Manifold/header/muffler/tail Pipe Problems of Ford Excursion

The contact owns a 2004 Ford Excursion. The contact stated that upon starting the vehicle, a large cloud of smoke emitted from the tail pipe. The failure recurred on an intermittent basis. The contact also stated that the engine fan would intermittently create a very loud noise. The vehicle was taken to an authorized dealer and the contact was informed that coolant was leaking into the engine. The contact was informed that the engine would need to be rebuilt. The vehicle was not repaired. The manufacturer was made aware of the failure, but offered no assistance. The failure mileage was 81,000. Updated 11/01/lj.

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I was driving my Excursion aeound 25 mph and as I accelerated to 35 mph I heard a loud bang and thought my exhaust manifold may have cracked or came loose. After further investigation I found the spark plug wire and spark plug were blown out. Called local mechanic and said I needed to bring it to Ford for approx 4k, Ford would replace the head. I went on line and purchased a kit, Ford is aware of the problem with the spark plug being blown out of the head but will not recall the truck. Note that this is affecting many vehicles, not only Ford. This is a huge issue and very unfair that the manufacturer of the head is getting away with the poor quality control and the fact that they are not correcting the issue for the consumer.

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Was starting from a stop to make a left turn when driver heard a loud pop. There was a sudden loss of power and some smoke. The vehicle was towed and diagnosed. The #3 plug on the right bank has blown completely out and damaged the coil pack. A phone call to the dealer yielded no help other than we can have it towed there to be repaired, as it likely needs a new head. Some internet research and talking to other Ford owners definitely suggest that this is a design problem with the alum heads blowing out spark plugs, and the #3 r plug seems to be common. This could cause fuel/vapors to be exhausted and sprayed on a hot manifold and cause a fire. It sounds like there may have already been some fires attributed to this problem. This sound like a case where the dealer/Ford refuses to admit that it is a problem and fix it for owners. Before there are serious injuries from a crash or a fire, Ford should be compelled to fix this issue. Its unlikely that Ford will answer the call without pressure from NHTSA. There seem to be far too many of the same type of problems with this 5. 4l motor for it to be a coincidence.

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Exhaust manifold bolts, rusted and broken off, right bank.

A spark plug blew out of my 2000 Ford Excursion today on my way home. It was a loud bang, I thought the exhaust manifold cracked or muffler went. Apparently this is a common problem that Ford will not repair. It will cost about $4500. To fix. I am very surprised that I did not hear this on the news, it has happened to many Ford owners but never heard about it until I had this issue. It is very unfair that it is a common problem with Ford and the government does not enforce a recall. Ford recalled but did not correct the cruise control defect that could cause a fire. Fire. . . That is enough reason to recall the vehicle.

2001 Ford Excursion v10. Exhaust manifold bolts breaking on both banks of engine. Rust and corrosion looks to be the cause. Vehicle has only 61,000 miles on it. This is a big problem with Ford v10 engines as there are many instances that can be found on the internet. Exhaust gases can and do leak because of the bolts breaking. This releases un-treated exhaust gas into the atmosphere, hydrocarbons and nitrates of oxygen are the worst and normally would be treated by the catalytic converter. Ford will not repair the condition under any warranty. I believe that this should be a recall as the effect of the problem is a public health issue.

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I own a 2000 Ford Excursion with a v10. While driving home from my son's track meet in a construction zone on i94 in mount clemens michigan during rush hour I had a spark plug blow out. We (my wife, my son and I) were moving about 10 miles an hour in the construction traffic when we began to slowly speed up. I accelerated and boom, there was a very loud sound of knocking. I nearly hit the dividing wall it scared me so bad. I was able to pull over about 150-200 feet ahead through the construction barrels. I opened my hood and discovered that one of my coil packs was sticking up a few inches and broken. I called my insurance company (usaa) for roadside assistance. Within an hour and a half they sent a tow truck and had me towed (about 7 miles) home. The next day I was able to better inspect what had gone wrong. The motorcraft spark plug had completely un-threaded itself and the compression of the motor turned the spark plug into a projectile that completely demolished the coil pack. The coil pack snapped from its retaining bolt and was beating against my fuel rail. Luckily I was able to pull over as soon as I did because I could only imagine if I had been in an area where I was traveling the actual 70 mph speed limit and the damage to my fuel rail could have been disastrous possibly causing a fire. I contacted russ milne Ford in clinton twp michigan about this issue and they stated that it would cost over $1000 to replace the head and that it was caused by the threads on the head or improper torquing of the spark plug. I found that amazing since I had my truck serviced by them about a year before because of an slight engine knock that I had on the passenger side of the motor along with a few other minor things. They never were able to find the cause of the "engine knock". Unfortunately for me the engine knock was a sign of the pending failure that I wish had been discovered before the blow out. No repairs yet.

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.

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While driving my 2002 Ford Excursion on the interstate at about 65 mph, I heard a thump under the hood and then my engine began to make a loud clunky sound (almost as if there were no muffler). One of the sparks plugs had blown out of the engine! luckily, my Excursion was still drivable and I was within a few miles of my home and could park it until I could seek repairs on Monday. I did not take it to the Ford dealership (trust issues). I took it to tune-up 2000, where they told me the spark plug threads had stripped out causing it to blow form the engine. It had to be re-threaded, costing me $500. This puts my repair bills, for my less than four year old Excursion, at over $3500 in 2005. The entire transmission had to be rebuilt this summer due to a cracked transmission case.

Consumer has taken vehicle to the dealership on two occasions concerning exhaust clamp cracking and falling off. Mechanic was able to fix the problem.