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2000-2005 Excursion Technical Service Bulletins
Courtesy of: Ford Motor Company


All Technical Service Bulletins are available in downloadable pdf format which require Adobe Reader to view.

ARTICLE TITLEARTICLE NO.MODEL YEAR
000102030405
Excursion
WARNING INDICATORS - PARKING AID - REVERSE SENSING SYSTEM (RSS) AND FORWARD SENSING SYSTEM (FSS) - FALSE ACTIVATION OF WARNING TONE - SERVICE TIPS 04-26-02 (21 KB) XXXXX 
MIL ILLUMINATED WITH DTC P0756, P0761 OR P0771 AFTER OVERHAUL OR INSTALLATION OF 2005 TORQSHIFT TRANSMISSION 04-25-16 (6 KB)    XX 
HARD START OR NO START - 7.3L 04-25-04 (33 KB) XXXX  
SAFETY BELT RETRCTION SPEED 04-24-21 (10 KB) XXXXXX
MOMENTARY RETURN TO IDLE DURING AGGRESSIVE ACCELERATION - DIAGNOSTIC TROUBLE CODE (DTC) P0123 - 7.3L ENGINE 04-24-11 (7 KB)  XXX  
REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR 04-24-05 (96 KB) XXXXXX
LEATHER-WRAPPED STEERING WHEEL - LEATHER COMING LOOSE 04-24-03 (7 KB) XXXXXX
STEERING GEAR NOISE - 6.0L DIESEL ENGINE 04-23-08 (108 KB)     X 
MISFIRE, LACK OF POWER, BUCK/JERK, EXCESSIVE SMOKE, CRANK/NO START - 6.0L ENGINE - DIAGNOSTICS FOR FUEL SYSTEM - SERVICE TIPS 04-23-03 (9 KB)    XXX
LOW POWER - COLD SIDE CHARGE AIR COOLER (CAC) DISCONNECTED - OIL LEAK AT COLD SIDE CAC CONNECTIONS - 6.0L ENGINE - VEHICLES BUILT 12/15/2003 THROUGH 4/1/2004 04-20-09 (7 KB)     X 
INTERIOR PLASTIC TRIM - PAINT-TO-MATCH AND REPAIR - INTERIOR SPRAY PAINT AND ADHESION PROMOTER USAGE INSTRUCTIONS 04-20-07 (11 KB)     XX
OIL LEAK - TURBO PEDESTAL SEAL AT EXHAUST BACK PRESSURE ACTUATOR (EBP) - 7.3L DIESEL 04-20-02 (55 KB) XXXX  
WATER-IN-FUEL (WIF) LAMP 04-19-04 (6 KB)    XX 
ADDING ADDITIONAL BULBS TO TURN INDICATOR OR HAZARD FLASHER CIRCUITS - SERVICE TIPS 04-18-15 (22 KB) XXXXXX
DRIVEABILITY - NO START OR CONSTANT ENGINE MISFIRE - FUEL INJECTION CONTROL MODULE (FICM) DIAGNOSIS - 6.0L DIESEL 04-18-06 (112 KB)    XX 
AXLE - FRONT HUBS NOT ENGAGING, NOT STAYING ENGAGED AND/OR UNLOCKING 04-18-05 (58 KB) XXXXX 
TURBO-INDUCED EXHAUST MOAN/DRONE AT 1600-1800 RPM - 6.0L BUILT AFTER 9/29/2003 04-18-04 (59 KB)     X 
HARD START OR NO START - GPCM CONNECTOR SERVICE KIT AVAILABLE - 6.0L ENGINE 04-17-13 (7 KB)    XX 
MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - SYSTEM LEAN DIAGNOSTIC TROUBLE CODES (DTC'S) - SERVICE TIPS 04-17-04 (13 KB) XXXXX 
ENGINE MISFIRE OR ROUGH RUNNING - COIL ON PLUG (COP) IGNITION SYSTEMS - WDS COP KIT DIAGNOSTIC TIPS 04-16-01 (159 KB) XXXXXX
FRONT END ACCESSORY DRIVE (FEAD) BELT NOISE - VEHICLES BUILT PRIOR TO 6/1/2004 - 6.0L ENGINE 04-14-12 (6 KB)    XX 
6.0L ENGINE - LOW RPM, BUCK/JERK, MISS, STUMBLE - AFTER DECELERATION DOWN LONG GRADE WITH THE CRUISE CONTROL ENGAGED 04-13-08 (7 KB)     X 
BODY - PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION 04-09-06 (11 KB)     XX
ENGINE - EXHAUST - TURBO-INDUCED EXHAUST MOAN/DRONE AT 1600-1800 RPM - 6.0L BUILT PRIOR TO 9/29/2003
NOISE - VIBRATION - TURBO-INDUCED EXHAUST MOAN/DRONE AT 1600-1800 RPM - 6.0L BUILT PRIOR TO 9/29/2003
04-09-04 (61 KB)    XX 
DRIVEABILITY - RUNS ROUGH AND/OR LOW POWER - 6.0L DIESEL ENGINE ONLY
ENGINE - FUEL IN OIL - 6.0L DIESEL - INJECTOR DIAGNOSTICS
04-09-03 (155 KB)    XX 
DRIVEABILITY - WATER-IN-FUEL LAMP ILLUMINATED AFTER DRAINING HEATED FUEL CONDITIONING MODULE (HFCM) - VEHICLES BUILT PRIOR TO 11/1/2003 - 6.0L ENGINE
ENGINE - FUEL SYSTEM - WATER-IN-FUEL LAMP ILLUMINATED AFTER DRAINING HEATER FUEL CONDITIONING MODULE (HFCM) - VEHICLES BUILT PRIOR TO 11/1/2003 - 6.0L ENGINE
04-09-02 (117 KB)    XX 
ENGINE - 7.3L DIESEL DI - HIGH PRESSURE OIL PUMP LEAK 04-04-04 (61 KB) XXXX  
BODY - MIRROR - EXTERIOR MIRROR GLASS AND MOTOR REPLACEMENT - SERVICE TIPS 03-23-02 (418 KB) XXXXX 
DRIVEABILITY - LOSS OF POWER AND EXTERNAL TURBO OIL LEAK - 7.3L DIESEL
ENGINE - 7.3L DIESEL - LOSS OF POWER AND EXTERNAL TURBO OIL LEAK
NOISE - EXHAUST NOISE FROM TURBO - 7.3L DIESEL
03-21-49 (72 KB) XX    
DRIVEABILITY - P0340 CAMSHAFT POSITION SENSOR FALSE DIAGNOSTIC TROUBLE CODE - VEHICLES EQUIPPED WITH 7.3L DIESEL ENGINE ONLY
TRANSMISSION - 4R100 - DELAYED 3.4 SHIFT - VEHICLES EQUIPPED WITH 7.3L DIESEL ENGINE ONLY
03-21-48 (31 KB)   X   
ENGINE - 7.3L - OIL PAN CORROSION - SERVICE TIP 03-21-46 (7 KB) XXXX  
ENGINE - 7.3L - EXTERNAL OIL LEAK DIAGNOSIS FOR 7.3L DIT ENGINES 03-21-45 (7 KB) XXXX  
LACK OF POWER - UNDER A LOAD, AT CRUISE OR ON ACCELERATION - VEHICLES EQUIPPED WITH 7.3L DIT ENGINE ONLY - PRODUCED BEFORE 11/25/2000 ONLY
ENGINE - 7.3L DIT - LACK OF POWER UNDER A LOAD, AT CRUISE OR ON ACCELERATION - VEHICLES PRODUCED BEFORE 11/25/2000 ONLY
03-21-42 (8 KB) XX    
DRIVEABILITY - NO START, LOSS OF POWER OR ROUGH IDLE - DURING EXTREME COLD WEATHER OPERATION - FUEL GELLING - VEHICLES EQUIPPED WITH 7.3L ENGINE
FUEL - NO START, LOSS OF POWER OR ROUGH IDLE - DURING EXTREME COLD WEATHER OPERATION - FUEL GELLING - VEHICLES EQUIPPED WITH 7.3L ENGINE
03-21-41 (6 KB) XX    
DRIVEABILITY - BUCK/SURGE FELT WITH SPEED CONTROL ENGAGED - 7.3L ENGINE ONLY
ELECTRICAL - BUCK/SURGE FELT WITH SPEED CONTROL ENGAGED - 7.3L ENGINE ONLY
ELECTRICAL - SPEED CONTROL - BUCK/SURGE FELT WITH SPEED CONTROL ENGAGED - 7.3L ENGINE ONLY
03-21-40 (33 KB) X     
ENGINE - 7.3L DIESEL - ENGINE KNOCK OR "CACKLE" - 1999-2000 SUPER DUTY F-SERIES AND 2000 EXCURSIONS WITH ENGINE SERIAL NUMBERS 661894 THROUGH 1311240 - ALL 1998-2000 E-SERIES WITH ENGINE SERIAL NUMBERS 661974 THROUGH 1311240
NOISE - "CACKLE" OR ENGINE KNOCK - 7.3L DIESEL - 1999-2000 SUPER DUTY F-SERIES AND 2000 EXCURSIONS WITH ENGINE SERIAL NUMBERS 661894 THROUGH 1311240 - ALL 1998-2000 E-SERIES WITH ENGINE SERIAL NUMBERS 661974 THROUGH 1311240
03-21-39 (38 KB) X     
ENGINE - 7.3L DIT - HIGH INJECTION CONTROL PRESSURE READINGS - ENGINES BUILT AFTER ENGINE SERIAL NUMBER 896812 03-21-38 (7 KB) X     
ENGINE - 7.3L DIESEL - GLOW PLUG CONTROL MODULE - VEHICLES WITH CALIFORNIA EMISSIONS - SERVICE TIP 03-21-36 (615 KB) X     
DRIVEABILITY - VARIOUS DRIVEABILITY CONDITIONS - 6.0L DIT ENGINE - VEHICLES BUILT BEFORE 9/29/03 - CALIBRATION UPDATE - RUNNING CHANGE 03-20-12 (33 KB)    XX 
DRIVEABILITY - FUEL SYSTEM - INJECTOR COMBUSTION SEAL - INSTALLATION PROCEDURE - SERVICE TIP - 6.0L ENGINE
ENGINE - FUEL SYSTEM - INJECTOR COMBUSTION SEAL - INSTALLATION PROCEDURE - SERVICE TIP - 6.0L ENGINE
03-20-10 (22 KB)    X  
DRIVEABILITY - NO START/REPEAT STARTER FAILURE - REPEAT STARTER REPLACEMENT
ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER BETWEEN START AND RUN
ENGINE - STARTING - STARTER STAYING ENGAGED AT START UP
03-20-05 (116 KB)  XXX  
DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 03-20-03 (76 KB) XXXX  
BRAKES - BRAKE PULL - 4X4 F-250/350 AND 4X4 EXCURSION VEHICLES ONLY 03-19-10 (76 KB) XX    
ELECTRICAL - REMOTE KEYLESS ENTRY (RKE) SERVICE TIPS 03-18-01 (17 KB) XXXXX 
TRANSMISSION - NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS 03-14-08 (11 KB) XXXX  
SUSPENSION - 4X4 WHEEL HUB NON-ENGAGEMENT/DISENGAGEMENT
AXLE - 4X4 WHEEL HUB NON-ENGAGEMENT/DISENGAGEMENT
03-14-03 (21 KB) XXXX  
ELECTRICAL - WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS 03-11-06 (175 KB) XXXX  
SUSPENSION - ON-VEHICLE FRONT INTEGRATED HUB/BEARING ROCKING END-PLAY MEASUREMENT
AXLE - ON-VEHICLE FRONT INTEGRATED HUB/BEARING ROCKING END-PLAY MEASUREMENT
03-11-02 (212 KB) XXXXX 
DRIVEABILITY - ROUGH IDLE AND/OR HESITATION ON ACCELERATION - VEHICLES EQUIPPED WITH 5.4L OR 6.8L ENGINE ONLY 03-09-11 (51 KB) XXXX  
ENGINE - ENGINE OIL LEVEL INDICATOR MARKINGS - REPORTS OF LOW OIL LEVELS 03-08-03 (17 KB)   XX  
ENGINE - CYLINDER HEAD DECK LEAK - 4.6 AND 5.4L ENGINES - NEW "SERVICE-ONLY" GASKET AND CYLINDER HEAD KITS AVAILABILITY 03-06-02 (331 KB) XX    
DRIVEABILITY - "WAIT TO START" LAMP DOES NOT OPERATE PROPERLY
ELECTRICAL - LAMP - "WAIT TO START" LAMP DOES NOT OPERATE PROPERLY
03-04-05 (9 KB)   XX  
FRONT LOCKING HUBS - SERVICE TIP 03-04-01 (9 KB) XXXX  
BODY - PAINT - NO CLEARCOAT BLENDING - COLLISION MANUAL CHANGE 03-03-07 (6 KB)   XX  
ENGINE - 6.0L DIESEL - AIR FILTER SERVICE, REMOVAL OR REPLACEMENT - SERVICE TIPS 03-01-09 (278 KB)    X  
ELECTRICAL - CDX6 RADIO DAMAGED DURING SERVICE SHIPPING - CORRECT SHIPMENT PROCEDURES FOR CDX6 RADIO - SERVICE TIPS 02-25-02 (237 KB)  XXX  
COOLIONG SYSTEM - MOTORCRAFT PREMIUM GOLD ENGINE COOLANT - SERVICE TIPS 02-23-07 (9 KB)   X   
ENGINE - STRAIGHTEDGE PROCEDURE FOR CHECKING CYLINDER HEAD AND BLOCK FLATNESS 02-21-13 (84 KB) XXXX  
TRANSMISSION - 4R100/E4OD - TORQUE CONVERTER ACCESS EXTERNAL DUST PLUG MAY BECOME DISLODGED 02-21-01 (8 KB) XXXX  
CLIMATE CONTROL - A/C SERVICE TECH TIPS 02-20-08 (18 KB) XXXX  
LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK 02-17-06 (69 KB) XXXX  
BODY - PAINT - APPROVED PAINT MATERIALS FOR WARRANTY REPAIRS 02-16-07 (525 KB)    X  
FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER
RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP
NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO
02-16-04 (99 KB) XXX   
PAINT - NEW POLISHING PRODUCTS - SERVICE PROCEDURES 02-16-03 (108 KB)   XX  
ENGINE - NEW GASKET REMOVER/CLEANER AND SERVICE TIPS FOR ALUMINUM HEADS AND BLOCKS 02-11-04 (103 KB) XXX   
SHEET METAL - PRIMED SERVICE PARTS - PREP PROCEDURE AND MSDS INFORMATION 02-05-06 (206 KB)   X   
ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY 02-01-09 (17 KB) XXX   
BODY - TOP SURFACE OF REAR CARGO DOORS SCRATCHED 01-24-07 (21 KB)   X   
ENGINE - ENGINE OIL SYSTEM PRIMING PROCEDURES - SERVICE TIPS 01-24-06 (7 KB) XXX   
ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL
ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS
01-23-06 (7 KB) XXX   
DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH
ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH
01-21-13 (25 KB) XXX   
ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH 01-21-06 (12 KB) XX    
ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH 01-19-04 (5 KB)  X    
CLIMATE CONTROL - REPEAT HEATER CORE FAILURE
COOLING SYSTEM - REPEAT HEATER CORE FAILURE
01-15-06 (11 KB) XXX   
TRANSMISSION - 4R100 - DELAYED OR NO 2ND GEAR - DIAGNOSTIC TROUBLE CODES P0781, P0755 AND/OR P0756 - VEHICLES EQUIPPED WITH 4R100 TRANSMISSION WITH TRANSMISSION BUILD DATES BETWEEN 7/27/2000 AND 3/23/2001 ONLY 01-13-05 (88 KB)  X    
WIRING - WIRE HARNESS TERMINAL REPAIR KIT AND WIRE SPLICE PROCEDURE 01-10-12 (252 KB) XXX   
DRIVEABILITY - HO2S (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY 01-09-07 (67 KB) XX    
PASSIVE ANTI THEFT SYSTEM (PATS) - DIAGNOSTIC SERVICE TIPS 01-06-02 (44 KB) XX    
BRAKES - FRONT DISC BRAKE PAD AND/OR CALIPER RATTLE OVER BUMPS - REVISED FRONT BRAKE PADS
NOISE - RATTLE FROM FRONT DISC BRAKE PAD AND/OR CALIPER - REVISED FRONT BRAKE PADS
01-04-09 (5 KB) XX    
STEERING - WANDERING/STIFF STEERING OR POOR RETURNABILITY AFTER TURNS - 4X4 VEHICLES ONLY
SUSPENSION - WANDERING/STIFF STEERING OR POOR RETURNABILITY AFTER TURNS - 4X4 VEHICLES ONLY
01-03-02 (8 KB) XX    
DIAGNOSTIC TROUBLE CODES (DTCS) - P0350-P060 COIL DTCS STORED IN MEMORY - ROUGH IDLE - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - COIL ON PLUG APPLICATIONS ONLY
MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - ROUGH IDLE - DIAGNOSTIC TROUBLE CODES (DTCS) P0350-P0360 COIL DTCS STORED IN MEMORY - COIL ON PLUG APPLICATIONS ONLY
ROUGH IDLE - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0350-P0360 COIL DTCS STORED IN MEMORY
LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - ROUGH IDLE - DIAGNOSTIC TROUBLE CODES (DTCS) P0350-P0360 COIL DTCS STORED IN MEMORY - COIL ON PLUG APPLICATIONS ONLY
01-01-06 (19 KB) X     
ENGINE - "MISS" NOISE FROM EXHAUST - UPDATED EXHAUST Y-PIPE AVAILABLE - VEHICLES EQUIPPED WITH 5.4L OR 6.8L ENGINE - BUILT THROUGH 9/10/2000
EXHAUST - "MISS" NOISE FROM EXHAUST - UPDATED EXHAUST Y-PIPE AVAILABLE - VEHICLES EQUIPPED WITH 5.4L OR 6.8L ENGINE - BUILT THROUGH 9/10/2000
NOISE - "MISS" NOISE FROM EXHAUST - UPDATED EXHAUST Y-PIPE AVAILABLE - VEHICLES EQUIPPED WITH 5.4L OR 6.8L ENGINE - BUILT THROUGH 9/10/2000
01-01-03 (14 KB) XX    
ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN -12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000
NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN -12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000
00-26-01 (27 KB) X     
TRANSMISSION - 4R100 - FLUID OVERHEATS DURING SEVERE DUTY - AVAILABILITY OF UPDATED FLUID COOLER/FILTER KIT - VEHICLES PRODUCED BEFORE 2/6/2000 00-24-04 (5 KB) X     
COOLING SYSTEM - COOLANT LEAK FROM PASSENGER SIDE OF INTAKE MANIFOLD AT REAR CORNER OF HEAD - VEHICLES BUILT FROM 7/1/1998 THROUGH 6/30/2000 - VEHICLES WITH 4.6L 2V OR 5.4L 2V ENGINE
ENGINE - 4.6l 2V OR 5.4L 2V - COOLANT LEAK FROM PASSENGER SIDE OF INTAKE MANIFOLD AT REAR CORNER OF HEAD - VEHICLES BUILT FROM 7/1/1998 THROUGH 6/30/2000
00-18-03 (9 KB) X     
WINDSHIELD WIPERS - FRONT WIPERS OPERATE WHILE SWITCH IS IN "OFF" POSITION 00-09-06 (6 KB) X     
MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0135, P0141, P0155, P0161, AND P0455 - NO DRIVEABILITY CONCERNS - VEHICLES WITH 5.4L ENGINE
LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0135, P0141, P0155, P0161, AND P0455 - NO DRIVEABILITY CONCERNS - VEHICLES WITH 5.4L ENGINE
POWERTRAIN CONTROL MODULE (PCM) - REPROGRAM - VEHICLES WITH 5.4L ENGINES
99-25-03 (11 KB) X     
TRANSMISSION - 4R100 - SERVICE PROCEDURE FOR ORANGE SERVICE TAGGED TRANSMISSION 99-21-11 (11 KB) X