2002 Ford Excursion: what breaks, and at what mileage

What owners report breaking

Owners have reported 37 named failure modes on the 2002 Ford Excursion, and the three most-reported carry 34% of everything filed, which is an unusually even spread for one model year.

Misfire or rough idle leads with 19 reports, about 0.4 per 1,000 vehicles and with the middle half of reports between 68k to 110,000 miles.

Other wheel or tire problem follows with 19 reports, usually reported between 29k to 45,000 miles.

Other engine problem follows with 13 reports, usually reported between 48k to 110,000 miles. 1 of those report mention a fire.

By system, the reports fall mostly into engine (43), wheels (27) and adas (17).

Severity, and what it costs

Across the named modes, 16 mention a crash, 9 a fire and 3 an injury. Those are the words owners used in their own complaints, and NHTSA does not verify them, but they are the closest thing in this data to a measure of what a failure actually did.

The average severity weight across every report on this year is 4.89, where a stalled engine or a failed airbag weighs many times more than a rattling trim panel, and a figure this high means the reports are dominated by failures with safety consequences rather than annoyances. The weighting is set out in full on the methodology page.

What the top failures cost to put right, as editorial estimates for an independent US shop rather than figures from NHTSA: misfire or rough idle at $250–$1,600, other wheel or tire problem at $200–$1,500, other engine problem at $300–$4,000 and other speed control problem at $250–$2,000. Dealer labour, a seized bolt or a part that is no longer made can push any of these past the top of its range.

33% of the reports on this year sit in the engine, transmission, drivetrain or cooling systems — the four where a repair bill is usually four figures.

How often, against how many were built

Scaled by an estimate of how many of these cars exist, the 2002 Ford Excursion draws about 3.1 per 1,000 vehicles, which puts it in the 77th percentile of complaint rates among 2002 vehicles we can rate.

That denominator is the weakest number on the page and it is fair to say so plainly. Rate per 1,000 uses a fleet-size estimate derived from recall paperwork for this exact model year. It is a lower bound.

The working figure is 47,872 vehicles. If the true number is twice that, every rate on this page is half what it says; the ranking against other 2002 vehicles, which is what the risk score uses, is far more robust than the rate itself.

Recalls on the 2002 model year

NHTSA has issued 5 recall campaigns covering the 2002 Ford Excursion, affecting an estimated 104,071 vehicles. A recall is a different kind of evidence from a complaint: it is the regulator and the manufacturer agreeing that something has to be fixed, and the fix is free for as long as the car exists.

The campaigns cover exterior lighting:tail lights, vehicle speed control, wheels:hub and engine and engine cooling:engine:diesel. Whether the work was actually done on the car in front of you is a question only the VIN can answer, and the manufacturer or NHTSA will answer it free.

One caution about reading these together: a recall usually raises the complaint count for the same part, because owners who read about it go and file. The mileages stay informative; the counts get noisy.

How 2002 compares with the other years

High risk for a 2002 — 209th riskiest of the 329 2002 vehicles we can rate. Every score on this site is a rank inside its own model year, which is what makes a 2004 and a 2019 comparable at all.

Across the 6 model years of this car that carry enough reports to score, 2005 comes out best at 65 and 2003 worst at 70, with 2002 itself at 66.

No other year of this model scores meaningfully better than 2002, so if this generation is what you want, the year is not the lever.

Within the 2000–2005 generation specifically, 2005 is the strongest year at 65 and 2003 the weakest at 70.

What to look at before buying one

The mileages below are where the first quarter of reports for each mode had already been filed, which makes them the point at which a fault is worth looking for rather than the point at which it happens: other speed control problem from about 25k, other wheel or tire problem from about 29k, other engine problem from about 48k and misfire or rough idle from about 68k.

On a 2002 Ford Excursion with more miles than that on it, the useful question to put to a seller or a mechanic is whether other speed control problem has been dealt with, and if so with what parts and at whose expense. A car that has already had the repair is in a different position from one that has not.

Treat it as where to point the inspection, not as a prediction. A well-maintained example can sail past every mileage on this page, and a neglected one can fail well before the first of them.

Where these figures stop being useful

150 owner reports; fleet size estimated from this year's own recall paperwork. Every count on this page is therefore a floor: it is the number of owners who went to the trouble of filing with a federal agency, which is a small and self-selected fraction of the owners who had the fault.

Of those 150 reports, 96 carried an odometer reading, so the mileages here describe 64% of the sample rather than all of it. Owners also round: readings pile up on multiples of ten thousand, which is why this site publishes "about 90,000 miles" and not "91,438".

The failure modes are assigned by software reading the owner's own words, which is accurate in bulk and wrong in individual cases. A mode with a handful of reports may contain a misfiled one.

And nothing here predicts what one car will do. These are other people's complaints, filed years apart, on cars maintained by strangers. Read the page as a map of where this model year has previously gone wrong, then have the specific car in front of you inspected.