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2005 Ford Excursion Recalls, Problems & Maintenance

The 2005 Ford Excursion has no open NHTSA recalls. Owners report 7 recurring issue clusters, led by “6.0L diesel EGR cooler and head gasket failures.” 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 2005 Ford Excursion.

Reported to NHTSA

6.0L diesel EGR cooler and head gasket failures

ENGINE AND ENGINE COOLING

6 NHTSA complaints · 2010-09 → 2018-02

“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”
— Owner report, NHTSA ODI #10538284
“TL* THE CONTACT OWNS A 2005 FORD EXCURSION. WHILE UNDERGOING ROUTINE SERVICE BY AN INDEPENDENT MECHANIC, THE TECHNICIAN NOTICED THAT THE COOLANT LEAKING THROUGH THE ENGINE CYLINDER AND THE HEAD GASKETS NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED”
— Owner report, NHTSA ODI #11074984
“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”
— Owner report, NHTSA ODI #10464707

Read all complaints on NHTSA →

Turn signal and exterior lighting switch failure

EXTERIOR LIGHTING

3 NHTSA complaints · 2011-09 → 2015-11

“TL* THE CONTACT OWNS A 2005 FORD EXCURSION. THE CONTACT STATED THAT THE MULTI-FUNCTION SWITCH FAILED. AS A RESULT, THE BRAKE LIGHTS AND TURN SIGNALS WOULD NOT ILLUMINATE. THE VEHICLE WAS INSPECTED BY THE OWNER AND THE MULTI-FUNCTION SWITCH WAS REPAIRED”
— Owner report, NHTSA ODI #10453084
“LEFT TURN SIGNAL INOPERATIVE WHEN TURNED ON NORMALLY, IF SIGNAL LEVER IS HELD PARTIALLY TO THE LEFT BEFORE THE DETENT TO HOLD IT IN THE LEFT SIGNAL POSITION, THE SIGNAL WILL WORK”
— Owner report, NHTSA ODI #10427588
“TL* THE CONTACT OWNS A 2005 FORD EXCURSION. THE CONTACT STATED THAT THE EXTERIOR LIGHTS WOULD NOT FUNCTION. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER 11V352000 (EXTERIOR LIGHTING)”
— Owner report, NHTSA ODI #10790300

Read all complaints on NHTSA →

Tire tread and sidewall separation

TIRES

2 NHTSA complaints · 2012-07 → 2023-02

“LT275/65/R18 Tire developed a massive approximately 18in x 3in bubble on the inner section of tread causing significant vibration and excessive wear in that area in less than 50 miles”
— Owner report, NHTSA ODI #11507922
“I PURCHASED A 2005 FORD EXCURSION LIMITED USED IN MAY OF 2011. THE VEHICLE WAS PURCHASED WITH NEW BCT RADIAL A/P LT265/75R16 TIRES. AFTER APPROXIMATELY 2 MONTHS THE VEHICLE WOULD SHAKE AND VIBRATE AT HIGHWAY SPEEDS”
— Owner report, NHTSA ODI #10465933

Read all complaints on NHTSA →

Spark plug ejection from cylinder head

ENGINE

2 NHTSA complaints · 2008-04 → 2014-11

“TL* THE CONTACT OWNS A 2005 FORD EXCURSION. WHILE DRIVING APPROXIMATELY 10 MPH, THE CHECK ENGINE WARNING LIGHT ILLUMINATED AND THE SPARK PLUGS DETACHED FROM THE CYLINDER HEAD. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC”
— Owner report, NHTSA ODI #10654556
“SPARK PLUG BLOWN OUT OF HEAD OF VEHICLE, BROUGHT TO DEALER AND WAS TOLD IT WAS NOT COVERED BY WARRANTY BECAUSE THE PLUG HAD LOOSENED ,THESE PLUGS WERE FACTORY INSTALLED THEREFORE IT SHOULD BE CONSIDERED DEFECTIVE WORKMANSHIP AND SHOULD BE COVERED UNDER WARRANTY”
— Owner report, NHTSA ODI #10224058

Read all complaints on NHTSA →

Steering wander and difficulty maintaining lane

STEERING

2 NHTSA complaints · 2015-05 → 2025-08

“Several times I’ll be driving and the steering wheel will jerk in one direction and wobble violently I will grab it to correct it and basically fight to keep it in the lane so I have to pull over and try again”
— Owner report, NHTSA ODI #11680694
“CAR STEERS SIDE TO SIDE AND EXTREMELY DIFFICULT TO KEEP WITHIN THE LANES.YOU HAVE TO HOLD STEERING WITH 100 % CONCENTRATION AND CONSTANTLY MANEUVER IT TO KEEP IT STRAIGHT.ALSO TEND TO VEER TO THE LEFT.LOT OF STEERING PLAY”
— Owner report, NHTSA ODI #10716812

Read all complaints on NHTSA →

Engine stall and loss of power, fuel injector control module

ELECTRICAL SYSTEM

36 NHTSA complaints · 2005-11 → 2020-08

“WHILE DRIVING, THE ENGINE JUST QUITS AND LOSES ALL POWER. I HAVE TO SHIFT INTO NEUTRAL, TURN THE KEY ALL THE WAY TO OFF, AND RESTART THE ENGINE. SOMETIMES IT STARTS RIGHT UP, OTHER TIMES IT TAKES SEVERAL (MANY) TRIES TO GET THE ENGINE TO RESTART”
— Owner report, NHTSA ODI #11349212
“THERE WAS NO WARNING. WE WERE ON THE FREEWAY GOING 75MPH. THE FORD EXCURSION STOPPED RUNNING. THERE WAS NO POWER TO THE BRAKES OR STEERING. I GOT IT TO THE SIDE OF THE SHOULDER OF THE FREEWAY WHERE WE WAITED FOR 2 HOURS FOR HELP. THIS IS THE THIRD TIME THIS HAS HAPPENED”
— Owner report, NHTSA ODI #10408453
“TL*THE CONTACT OWNS A 2005 FORD EXCURSION. THE CONTACT HEARD NOISES COMING FROM THE VEHICLE. WHILE DRIVING 65 MPH, THE VEHICLE STALLED IN THE MIDDLE OF THE ROAD. THE FAILURE OCCURRED WITHOUT WARNING AND THE VEHICLE COULD NOT BE RESTARTED”
— Owner report, NHTSA ODI #10262037

Read all complaints on NHTSA →

Airbag non-deployment in crash

AIR BAGS

2 NHTSA complaints · 2010-06 → 2017-07

“I WAS INVOLVED IN AN ACCIDENT IN MY 2005 FORD EXCURSION AND THE AIRBAGS DID NOT DEPLOY. A MINIVAN PULLED OUT FROM A STOP SIGN AND I HIT HER IN THE SIDE. ALL OF THE VAN'S AIRBAGS DEPLOYED BUT MINE DID NOT”
— Owner report, NHTSA ODI #10336940
“DURING A SINGLE VEHICLE ACCIDENT DUE TO LOSING CONTROL AT, ACCORDING TO THE POLICE REPORT, 65 MPH AND RUNNING FRONT-END FIRST IN TO A ROCKY MOUNTAIN BANK THEN BOUNCING OFF SAID BANK ROTATING THE VEHICLE, AGAIN ACCORDING TO THE ACCIDENT REPORT, ROUGHLY 120-DEGREES THE FACTORY AIRB”
— Owner report, NHTSA ODI #11004995

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)

40 crashes 1990–2024

How the 40 occupant deaths break down

20

driver deaths

20

passenger deaths

40

occupant deaths

Crash years covered: 1990–2024 This model year first appears in 2005 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.

2

complaints mentioning a crash

1

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 2005 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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