Two problems related to gas recirculation valve (egr valve) have been reported for the 2005 Ford Excursion. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2005 Ford Excursion based on all problems reported for the 2005 Excursion.
Tl- the contact owns a 2005 Ford Excursion. The contact stated that she took her vehicle to the dealer for an oil change and was informed that the egr cooler would need to be replaced. The manufacturer was contacted but offered no assistance. The vehicle had not been repaired. The failure and current mileages were 106,000. Kmj.
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 arp racing head bolts($600). I researched it online and found he was correct. I provided the bolts and Ford did the repair under warranty. In 2008, the egr cooler/oil cooler ruptured and had to be replaced (under warranty). In 2009, the ficm module malfunctioned. Since the truck was now out of warranty, Ford wanted $700 for the part, plus labor. In 2010, the egr cooler/oil cooler ruptured again. Since the truck was out of warranty, I was told it would be $4000 to repair. I researched online again and found the whole egr design was flawed. I purchased an aftermarket designed cooler and, since then, have had no more problems.