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2002 Ford Excursion Recalls, Problems & Maintenance

The 2002 Ford Excursion has no open NHTSA recalls. Owners report 8 recurring issue clusters, led by “Spark plug ejection from cylinder head.” Ford uses the Intelligent Oil-Life Monitor (IOLM) to determine when oil changes are due based on actual driving load — not just mileage. Ford's published cap is 10,000 miles or 1 year, whichever comes first. The schedule below reflects Ford's Normal service intervals; F-Series trucks and Super Duty have additional towing-specific items.

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No open recalls on file. NHTSA lists no unrepaired safety recalls for this year, make and model. A recall can be issued at any time, and a specific car can still have one open — check yours by VIN at nhtsa.gov/recalls.

Known issues & problems for this vehicle

What drivers and federal regulators have officially reported about the 2002 Ford Excursion.

Reported to NHTSA

Spark plug ejection from cylinder head

ENGINE AND ENGINE COOLING

21 NHTSA complaints · 2004-07 → 2016-08

“THE SPARK PLUG BLEW OUT OF THE CYLINDER HEAD (CYL #3), DAMAGING THE THREAD, THE SPARK PLUG, THE SPARK PLUG BOOT AND THE IGNITION COIL. THIS IS THE SECOND TIME THIS HAS OCCURRED IN THIS VEHICLE IN THE LAST TWO YEARS”
— Owner report, NHTSA ODI #10463359
“2002 FORD TRITON 6.8L V10 ENGINE IN AN EXCURSION VEHICLE EJECTED AN ORIGINAL (UNCHANGED, FACTORY TORQUED) SPARK PLUG WITH GREAT FORCE AND DAMAGE IN THE ENGINE COMPARTMENT”
— Owner report, NHTSA ODI #10384087
“I HAVE A FORD EXCURSION 2002 V10 WITH 116000 MILES ON IT. AFTER 8 HOURS OF A ROAD TRIP ONE OF THE SPARK PLUGS EJECTED FROM THE ENGINE. THIS IS THE SECOND TIME THIS HAS HAPPENED WITH THIS MOTOR. I PURCHASED THE VEHICLE AT 100,000 MILES AND THE OWNER HAD IT HAPPEN ONCE TO HIM. *TR”
— Owner report, NHTSA ODI #10274239

Read all complaints on NHTSA →

Tire tread separation and blowouts

TIRES

16 NHTSA complaints · 2003-03 → 2019-06

“ON 6/5/2013, I WAS DRIVING ON FREEWAY AT APPROX. 70MPH AND TREAD SEPARATED FROM RT. REAR TIRE CAUSING VEHICLE TO SWERVE INTO ADJACENT LANE. DAMAGE TO QUARTER PANEL AND RUNNING BOARD”
— Owner report, NHTSA ODI #10515876
“TRAVELING EAST BOUND ON I-84 10 MILES FROM MOUNTAIN HOME, IDAHO WHEN MY LEFT REAR TIRE TREAD SEPARATED FROM THE TIRE AND THEN THE TIRE BLEW. TIRE TYPE WAS A FIRESTONE LT 365/75R16 LOAD RANGE D STEELTEX R4S MODEL”
— Owner report, NHTSA ODI #10090995
“FREEWAY DRIVING AT 65 MPH WHEN NO APPARENT REASON REAR LEFT TIRE BLOWOUT. FURTHER INVESTAGATION FOUND THE TIRE HAD SIDEWALL PEELED AWAY AND THE TREAD WAS WRAPPED AROUND THE AXLE. NOT BEFORE DOING DAMAGE TO REAR QUARTER PANEL AND PARKING BRAKE CABLE. FULL TREAD SEPARATION.*AK”
— Owner report, NHTSA ODI #10020866

Read all complaints on NHTSA →

Firestone Steeltex recall replacement and reimbursement

TIRES

8 NHTSA complaints · 2004-03 → 2005-01

“CONSUMER RECEIVED RECALL 03T 002 000 CONCERNING FIRESTONE, STEELTEX A/T, LT265/75R16 LOAD RANGE D FROM THE MANUFACTURER ON MARCH 2004. CONSUMER WAS TOLD BY DEALER AND MANUFACTURER THAT THE TIRES NEEDED WERE NOT AVAILABLE”
— Owner report, NHTSA ODI #10079511
“THE DEALERSHIP REPLACED THE FRONT AND REAR TIRES, MANUFACTURER AND CONSUMER SPLIT THE COST OF THE TIRES. ONE YEAR LATER CONSUMER RECEIVED A RECALL LETTER, ON FIRESTONE, STEELTEX A/T, 265/75R16, BUT MANUFACTURER REFUSED TO REIMBURSE THE MONEY THAT HE ALREADY PAID ABOUT A YEAR AGO”
— Owner report, NHTSA ODI #10066943
“4/4/04 I REC'D A FLAT TI,E TOLD IT WAS IRREPARABLE SINCE AIR WAS SEEPING OUT OF THE SIDEWALL. 4/5/04, I RECEIVE LETTER FROM FIRESTONE/FORD REAGRDING TIRE RECALL ON MY 2002 FORD EXCURSION”
— Owner report, NHTSA ODI #10068060

Read all complaints on NHTSA →

Warped brake rotors and vibration when braking

SERVICE BRAKES, HYDRAULIC

5 NHTSA complaints · 2003-09 → 2006-02

“MY PROBLEM IS THE TRUCK HAS WARPED 4 SETS OF FRONT ROTORS IN 80,000 MILES. IT HAS YET TO EVEN WEAR THE REAR ROTORS. EACH TIME IT HAS WARPED THE ROTORS THE PADS WERE REPLACED. THE FIRST 2 SETS OF ROTORS WERE FROM FORD”
— Owner report, NHTSA ODI #10127413
“I STARTED EXPERIENCING VIBRATING IN MY STEERING WHEEL DURING BRAKING SEVERAL MONTHS AGO. THE VIBRATION CONTINUED TO GET WORSE. I HAD THE BRAKES CHECKED AND I FOUND OUT THAT ALL FOUR ROTORS WERE WARPED ON THE VEHICLE”
— Owner report, NHTSA ODI #10078547
“FRONT ROTORS RUSTED IN CENTER AREA BETWEEN ROTOR BRAKE SURFACE. AT 30,000 MILES MY 2002 FORD EXCURSION STARTED TO SHAKE VIOLENTLY WHEN BRAKING AT SPEEDS ABOVE 40 MPH. LUCK FOR US WE WERE DRIVING IN LOWER SPEED CONDITIONS IN RESIDENTIAL TRAFFIC”
— Owner report, NHTSA ODI #10039262

Read all complaints on NHTSA →

Reduced braking effectiveness and brake pedal loss

SERVICE BRAKES, HYDRAULIC

6 NHTSA complaints · 2002-07 → 2013-02

“ON 8-25-03 , I TOOK MY 2002 FORD EXCURSION IN TO BERRYVILLE FORD IN BERRYVILLE ARKANSAS BECAUSE THE VEHICLE WOULD NOT STOP IN A REASONABLE DISTANCE”
— Owner report, NHTSA ODI #10039561
“2002 FORD EXCURSION. TWO INSTANCE OF THE VEHICLE NOT RESPONDING TO PRESSURE APPLIED TO THE BRAKE PEDAL AT LOW SPEED. VEHICLE CONTINUES TO ROLL WITH VERY LITTLE STOPPING ACTION. TAKEN TO DEALERSHIP WHERE NOTHING WAS FOUND. *NLM”
— Owner report, NHTSA ODI #10018824
“WHILE APPLYING BRAKES VEHICLE WILL NOT STOP. CONSUMER WILL SHIFT VEHICLE IN PARK TO COME TO A COMPLETE STOP. DEALERSHIP SHIP IS AWARE OF PROBLEM.*AK”
— Owner report, NHTSA ODI #8015006

Read all complaints on NHTSA →

Fire and smoke with speed control switch cited

VEHICLE SPEED CONTROL

5 NHTSA complaints · 2005-10 → 2010-11

“MY 2002 FORD EXCURSION CAUGHT ON FIRE ON JUNE 10, 2008. FORD SAID IT WAS THE SPEED CONTROL SWITCH. THEY HAVE REFUSED TO PAY FOR REPAIRS BECAUSE THEY CLAIM THAT THEY SENT LETTERS, WHICH I NEVER RECEIVED. *TR”
— Owner report, NHTSA ODI #10232222
“DT: 2002 FORD EXCURSION. THERE IS A SPEED CONTROL DEACTIVATION SWITCH THAT HAS BEEN RECALLED ON EVERY FORD TRUCK EXCEPT THE FORD EXCURSION ,AND THE RECALL NUMBER IS 05S28. THE IDENTICAL SWITCH IS IN THE CONTACT'S FORD EXCURSION WHICH CAUGHT ON FIRE ON SEPTEMBER 29, 2005”
— Owner report, NHTSA ODI #10139488
“TL*THE CONTACT OWNS A 2002 FORD EXCURSION. WHILE DRIVING APPROXIMATELY 45 MPH, THE CONTACT NOTICED SMOKE COMING FROM THE STEERING COLUMN. THE CONSUMER PULLED OVER TO THE SIDE OF THE ROAD.THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR INSPECTION”
— Owner report, NHTSA ODI #10274039

Read all complaints on NHTSA →

Unintended acceleration and power surge

VEHICLE SPEED CONTROL

5 NHTSA complaints · 2003-02 → 2013-07

“TL* THE CONTACT OWNS A 2002 FORD EXCURSION. THE CONTACT STATED THAT WHILE DRIVING 70 MPH, SHE APPLIED THE BRAKES TO DISENGAGE THE CRUISE CONTROL AND THE VEHICLE CONTINUED TO ACCELERATE INDEPENDENTLY. THE CONTACT WAS ABLE TO GET THE VEHICLE TO STOP AFTER SEVERAL MINUTES”
— Owner report, NHTSA ODI #10525170
“TL*THE CONTACT OWNS A 2002 FORD EXCURSION. WHILE PARKED, THE VEHICLE ACCELERATED WITHOUT WARNING AND CRASHED INTO THE FRONT OF ANOTHER VEHICLE. THE DEALER WAS UNABLE TO DIAGNOSE THE CAUSE OF FAILURE. THE VEHICLE WAS TAKEN TO A SECOND DEALER WHO REPLACED THE THROTTLE CABLE”
— Owner report, NHTSA ODI #10195953
“WHILE DRIVING AT 20 MPH THE VEHICLE ACCELERATED INTERMITTENTLY. THE CONSUMER STATED THE ONLY WAY TO STOP THE VEHICLE WAS BY SHUTTING THE ENGINE OFF. THE DEALER STATED THEY COULD NOT DUPLICATE THE PROBLEM. PLEASE PROVIDE ADDITIONAL INFORMATION”
— Owner report, NHTSA ODI #10112956

Read all complaints on NHTSA →

Engine stalling without warning

ENGINE AND ENGINE COOLING

8 NHTSA complaints · 2002-05 → 2019-09

“TL* THE CONTACT OWNS A 2002 FORD EXCURSION. THE CONTACT WAS DRIVING 45 MPH WHEN THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS RESTARTED AFTER THE FAILURE AND TAKEN TO A PRIVATE MECHANIC. THE MECHANIC CONFIRMED THAT THE CAMSHAFT SENSOR NEEDED TO BE REPLACED”
— Owner report, NHTSA ODI #10444345
“A SENSOR FAILS AND CAUSES ENGINE TO STOP RUNNING - HAS HAPPENED WHILE GOING 65MPH ON AN INTERSTATE HIWAY - ENGINE MAY RESTART BUT CAR IS LEFT COASTING, TOTALLY WITHOUT POWER AT HIWAY SPEEDS. ENGINE HAS STOPPED 4 TIMES NOW. ONLY LAST OCCURRANCE IS LISTED HERE. *AK”
— Owner report, NHTSA ODI #10059072
“2002 FORD EXCURSION, LIMITED. ENGINE STALLS WHEN COMING TO STOP AT TRAFFIC SIGNS, SIGNALS. WILL RESTART IN PARK BUT DIE IMMEDIATELY UPON BEING PUT BACK IN GEAR”
— Owner report, NHTSA ODI #10003110

Read all complaints on NHTSA →

Issues on other model years

Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 20, 2026. Investigation data refreshed Sep 20, 2026.

We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.

Raw data + downloads for this vehicle →

Essential maintenance

Critical for safety and preventing major damage

Engine Oil & Filter

Every 7,500 mi

Replace synthetic-blend or full-synthetic Motorcraft oil per the IOLM, or every 7,500-10,000 miles. EcoBoost engines require full synthetic; Coyote 5.0L V8 specifies SAE 5W-30.

Estimated cost — typical U.S. ranges

Dealer

~$120–$160

Shop

~$85–$115

DIY

~$25–$55

Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.

Tire Rotation

Every 10,000 mi

Rotate tires every 10,000 miles, or with every other oil change. F-150 4x4 owners should rotate every 5,000-7,500 miles to even out drivetrain bias wear.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Often free at the shop where you bought the tires — worth asking before paying.

Brake Inspection

Every 10,000 mi

Inspect brake pads, rotors, and brake fluid level every 10,000 miles. Front pads on F-150 and Explorer typically last 40,000-60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.

Brake Fluid

Every 45,000 mi

Ford specifies brake fluid replacement on an inspection basis, but moisture testing every 3 years is recommended. Replace if reading exceeds 3% water content.

Estimated cost — typical U.S. ranges

Dealer

~$180–$200

Shop

~$125–$140

DIY

~$10–$25

DOT 3 or 4 — match the cap. Vacuum bleeders make this a one-person DIY.

Important maintenance

Keeps your vehicle running smoothly and efficiently

Engine Air Filter

Every 30,000 mi

Replace the engine air filter every 30,000 miles. EcoBoost turbocharged engines are sensitive to airflow restriction — don't extend.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

5-minute job on most cars; the airbox lid usually has clips, no tools needed.

Automatic Transmission Fluid

Every 150,000 mi

Ford 6R80, 10R80, and 8F transmissions use Mercon LV fluid rated 150,000 miles under normal service. Severe service (towing, plowing) drops this to 60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$330–$500

Shop

~$235–$355

DIY

~$60–$180

Some sealed transmissions have no dipstick — fill is precise and best left to a shop. Many drivers can still DIY drain-and-fill.

Transfer Case Fluid (4WD models)

Every 60,000 mi

On 4x4 models, replace transfer case fluid every 60,000 miles. Use Motorcraft XL-12 — do not substitute generic transfer case fluid.

Estimated cost — typical U.S. ranges

Dealer

~$105–$140

Shop

~$75–$100

DIY

~$15–$40

AWD/4WD vehicles only. Easy drain-and-fill on most platforms.

Rear Differential Fluid

Every 100,000 mi

F-Series and Expedition: replace rear axle fluid every 100,000 miles, or 50,000 miles if towing. Limited-slip rear ends require friction-modifier additive.

Estimated cost — typical U.S. ranges

Dealer

~$150–$195

Shop

~$105–$135

DIY

~$20–$50

Drain plug + fill plug — straightforward DIY. AWD vehicles have two; budget for both.

Spark Plugs

Every 100,000 mi

Iridium spark plugs on Coyote 5.0L, EcoBoost 2.7L/3.5L, and 2.3L are rated 100,000 miles. EcoBoost engines: never exceed the interval — gap erosion causes coil failure.

Estimated cost — typical U.S. ranges

Dealer

~$285–$390

Shop

~$200–$275

DIY

~$25–$100

Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.

Engine Coolant

Every 50,000 mi

Motorcraft Orange (Dex-Cool compatible) coolant: first change at 100,000 miles, then every 50,000. Older trucks with Yellow Motorcraft coolant: 50,000 miles throughout.

Estimated cost — typical U.S. ranges

Dealer

~$285–$330

Shop

~$200–$235

DIY

~$25–$60

Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.

Recommended maintenance

Extends the life of your vehicle and improves comfort

Cabin Air Filter

Every 20,000 mi

Replace the cabin air filter every 20,000 miles. On F-150, located behind the glove box; on Escape and Explorer, accessed from the passenger footwell.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

Usually behind the glovebox. Shops charge labor for a 10-minute job — easy DIY win.

Fatal crash history & reported problems

Occupant deaths in fatal crashes (FARS)

71 crashes 1990–2024

How the 71 occupant deaths break down

41

driver deaths

30

passenger deaths

71

occupant deaths

Crash years covered: 1990–2024 This model year first appears in 2002 crashes. Older models have had more years on the road to appear in these crashes, so a higher count here does not by itself mean a vehicle is less safe.

FARS counts every occupant death in a fatal crash, whatever the cause — it does not mean the vehicle was at fault or defective. Counts are not adjusted for how many of each vehicle are on the road. How to read this number

FARS 2024 data is an annual report file. NHTSA revises these records when the final file is published, so this count can change.

Why we show driver deaths too

Every vehicle has exactly one driver seat, so driver deaths line up fairly when you compare one model to another. Occupant deaths include passengers, so a three row SUV can show a higher number than a two seat car simply because it carries more people.

Both figures are plain counts, not rates. A rate would need to know how many of each vehicle are on the road, and that registration data is not public, so we do not publish rates or scores of any kind.

IIHS publishes driver death rates using this same driver only idea, paired with a registered vehicle years denominator we do not have. Their rates and these counts answer different questions, so do not read either number here as a safety rating.

Owner-reported problem signals

Separate from the federal fatality data above: complaints owners filed with NHTSA about this year and model. These are reports of problems, unverified, and are counted here only as signals.

15

complaints mentioning a crash

13

complaints mentioning a fire

Reviewed known issues for this vehicle

Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.

How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.

This maintenance schedule for the 2002 Ford Excursion reflects Ford's published service intervals and the Intelligent Oil-Life Monitor system. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.

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