2001 Ford Excursion

THE CAM POSITION SENSOR (CPS) PROVIDES A CRITICAL SIGNAL TO THE SUBJECT VEHICLE (SV) ENGINE MANAGEMENT SYSTEM, THE LOSS OF WHICH RESULTS IN AN ENGINE STALL.DURING PE06-011, FORD STATED IN THEIR RESPONSE TO ODI THAT IT IS CONTINUING TO INVESTIGATE ALLEGATIONS OF CPS RELATED ENGINE STALL AND FURTHER ADVISED THAT AN UPDATE WILL BE PROVIDED UPON COMPLETION OF THE INVESTIGATION.FORD DATA SHOWS THAT 20% OF THE 716,000 SVS ARE EQUIPPED WITH MANUAL TRANSMISSIONS WHICH ARE CAPABLE OF BACK-DRIVING THE ENGINE WHEN A STALL OCCURS; POWER ASSISTED STEERING AND BRAKING ARE NOT LOST DURING ENGINE BACK-DRIVE.FORD DATA ALSO INDICATES THAT BACK-DRIVE OCCURS IN AUTOMATIC TRANSMISSION VEHICLES ABOVE CERTAIN ROAD SPEEDS.THE MANUFACTURER REPORTS NOTED REFERENCE 755 UNIQUE VEHICLES; 2 ARE DUPLICATIVE OF ODI REPORTS.IN ITS REVIEW OF CUSTOMER AND FIELD REPORTS, FORD IDENTIFIED SOME 800 REPORTS ALLEGING ONE OR MORE ENGINE STALLS POTENTIALLY RELATED TO A CPS FAILURE IN THESE 755 VEHICLES (FORD?S ?A? CATEGORY REPORTS).ODI HAS NOT COMPLETED ITS REVIEW OF THESE OR OTHER FORD REPORTS, NOR HAS IT CONFIRMED THIS COUNT.ALL BUT ONE OF THE 9 CRASH ALLEGATIONS APPEAR TO BE MINOR IN NATURE ALTHOUGH ODI IS STILL INVESTIGATING THESE CRASH/INJURY ALLEGATIONS AND WHETHER OR NOT THEY INVOLVE A CPS FAILURE.BASED ON EARLY ASSESSMENT OF THE APPROXIMATELY 166,000 SUBJECT VEHICLE WARRANTY CLAIMS FORD PAID, THERE APPEARS TO BE VARIABILITY IN CLAIM RATES BETWEEN CERTAIN SV PRODUCTION PERIODS; AN EXPLANATION FOR THIS HAS NOT BEEN IDENTIFIED.FORD REVIEWED A SAMPLE OF THE WARRANTY CLAIMS AND INDICATED THAT ABOUT HALF MAY INVOLVE A STALL DUE TO CPS FAILURE; ODI HAS YET TO CONFIRM THIS ASSESSMENT.THE INVESTIGATION IS THEREFORE UPGRADED TO ENGINEERING ANALYSIS EA06-012 SO THAT ODI CAN CONTINUE TO INVESTIGATE THE SCOPE, FREQUENCY AND CONSEQUENCES OF CPS RELATED ENGINE STALLING.

ON SEPTEMBER 6, 2005, ODI RECEIVED A PETITION REQUESTING THAT THE AGENCY INVESTIGATE ALLEGATIONS OF ENGINE SPARK PLUG EJECTION IN CERTAIN MODEL YEAR 1997 THROUGH 2004 FORD VEHICLES WITH TRITON V-8 AND V-10 ENGINES.ODI RECEIVED A TOTAL OF 474 NON-DUPLICATIVE COMPLAINTS ON THE SUBJECT VEHICLES WHERE THE COMPLAINANT, OR THE DEALER REPAIRING THE VEHICLE, REPORTED THAT A SPARK PLUG DETACHED FROM THE CYLINDER AND/OR EJECTED FROM THE ENGINE.AS OF DECEMBER 8, 2005, ODI IS NOT AWARE OF ANY ALLEGATIONS WHERE THE ALLEGED DEFECT RESULTED IN A LOSS OF VEHICLE CONTROL, A CRASH, AN INJURY, OR A FATALITY IN ANY OF THE 10,319,810 SUBJECT VEHICLES.IN ADDITION, ODI IS AWARE OF ONLY TWO INCIDENTS WHERE THE VEHICLE STALLED WITHOUT RESTART.INFORMATION CONTAINED IN THE ODI CONSUMER COMPLAINTS AND OBTAINED FROM 72 TELEPHONE INTERVIEWS WITH COMPLAINANTS SHOWED THE FOLLOWING:(1) 99% OF THE COMPLAINTS WERE ON MY 1997 TO 2002 SUBJECT VEHICLES.(2) MOST THE COMPLAINANTS REPORTED HEARING A LOUD POP WHILE DRIVING OR UPON STARTING UP THE VEHICLE FOLLOWED BY A LOUD, REPETITIVE CLICKING OR POPPING SOUND.(3) MANY OF THE COMPLAINANTS REPORTED THAT THE POPPING SOUND WAS ACCOMPANIED BY SOME LOSS OF VEHICLE POWER; HOWEVER, IN 99% OF THE INCIDENTS REPORTED, THE VEHICLE DID NOT STALL.IN THE VERY FEW INCIDENTS WHERE THE VEHICLE DID STALL, MOST VEHICLES COULD BE RESTARTED.(4) ONLY A SMALL PERCENTAGE OF THE COMPLAINANTS CITED THAT THEY SMELLED GAS OR A SLIGHT BURNING SMELL WHEN THE INCIDENT OCCURRED.(5) IN ALL BUT A VERY FEW INCIDENTS, VEHICLE DAMAGE WAS LIMITED TO THE ENGINE.IN ONE INCIDENT, THE COMPLAINT REPORTED THAT THE FUEL RAIL WAS DAMAGED AND REPLACED AFTER ONE OF THE SPARK PLUGS EJECTED FROM THE ENGINE; HOWEVER, THE COMPLAINANT REPORTED THAT THE DAMAGE DID NOT RESULT IN ANY TYPE OF FUEL LEAK OR FIRE.IN ANOTHER INCIDENT, THE ONLY INCIDENT WHERE A FIRE WAS ALLEGED, THE COMPLAINANT REPORTED THAT NO FLUID LEAK WAS OBSERVED, BUT THAT A FIRE RESULTED AFTER THE SPARK PLUG HAD EJECTED FROM THE ENGINE AND HE HAD RESTARTED THE VEHICLE AND DRIVEN TO ANOTHER LOCATION.NONE OF THE COMPLAINANTS REPORTED ANY DAMAGE TO THE VEHICLE HOOD.(6) ONLY TWO COMPLAINANTS REPORTED THAT THEY OBSERVED WHAT APPEARED TO BE SOME DROPS OF FUEL COMING FROM THE CYLINDER WHERE THE SPARK PLUG HAD FAILED OR ON THE SPARK PLUG ITSELF; HOWEVER, EACH OF THESE COMPLAINANTS REPORTED THAT THERE WAS NO SMOKE OR FLAMES AS A RESULT OF HIS INCIDENT.AS THE PETITIONER NOTED, AND ODI?S ANALYSIS SHOWED, IT IS POSSIBLE FOR A SPARK PLUG TO DETACH FROM THE ENGINE CYLINDER THREADS IN THE SUBJECT VEHICLES.HOWEVER, ODI?S ANALYSIS OF 474 COMPLAINTS DESCRIBING SUCH INCIDENTS FOUND ONLY A VERY FEW ALLEGED ANY SAFETY-RELATED CONSEQUENCES.NONE OF THESE SHOWED ANY EVIDENCE OF A SERIOUS SAFETY CONSEQUENCE.GIVEN THE LARGE POPULATION AND RELATIVELY LONG EXPOSURE TIME OF THE SUBJECT VEHICLES, THE COMPLAINT ANALYSIS INDICATES THAT THE RISK TO MOTOR VEHICLE SAFETY FROM THE ALLEGED DEFECT IS VERY LOW.IN VIEW OF THE FOREGOING, IT IS UNLIKELY THAT NHTSA WOULD ISSUE AN ORDER FOR THE NOTIFICATION AND REMEDY OF THE ALLEGED DEFECT AT THE CONCLUSION OF THE INVESTIGATION REQUESTED IN THE PETITION.THEREFORE, IN VIEW OF THE NEED TO ALLOCATE AND PRIORITIZE NHTSA?S LIMITED RESOURCES TO BEST ACCOMPLISH THE AGENCY?S SAFETY MISSION, THE PETITION IS DENIED.

EA05-005 IS CLOSED WITH FORD?S ACTIONS IN RECALLS 05V-017, 05V-388, AND 06V-286, RECALLING APPROXIMATELY 6.7 MILLION VEHICLES EQUIPPED WITH TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCHES (SCDS).THE BRAKE SYSTEMS IN THESE RECALLED VEHICLES GENERATE A VACUUM THAT CAN POTENTIALLY CAUSE THE SCDS TO FAIL AND, IN CERTAIN SWITCH INSTALLATION ORIENTATIONS, CATCH FIRE.FORD IS ALSO INCLUDING THE ENTIRE POPULATION OF 1998 EXPLORERS.FORD HAS INFORMED ODI THAT TESTING TO DETERMINE THE CAUSE OF FAILURES IN THE 1998 EXPLORERS WILL CONTINUE AFTER THIS INVESTIGATION IS CLOSED.ODI BELIEVES THAT THE VEHICLES EXHIBITING THE FACTORS CAUSING SCDS FAILURE DESCRIBED IN THIS REPORT CORRELATE WELL WITH THE OBSERVED FAILURE RATES ON THESE VEHICLES BY MODEL AND MODEL YEAR.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST IN THE NON-RECALLED VEHICLES MANUFACTURED WITH SCDS THAT ARE NOT INCLUDED IN FORD?S RECALLS.ODI WILL CONTINUE TO MONITOR THE NON-RECALLED POPULATION FOR INCIDENCE OF ENGINE COMPARTMENT FIRES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE ATTACHED CLOSING REPORT FOR DETAILS.

DURING THE INITIAL RECALL CAMPAIGN IN 2001, THE SUBJECT VEHICLES WERE INSPECTED BY FORD DEALERSHIPS USING A TEST TOOL THAT WOULD DETECT A DEFECTIVE FRONT SEAT OUTBOARD SEAT BELT BUCKLE ASSEMBLY.APPROXIMATELY ONE MILLION VEHICLES PASSED THE INSPECTION TEST FOR ONE OR BOTH FRONT BUCKLES.SUBSEQUENT TO THE RECALL SERVICE ACTION, ODI RECEIVED 15 CONSUMER REPORTS ALLEGING THAT A PASSED INSPECTION BUCKLE SUBSEQUENTLY FAILED TO LATCH OR INADVERTENTLY UNLATCHED DURING USE.IN ADDITION, FORD HAS IDENTIFIED 543 OWNER AND FIELD REPORTS ALLEGING BUCKLE FAILURE SUBSEQUENT TO PASSING THE INSPECTION TEST.FORD TESTED AND EXAMINED OVER 100 WARRANTY-RETURNED BUCKLES AND FOUND THAT 44% OF THE BUCKLES HAD NO PROBLEM OR A CONDITION NOT RELATED TO THE RECALL INSPECTION (NON-LATCH RELATED BUCKLE DAMAGE OR FOREIGN CONTAMINATION).WARRANTY CLAIMS WERE HIGHEST DURING THE 18-MONTH PERIOD AFTER THE START OF THE RECALL (JULY 2001) AND HAVE BEEN DECLINING DURING THE PAST 24 MONTHS.OVER THE PAST 12 MONTHS, FORD HAS RECEIVED APPROXIMATELY 12 WARRANTY CLAIMS PER MONTH OUT OF A VEHICLE POPULATION OF ABOUT ONE MILLION.COMPLAINTS COUNTS ARE ALSO DECREASING.DURING THE PAST SEVEN MONTHS, ODI HAS RECEIVED ONLY TWO COMPLAINTS. A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

Odometer Fraud. The contact was interested in purchasing a 2001 Ford Excursion at the dealer who advertised the mileage on the vehicle as 120,000 on Saturday, December 6th, 2025; however, the odometer showed a mileage of 116,000. While noticing the difference, the contact decided to research the VIN online and discovered that on January 20th, 2024, in Maryland, the mileage was recorded for the vehicle at the time of servicing at 212,820. The contact asked the dealer for clarity on the difference in the mileage; however, the dealer failed to provide an explanation. The dealer stated that no laws in the state of Utah were being violated where the vehicle was being sold and disconnected the call. The contact reported the issue to the NHTSA after discovering the discrepancy.

NHTSA ID

11703730

Incident

Dec 6, 2025

Mileage

212,820 mi

Tie rod end broke in half. Tie rod fell to the ground

NHTSA ID

11518816

Incident

Apr 20, 2023

The contact owns a 2001 Ford Excursion. The contact stated that while the vehicle was parked and unattended, the vehicle caught fire without warning. There were no reported injuries, police reports, or air bag deployments. The fire department and city employees extinguished the fire. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 135,000.

NHTSA ID

11511521

Incident

Mar 12, 2023

Mileage

135,000 mi

CRUISE CONTROL CUTOUT SWITCH MOUNTED ON MASTER CYLINDER IS FULL OF BRAKE FLUID INCLUDING THE ELECTRICAL CONNECTOR. THE VIN NUMBER DOESN'T LINK TO A RECALL. PERHAPS THE PREVIOUS OWNER HAD SWITCH REPLACED UNDER RECALL OR PERHAPS THIS VIN WASN'T IN THE ORIGINAL RECALL. IN ANY EVENT A FIRE HAZARD IS PRESENT.

NHTSA ID

11102252

Incident

Jun 17, 2018

Mileage

70,000 mi

TL* THE CONTACT OWNS A 2001 FORD EXCURSION EQUIPPED WITH FIRESTONE STEELTEX A/T TIRES, SIZE: LT265/75R16 119/116R (NA). WHILE DRIVING 55 MPH, THE TIRES EXPLODED AND CAUSED CONSIDERABLE DAMAGE TO THE VEHICLE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE VEHICLE AND TIRE FAILURE MILEAGE WAS 147,000.

NHTSA ID

10783698

Incident

Oct 13, 2015

Mileage

147,000 mi

DROVE TO LOCAL HIGH SCHOOL AROUND 7:30AM AND RETURNED HOME AROUND 7:45 AM ABOUT A HOUR LATER I WAS NOTIFIED BY MY NEIGHBOR THAT MY FORD EXCURSION WAS ON FIRE, THE FIRE FLAMES WERE COMING FROM THE ENGINE COMPARTMENT. THE EXCURSION WAS PARK IN THE DRIVEWAY.

NHTSA ID

10778903

Incident

Sep 28, 2015

Mileage

120,000 mi

TL* THE CONTACT OWNS A 2001 FORD EXCURSION. WHILE TRAVELING AT 70 MPH, THE SPEED BEGAN TO REDUCE. THE VEHICLE WAS TOWED TO A DEALER WHERE IT WAS DIAGNOSED THAT THREAD GAVE WAY ON THE MOTOR HEAD. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 120,000.

NHTSA ID

10767514

Incident

Sep 20, 2015

Mileage

120,000 mi

TL* THE CONTACT OWNS A 2001 FORD EXCURSION. THE CONTACT STATED THAT WHILE PARKED, THE VEHICLE CAUGHT ON FIRE. THE FIRE DEPARTMENT EXTINGUISHED THE FIRE. A POLICE REPORT WAS FILED AND THERE WERE NO INJURIES REPORTED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN.

NHTSA ID

10732137

Incident

Jul 4, 2015

This SKU is a front upper ball joint. The Customer communication requested return of unsold inventory to inspect for ball studs with excessive rotational friction in the ball joint assembly. Excessive friction in the ball joint assembly may cause a perceptible increase in steering effort.

SOME 1997-2008 VEHICLES EQUIPPED WITH A 4.6L 2V, 5.4L 2V, OR 6.8L 2V ENGINE--SPARK PLUG THREAD REPAIR PROCEDURE--NOT COVERED UNDER NEW VEHICLE LIMITED WARRANTY. *NJ THIS INCLUDES F-53 MOTORHOME CHASSIS. UPDATED 2/23/10. *PE

FUEL CONDITIONER. LOW POWER, POOR FUEL ECONOMY, FUEL GELLING IN COLD WEATHER, EXCESSIVE WHITE SMOKE ON COLD START, HARD START, OR COKING OF COMPONENTS EXPOSED TO EXHAUST. *TT

WDS COP KIT DIAGNOSTIC TIP - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING. *TT

VACUUM PUMP INOPERATIVE OR RUNS CONTINUOUSLY - CLIMATE CONTROL DEFAULTS TO DEFROST MODE. *TT

SAFETY BELT RETRACTION SPEED. *TT