The contact owns a 2003 Ford Excursion. The contact was driving approximately 65 mph on a wet road and suddenly, excessive white smoke expelled from the rear tail pipe exhaust system. The driver pulled over to the side of the road and the engine stalled without warning. The vehicle restarted and resumed normal operation. The engine stalled again and the vehicle was towed to an authorized dealer. The technician stated that the failure was contributed to a broken fuel injector which also resulted in damages to the engine. The estimated repair cost was $12,000. The vehicle has not been repaired for the malfunction at this time. The failure and current mileages were 78,000. Updated 02/01/10 the consumer stated that the vehicle ran rough and it lacked power. The dealer found the #1 cylinder had a broken piston. The consumer stated the check engine light never illuminated to warn him there was problem. Updated 02/02/10.

- Spring Valley , WI, USA

2003 Ford Excursion limited with 6.0L diesel engine. Only two weeks ago, my truck began to surge in acceleration at both idle and while cruising. It has also begun to stall out at both idle and while cruising. Also the vehicle has begun to have a strong smell of diesel fuel which enters the passenger cabin at start up. My service engine light has begun to light up and I checked the light with a digital diagnostic code reader. The code was P2285 (injector control pressure sensor circuit low). The situation is quite dangerous. My wife had complained that the vehicle surged ahead and she almost hit the car in front of her while stopped at a red light. When I drove the vehicle, it also began to buck and surge in both forward and reverse. While backing out of my driveway, the vehicle accelerated rearward and only by my having my foot near the brake pedal, stopped it from racing rearward. The vehicle has also cut off while at idle and while driving now. Again, a very dangerous condition. I have seen on the Ford truck enthusiast websites that I am not alone. There have been many complaints of this condition and faulty injector control pressure sensors especially in the '03 models but even later models. I am just out of warranty by a week, and Ford said they could do nothing for me. I have seen what the dealers have quoted others to fix the problem up to $2000 for wide ranging solutions (replacing turbos, replacing all injectors, etc.) I use this truck to Transport my disabled child and definitely cannot afford the dealer to rip me off for $2000. It is a $140 part and should take no longer than an hour of a technician's time to replace the sensor and pigtail harness. Clearly, Ford knows that they have a problem as they had a cust. Service program 03B05 and 03B06 regarding this issue for 47,000 other '03 trucks with the 6.0L engine. They said my vehicle's VIN did not fall into those 47,000. Obviously it affects many more trucks than the 47,000.

- Miami, FL, USA

I purchased a new Ford Excursion in late December of 03. It leaked oil from the engine block due to defects in its manufacture. The engine was replaced after much conflict by the dealer with a used remanufactured engine under warranty after only 11,700 miles. The used engine leaked from the rear of the block in the same way as the original engine. Ford refused to replace the engine with a new motor. The used engine suffered from erratic idle, leakage etc. It seemed destined to fail as the original engine did. I lost over $20,000 after accepting an arbitration decision. The vehicle did not make it to 13,000 miles. Unbelievably poor quality and no support. Simply a rip off to consumers. The vehicle was towed to the dealer once, and was driven there 4 times, totaling over 100 miles and 72 days out of service.

- Silt, CO, USA

Faulty fuel injectors in the 6.0 liter diesel engine resulting in excessive amounts of diesel fuel to enter the oil crankcase. Oil level in crankcase is diluted with fuel to the extent of being measured on the dipstick by several inches and flash point of oil reduced to half of the flash point of the oil.

- Ballwin, MO, USA

Ford Excursion 6.0L powerstroke diesel. The consumer has taken the vehicle to the dealership on three separate occasions because the engine failed to respond to the throttle while in drive, also a leak is coming from the rear main seal. To date Ford Motor Company has failed to fix the problem. Please respond promptly in resolving matters. The consumer wa stold the injection control pressure sensor needed to be repalced. There was a customer service program regarding the problem.

- Simi Valley, CA, USA

My 2003 Excursion had a major turbo failure while traveling on I-10 on 12-26-03. My family and myself were traveling to houston. The vehicle only had a total of 1,049 life to date miles. While on the interstate for about 30 to 45 minutes we hear a larger pop noise and a large drop in the engine power. I only had a flash of a dash light and it went right back off. I was trying to get off the interstate. Was driving about 25 to 35 mph trying to get to the next exit. Notice large volume of smoke coming from the rear of the vehicle. I pulled over asap after seeing this. The smoke came into the cab from the ventilation system (A/C). Pulled my daughter from the vehicle, also had my wife get out of the vehicle. At this point released the hood lock, checking the heat on the hood first. Raised the hood found fire coming from exhaust pipe from the turbo. Just smother the fire out to ensure it would not spread. Saw the oil around the exhaust system through out the system. The vehicle has a 6.0 diesel engine and is a 4X4 Excursion. IM filing this report for the safety of otherS not for myself. My concern is for other people who are not exposed to this type of condition which can happen with a diesel engine. IM a vehicle superintendent of a large city transit system. And have seen fireS from a turbo failures. 6.0 diesel is a international product, and the series 40 engines are prone for this type of failures. This may be the only failure that is reported for the 2003 6.0 diesel. But with only 1,049 miles this failure should have not occurred. Their should be some way to ensure the check engine light should have came on and stayed on for this condition for a failed turbo. ItS at the dealer at this time getting repaired. Best regards, bryan J. garner

- Manchaca, TX, USA

Smell in passenger cab. High idle--8 mph. High road idle:40 mph. Stalling, surging. Air conditioning loses charge.

- New Port Richey, FL, USA

When the engine is started, it frequently runs roughly for several seconds or more. It causes the vehicle to lurch when put in gear and has almost led to me striking vehicles parked in front and behind me when I have tried to pull out of parellel parking spaces. It has also caused me to strike my trailer as I attempt to hitch up to it and makes that process very challenging. This vehicle has done this since it was new and has been back to the dealer twice for repairs which have failed to correct the problem.

- Laytonsville, MD, USA

Truck purchased March 31, 2003. 7 days later took truck in for transmission replacement. Truck was in shop for 9 days. 7 days after truck was out of shop went into shop again for 23 days for defective paint job. Took truck in again on August 21, 2003 for ac not working and clicking sound in transmission. Still in shop.

- Clinton Township, MI, USA