2002 Ford Excursion Service and Repair Manual

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Factory-Grade Data

The 2002 Ford Excursion service and repair manual is a detailed, OEM-style reference for diagnostics, maintenance, and repair work. Use it to verify procedures, specifications, and system information before you start a job.

You'll find coverage across key vehicle systems with clear section structure, including wiring diagrams and powertrain, braking, steering, suspension, HVAC, and electrical topics. Digital format makes it easy to search while you work.

Trims covered

  • Limited Sport Utility 4-Door
  • XLT Sport Utility 4-Door

Engines covered

  • 6.8L 415Cu. In. V10 GAS SOHC Naturally Aspirated
  • 7.3L 445Cu. In. V8 DIESEL OHV Turbocharged
  • 5.4L 330Cu. In. V8 GAS SOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2002 Ford Excursion Recalls & Complaints

NHTSA #09V39900013/10/2009Component: VEHICLE SPEED CONTROL

FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXP

Consequence

A VEHICLE FIRE COULD OCCUR WITH OR WITHOUT THE ENGINE RUNNING.

Remedy

FORD WILL NOTIFY OWNERS THAT DEALERS WILL INSTALL A FUSED WIRING HARNESS IN LINE WITH THE

NHTSA #11V35200013/07/2011Component: EXTERIOR LIGHTING:TAIL LIGHTS

FORD IS RECALLING CERTAIN MODEL YEAR 2011 RANGER TRUCKS BUILT FROM JANUARY 25, 2011, THROUGH APRIL 25, 2011 AT THE TWIN CITIES ASSEMBLY PLANT, AND SERVICE PARTS DISTRIBUTED TO DEAL

Consequence

NON-FUNCTIONING LIGHTS COULD INCREASE THE RISK OF A CRASH.

Remedy

DEALERS WILL REPLACE THE SWITCHES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 15, 2

TSB #10148818

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

TSB #10026321

FORD: VEHICLES MISTAKENLY CHARGED $100 POWERTRAIN WARRANTY DEDUCTIBLE FOR FUEL INJECTOR REPAIR OR REPAIRS. NO MODEL OR MODEL YEARS PROVIDED. *PE ECONOLINE, EXCURSION AND F-SERIES SUPER DUTY VEHICLES, MODEL YEARS 2002-2005. UPDATED 10/24/08.

TSB #10023943

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

TSB #10022675

BRAKE BOOSTER SYSTEM MAY EXHIBIT A BRAKE PEDAL KICKBACK AND/OR GRABBING CONDITION WHEN APPLYING THE BRAKES. *NJ

TSB #10019075

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

TSB #10018745

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

TSB #10018067

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

TSB #10018054

SERVICE KIT AVAILABLE FOR WIPER MOTOR WIRING. *TT

Showing the 8 most recent of 124 technical service bulletins on file with NHTSA.

20020625Component: VEHICLE SPEED CONTROLCrash reported6 injured

WHEN APPLYING ACCELERATOR PEDAL IT WILL GO TO THE FLOOR INTERMITTENTLY, ENGINE WILL NOT REVV, AND VEHICLE WILL NOT MOVE FORWARD. VEHICLE WAS REARENDED AFTER CONSUMER WAS AT A STOP.

20050307Component: AIR BAGS:FRONTALCrash reported2 injured

THE SUV TRUCK WAS INVOLVED IN A T-BONE COLLISION OF 55 MPH AND NEITHER FRONTAL AIR BAGS DEPLOYED. NO ONE WAS TRANSPORTED TO THE LOCAL HOSPITAL, BUT THE DRIVER AND PASSENGER SUSTAI

20040227Component: SERVICE BRAKES, AIR:ANTILOCKCrash reported1 injured

WHILE DRIVING AT A SLOW SPEED A CAR MADE A SUDDEN STOP IN FRONT OF NO MATTER HOW HARD I STEP ON THE BRAKES THE TRUCK DID NOT STOP.*AK

20020716Component: AIR BAGS:FRONTALCrash reported1 injured

FRONT CRASH AT 55 MPH, NEITHER AIRBAG DEPLOYED. NO INJURIES, DAMAGE TO VEHICLE UNKNOWN AT THIS TIME.*AK CONSUMER STATED THAT ONE PERSON FROM THE OTHER VEHICLE WAS INJURED. *YH

Showing the 4 most serious of 150 complaints filed with NHTSA.

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