Ford Excursion 2000-2006 Service & Repair Workshop Manual
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🏷️ Basic Information Identification Make: Ford Model: Excursion Year: 2000-2006 Codes Platform Code: UN171 Vin Code: 1FTEE 👋 Introduction Market Position Segment: Full-size SUV, positioned as a heavy-duty, family-oriented vehicle. Competitive Analysis Competitors: Chevrolet Suburban, GMC Yukon XL, Dodge Durango (for early models, though Excursion was significantly larger). Key Features Attributes: Exceptional towing and hauling capacity, spacious interior for up to nine occupants, robust construction derived from the Super Duty truck platform. Manual Purpose Utility: Provides professional-level repair and maintenance guidance for owners and technicians alike. 📋 Manual Details Coverage Areas Scope: Comprehensive repair, servicing, and troubleshooting for all systems. Page Count Estimated Pages: Hundreds (exact count not specified, but described as very detailed) Manual Type Type: Factory Service & Repair Workshop Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: V8 Triton, V10 Triton, 7.3L Power Stroke Diesel (including diagnostics, repair, overhaul) Transmission: 4R100 (automatic), ZF S6-650 (manual) (including removal, installation, overhaul, diagnostics) Drivetrain: 2WD/4WD systems, transfer case, differentials, axles, driveshafts Suspension: Front Twin I-Beam, rear solid axle, springs, shocks, steering components, alignment specifications Brakes: Front disc, rear disc, ABS system, hydraulic components, parking brake Electrical: Charging system, starting system, ignition system, lighting, body controls, instrument cluster, fuses, relays, wiring diagrams HVAC: Air conditioning system, heating system, climate control module, components Fuel System: Fuel tanks, fuel pump, fuel injectors, fuel pressure specifications, diesel injection systems Exhaust System: Catalytic converters, mufflers, exhaust pipes, hangers Body And Frame: Body panels, doors, hood, tailgate, interior trim, frame structure, glass replacement Powertrain Control Module (PCM): Diagnostics and programming (where applicable) Procedures Included Maintenance: Oil changes, fluid checks and changes, filter replacements, lubrication, tire rotations Troubleshooting: System-specific diagnostic flowcharts, symptom-based troubleshooting guides, DTC (Diagnostic Trouble Code) explanations Repair: Component replacement, adjustments, rebuild procedures for major systems Diagnostics: Step-by-step diagnostic procedures, use of scan tools, electrical testing Installation: New component installation, accessory installation (where covered) Technical Depth Depth: Full factory level; covers routine maintenance to complete engine/transmission rebuilds and complex electrical diagnostics. Detail Level: Includes hundreds of pages with detailed photos, diagrams, and exploded views. 📊 Manual Specifications File Format Compatibility: Compatible with all Windows & MAC computers. Print Quality Print Capability: Print single pages or the entire manual. Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper: Not Applicable (Digital Download) Licensing Usage Rights: Usable on unlimited computers for life; no expiry dates or renewal fees. ⚙️ Engine Specifications Primary Engine Engines Offered: 5.4L Triton V8, 6.8L Triton V10, 7.3L Power Stroke V8 Turbo Diesel. Performance 5.4L Triton V8 (Est. Power): 255 hp @ 4500 rpm, 350 lb-ft @ 3000 rpm 6.8L Triton V10 (Est. Power): 310 hp @ 4250 rpm, 425 lb-ft @ 3250 rpm 7.3L Power Stroke V8 Turbo Diesel (Est. Power): 250 hp @ 2600 rpm, 505 lb-ft @ 1600 rpm (Early models) / 275 hp @ 2600 rpm, 525 lb-ft @ 1600 rpm (Later models) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) for gasoline engines; HEUI (Hydraulically Actuated Electronically Controlled Unit Injector) for Power Stroke diesel. Engine Management ECM Type: Powertrain Control Module (PCM) for gasoline, Engine Control Module (ECM) for diesel. Cooling System Radiator Capacity Approx: Gasoline: 24-26 quarts; Diesel: 26-28 quarts (manual may specify exact capacities). 🔧 Transmission Standard Transmission Type: 4R100 4-speed automatic (standard on most models). Optional Optional Transmission: ZF S6-650 6-speed manual (available with V10 and 7.3L Power Stroke Diesel). Features Electronic Controls: Electronic transmission control for automatic transmissions (e.g., Progressive Range Select). Fluid Specification 4R100 Fluid: Mercon V (or equivalent, manual will specify) Zf S6-650 Fluid: Mercon ATF or equivalent manual transmission fluid (manual will specify). 📐 Dimensions Exterior Overall Length: Approx. 224.5 inches (5702 mm) Overall Width: Approx. 79.9 inches (2030 mm) Overall Height: Approx. 76.2 inches (1935 mm) Wheelbase: Approx. 137 inches (3480 mm) Cargo Cargo Volume Behind 3Rd Row: Approx. 46.6 cu ft Cargo Volume Behind 2Nd Row: Approx. 91.1 cu ft Cargo Volume Behind 1St Row: Approx. 133.5 cu ft Weights Curb Weight Approx: 6,500 - 7,500 lbs (depending on engine and drivetrain) Gross Vehicle Weight Rating Gvwr Approx: 9,200 - 9,700 lbs Towing Capacity Max Approx: Up to 10,000 - 12,000 lbs (properly equipped) 🛡️ Safety Features Ratings NHTSA Rollover Resistance Score: Often rated 4 out of 5 stars due to its high center of gravity, though specific year ratings may vary. Active Features Braking System: 4-wheel anti-lock disc brakes (ABS). Traction Control: Available Traction Control System (TCS). Passive Features Airbags: Driver and front passenger airbags. Seatbelts: 3-point seatbelts for all occupants, including second and third rows. Available adjustable shoulder belts. Child Seat Anchors: LATCH (Lower Anchors and Tethers for Children) system. 💡 Technology Features Infotainment Audio System: Optional premium audio systems, CD players, cassette players, and in-dash navigation (on some later models). Driver Assistance Cruise Control: Standard cruise control. Parking...
4R100 4-speed automatic (standard on most models).
Optional
Optional Transmission:
ZF S6-650 6-speed manual (available with V10 and 7.3L Power Stroke Diesel).
Features
Electronic Controls:
Electronic transmission control for automatic transmissions (e.g., Progressive Range Select).
Fluid Specification
4R100 Fluid:
Mercon V (or equivalent, manual will specify)
Zf S6-650 Fluid:
Mercon ATF or equivalent manual transmission fluid (manual will specify).
📐 Dimensions
Exterior
Overall Length:
Approx. 224.5 inches (5702 mm)
Overall Width:
Approx. 79.9 inches (2030 mm)
Overall Height:
Approx. 76.2 inches (1935 mm)
Wheelbase:
Approx. 137 inches (3480 mm)
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 46.6 cu ft
Cargo Volume Behind 2Nd Row:
Approx. 91.1 cu ft
Cargo Volume Behind 1St Row:
Approx. 133.5 cu ft
Weights
Curb Weight Approx:
6,500 - 7,500 lbs (depending on engine and drivetrain)
Gross Vehicle Weight Rating Gvwr Approx:
9,200 - 9,700 lbs
Towing Capacity Max Approx:
Up to 10,000 - 12,000 lbs (properly equipped)
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance Score:
Often rated 4 out of 5 stars due to its high center of gravity, though specific year ratings may vary.
Active Features
Braking System:
4-wheel anti-lock disc brakes (ABS).
Traction Control:
Available Traction Control System (TCS).
Passive Features
Airbags:
Driver and front passenger airbags.
Seatbelts:
3-point seatbelts for all occupants, including second and third rows. Available adjustable shoulder belts.
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) system.
💡 Technology Features
Infotainment
Audio System:
Optional premium audio systems, CD players, cassette players, and in-dash navigation (on some later models).
Driver Assistance
Cruise Control:
Standard cruise control.
Parking Sensors:
Optional rear parking assist sensors.
Connectivity
Connectivity Features:
No advanced smartphone integration or Bluetooth typically found in modern vehicles; focused on core vehicle functions.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles or 6 months (for gasoline engines); Diesel typically every 5,000-10,000 miles depending on oil type and usage (consult manual for specific recommendations).
Tire Rotation Interval:
Every 5,000 miles.
Transmission Fluid Change:
Every 30,000-60,000 miles, depending on towing and driving conditions (diesel transmission service may differ, consult manual).
Fluid Specifications
Engine Oil 5W20:
Recommended for 5.4L & 6.8L Triton V8 (check manual for exact spec).
Engine Oil 15W40:
Recommended for 7.3L Power Stroke Diesel (check manual for exact spec).
Coolant:
Ford Gold Coolant (or equivalent compatible with the original fill).
Brake Fluid:
DOT 3 (or equivalent).
Known Issues
Diesel Injector Problems:
7.3L Power Stroke can experience injector O-ring seal failures leading to fuel dilution of oil or hard starting. Manual will cover testing and replacement.
Transmission Hard Shifting:
4R100 transmission can develop issues with solenoids or valve body causing hard shifting. Manual provides diagnostic steps.
Rear Main Seal Leaks:
Can occur on both gasoline and diesel engines, especially on higher mileage vehicles. Manual covers replacement procedures.
Exhaust Manifold Cracks:
Common on V10 engines due to heat cycles. Manual will detail inspection and replacement.
Steering Play:
Worn steering gear or ball joints can lead to excessive play. Manual covers inspection and component replacement.
📚 Vehicle History
Brand Heritage
Ford Truck Lineage:
Built on the Ford Super Duty F-250/F-350 truck chassis, inheriting its robust construction and heavy-duty components.
Model Evolution
Introduction Year:
Introduced for the 2000 model year.
Facelift:
Received minor updates, including interior refinements and powertrain adjustments during its production run, but no major redesign.
Production
Production Years:
2000-2006
Manufacturing Location:
Kentucky Truck Plant, Louisville, Kentucky, USA
Discontinuation:
Discontinued after the 2006 model year due to declining sales and evolving market preferences towards more fuel-efficient SUVs and the rise of large crossovers.
🏆 Awards & Recognition
Recognitions
Popular Mechanics Editor S Choice:
Awarded 'Best in Class' in the large SUV category by Popular Mechanics in 2000 for its capability and towing prowess.
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