty.
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. The failure and current mileages were 95,000.
This vehicle has been serviced countless times for stalling. Each time the dealer has replaced the egr valve and other items because of failure codes. Each time the egr valve has failed. The dealer is "repairing" the vehicle and giving it back to me. Within 5 minutes after receiving the vehicle from the service department, it stalls again. The vehicle will stall at least 3 times during a 30 minute drive. It stalls on the freeway, on residential streets, starting from a dead stop, and if it is driving at a constant speed. This vehicle is not fixed and it is obvious the dealer cannot fix it! it is going in tomorrow for the 3rd time this month for the same problem. I have almost gotten in an accident from it stalling, and I have had many times where I have been in a dangerous situation from it stalling. The dealer cannot fix it, I cannot sale it to another person in this condition, and Ford won't do anything to help me. I am driving a very dangerous vehicle and have no way to fix it. What can I do? please give me a suggestion. Do I have any rights if the vehicle cannot be fix?.