2004 Ford Excursion Service and Repair Manual

This factory service and repair manual for the 2004 Ford Excursion covers four trims, Eddie Bauer, Limited, XLS and XLT, and three engines: the turbocharged 6.0-liter OHV V8 diesel, the naturally aspirated 6.8-liter SOHC V10 and the naturally aspirated 5.4-liter SOHC V8. The body is the four-door sport utility. Diesel and gasoline trucks diverge in fuel delivery, starting and charging, so each engine carries its own specifications and torque values, with wiring diagrams and diagnostic procedures written to match.

Engines covered

• 6.0L V8 (363 cu in) — OHV, turbocharged, diesel
• 6.8L V10 (415 cu in) — SOHC, naturally aspirated, gasoline
• 5.4L V8 (330 cu in) — SOHC, naturally aspirated, gasoline

Body styles covered

• 4-door sport utility

Trims covered

• Eddie Bauer
• Limited
• XLS
• XLT

Known issues on the 2004 Excursion. Two recalls are on federal record for the 2004 truck. The more significant covers 6.0-liter diesel vehicles that could stall without warning while driving and might not restart. The other is a tail lamp campaign reaching service parts distributed to dealers, where lights that do not work raise the risk of a crash. Owners have filed 95 complaints with NHTSA, with engine and cooling first, then the electrical system and vehicle speed control. Diesel engine diagnostics, charging and lighting wiring diagrams and the speed control circuits are all documented in this manual.