2005 Ford Excursion Service and Repair Manual

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Factory-Grade Data

The 2005 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

  • Eddie Bauer Sport Utility 4-Door
  • Limited Sport Utility 4-Door
  • XLS Sport Utility 4-Door
  • XLT Sport Utility 4-Door

Engines covered

  • 6.0L 363Cu. In. V8 DIESEL OHV Turbocharged
  • 6.8L 415Cu. In. V10 GAS SOHC Naturally Aspirated
  • 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

2005 Ford Excursion Recalls & Complaints

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

NHTSA #05V27000010/06/2005Component: ELECTRICAL SYSTEM:WIRING

CERTAIN PICKUP TRUCKS, SPORT UTILITY VEHICLES AND VANS EQUIPPED WITH 6.0L DIESEL ENGINES MAY EXPERIENCE STALLING WITHOUT WARNING WHILE DRIVING AND MAY OR MAY NOT RESTART.

Consequence

SHOULD THE ENGINE STALL, A VEHICLE CRASH COULD OCCUR.

Remedy

DEALERS WILL UPGRADE THE FUEL INJECTION CONTROL MODULE (FICM) WIRE HARNESS OR REPLACED, AN

TSB #10243490

When performing any transmission fluid changes or topoffs involving MERCON SP, MERCON LV has replaced all versions of MERCON SP and can be used going forward. Mixing MERCON LV and MERCON SP in the same transmission is acceptable. After 30-J

TSB #10109070

The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate

TSB #10056196

FORD: WHEN SHIFTING BETWEEN PARK, REVERSE AND/OR DURING 2-3 SHIFT, AN INTERMITTENT CLUNK OCCURS WITH A TORQSHIFT TRANSMISSION. MODEL 2003-2014 F-SUPER DUTY, E SERIES, EXCURSION, F-53 MOTORHOME CHASSIS, LOW CAB FORWARD. *PE

TSB #10055629

FORD: ON SOME TRUCKS, THERE IS A NO CRANK SITUATION AND IF VOLTAGE ON TRANSMISSION RANGE SENSOR AT PIN 21, IS LESS THAN 5 VOLTS, DISCONNECT THE ENGINE COOLING FAN CLUTCH, ELECTRONICALLY, AND RECHECK VOLTAGE. MODEL 2003-2007 F SUPER DUTY, 20

TSB #10034571

FORD: RUNS ROUGH, LACKS POWER, HARD START, NO START. SOME VEHICLES AND TRUCKS EQUIPPED WITH 6.0L ENGINE MAY EXHIBIT A RUNS ROUGH, LACKS POWER, HARD TO START, NO START CONCERN WITH OR WITHOUT DIAGNOSTIC TROUBLE CODE (DTC) P0611 CODE OR VARIO

TSB #10030836

FORD: MULTIPLE VEHICLES WITH A TORQ SHIFT TRANSMISSION INTERMITTENT CLUNK WHEN SHIFTING BETWEEN DRIVE, REVERSE AND PARK AND/OR DURING 2-3 UPSHIFT. MODELS F SUPER DUTY; E SERIES; EXCURSION; F53 MOTORHOME CHASSIS AND LOW CAB FORWARD. *PE

TSB #10028826

FORD: SOME VEHICLES WITH DIESEL ENGINES MAY EXPERIENCE NO STARTS, HARD STARTS OR ROUGH RUNNING WHEN COLD AND MAY BE ACCOMPANIED WITH DIAGNOSTIC TROUBLE CODES (DTCS) P0611, P1378 AND/OR ALL 8 INJECTOR CIRCUIT CODES. *PE

TSB #10028730

FORD: SOME VEHICLES EQUIPPED WITH 6.0L DIESEL ENGINE MAY EXHIBIT ANY ONE OR COMBINATION OF THE FOLLOWING CONCERNS-LACK OF POWER, WHITE/BLACK SMOKE OR A SURGE. *PE

Showing the 8 most recent of 82 technical service bulletins on file with NHTSA.

20100618Component: AIR BAGSCrash reported2 injured

I WAS INVOLVED IN AN ACCIDENT IN MY 2005 FORD EXCURSION AND THE AIRBAGS DID NOT DEPLOY. A MINIVAN PULLED OUT FROM A STOP SIGN AND I HIT HER IN THE SIDE. ALL OF THE VAN'S AIRBAGS

20170713Component: AIR BAGSCrash reported1 injured

DURING A SINGLE VEHICLE ACCIDENT DUE TO LOSING CONTROL AT, ACCORDING TO THE POLICE REPORT, 65 MPH AND RUNNING FRONT-END FIRST IN TO A ROCKY MOUNTAIN BANK THEN BOUNCING OFF SAID BAN

20110103Component: ENGINE AND ENGINE COOLING:ENGINE:DIESELFire reported

TL* THE CONTACT OWNS 2005 FORD EXCURSION DIESEL. THE CONTACT STATED THAT WHILE DRIVING 60 MPH, THE VEHICLE BEGAN SMOKING AND STALLED. THE CONTACT ATTEMPTED TO RESTART THE VEHICLE B

20250814Component: STEERING

Several times I’ll be driving and the steering wheel will jerk in one direction and wobble violently I will grab it to correct it and basically fight to keep it in the lane so I

Showing the 4 most serious of 84 complaints filed with NHTSA.

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