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1999-2005 Ford Excursion Repair Manual

Ford Excursion repair manualsThe first generation Ford Excursion was introduced in 1999 in a four-door sport utility vehicle body style (2WD and 4WD submodels). Three trim levels were available: base trim XL, standard trim XLT, highest trim Limited and two-tone trim Eddie Bauer.
General information: Class: full-size SUV; Body style: 4-door SUV with lift gate and 2 dutch doors; Layout: front engine, rear-wheel drive or four-wheel drive; Wheelbase: 137.1 in (3,482 mm); Length: 226.7 in (5,758 mm); Width: 80.0 in (2,032 mm) [1999-2001]; 79.9 in (2,029 mm) [2002-2005]; Height: 74.8 in (1,900 mm) [2WD]; 77.2 in (1,961 mm) [4WD].

1999-2005 Ford Excursion 4-door SUV

1999-2005 Ford Excursion 4-door SUV

5.4L Triton SOHC 2V V8 engine

5.4L Triton SOHC 2V V8 engine

6.8L Triton SOHC 2V V10 engine

6.8L Triton SOHC 2V V10 engine

7.3L PowerStroke OHV turbo V8 engine

7.3L PowerStroke OHV turbo V8 engine

4-speed 4R100 automatic transmission

4-speed 4R100 automatic transmission

5-speed 5R110W automatic transmission

5-speed 5R110W automatic transmission

Engines:
5.4L Triton SOHC 2V V8 produced 255 hp (190 kW) and 350 lb·ft (475 N·m)
General information: Configuration: 90° V8; Displacement: 4,951 cc (302.1 cu in); Cylinder bore: 3.629 in (92.2 mm); Piston stroke: 3.649 in (92.7 mm); Valvetrain: OHC with Roller finger followers.
6.8L Triton SOHC 2V V10 produced 255 hp (190 kW) and 350 lb·ft (475 N·m)
General information: Configuration: 90° V10; Displacement: 412.5 cu in (6,760 cc); Cylinder bore: 3.7 in (94.0 mm); Piston stroke: 4.2 in (105.8 mm); Valvetrain: OHC with Roller finger followers.
6.0L Powerstroke turbodiesel V8 produced 325 hp (242 kW) at 3,300 rpm and 560 lb·ft (759 N·m) at 2,000 rpm
General information: Configuration: 60° V6; Displacement: 365.0 cu in (5,981 cc); Cylinder bore: 3.7 in (95.0 mm); Piston stroke: 4.1 in (105.0 mm); Cylinder block alloy: Cast iron; Cylinder head alloy: Cast iron; Compression ratio: 18.0:1; Aspiration: Single Garrett GT3782VA variable geometry turbocharger (VGT); Injection: Direct injection, Electro Hydraulic Generation Two (G2) injection technology (HEUI injectors, 26,000 psi); Valvetrain: Single gear driven camshaft, 4-valves per cylinder (32 valve pushrod valvetrain); Emissions System: Exhaust gas recirculation (EGR) and diesel oxidation catalyst (DOC).
7.3L Powerstroke turbodiesel V10 produced 250 hp (186 kW) at 3,300 rpm and 525 lb·ft (712 N·m) at 2,000 rpm
General information: Configuration: 60° V6; Displacement: 444.0 cu in (7,275 cc); Cylinder bore: 4.1 in (104.4 mm); Piston stroke: 4.2 in (106.2 mm); Cylinder block alloy: Cast iron; Cylinder head alloy: Cast iron; Compression ratio: 17.5:1; Aspiration: Single Garrett GTP38 variable geometry turbocharger (VGT); Injection: Direct injection, HEUI (hydraulic electronic unit injection). See injector code breakdown below; Valvetrain: OHV, 2 valves per cylinder, hydraulic lifters (no valve adjustment necessary); Emissions System: Exhaust gas recirculation (EGR) and diesel oxidation catalyst (DOC).
Repair operations: repair operations possible with the engine in the vehicle; intake manifold: removal and installation; exhaust manifold: removal and installation; valve covers: removal and installation; cylinder head: removal, inspection and installation; spark plug thread repair; timing chain wear: check; timing cover and timing chain: removal and installation; oil pump: removal, inspection and installation; oil pan: removal, inspection and installation; camshaft and lifters: removal, inspection and installation.
General engine overhaul procedures: engine overhaul: disassembly sequence, general information and reassembly sequence; engine rebuilding alternatives; engine removal: methods and precautions; camshaft and bearings: inspection; crankshaft: inspection, removal, installation and main bearing oil clearance check; cylinder compression check; cylinder head: cleaning, inspection, disassembly and reassembly; cylinder honing; engine: removal and installation; engine block: cleaning and inspection; initial start-up and break-in after overhaul; main and connecting rod bearings: inspection; oil pump: inspection; piston rings: installation; piston/connecting rod assembly: removal, inspection and installation; timing chain/sprockets or gears: wear checks; valve adjustment and servicing; valve lifters and pushrods: inspection.
Transmissions:
4-speed Ford 4R100 automatic transmission
Gear ratios (overall): I – 2.71:1; II – 1.54:1; III – 1.0:1; IV – 0.71:1; R – 2.18:1
5-speed Ford 5R110W TorqShift automatic transmission
Gear ratios (overall): I – 3.11:1; II – 2.20:1; III – 1.54:1; IV – 1.0:1; V – 0.71:1; R – 2.88:1
Repair operations: manual shift linkage: inspection, removal, installation and adjustment; throttle valve mechanisms: removal, installation and adjustment; kickdown mechanisms: removal, installation and adjustment; vacuum modulator: check and replacement; band adjustment; automatic transmission: removal and installation; electronic shift transmission: general information; manual lever position sensor: adjustment; neutral start switch: adjustment.
Transfer case:
New Venture NV-273 transfer case
General information: Case material: Cast aluminum; Transfer case type: Chain drive; Shift type: Electric shift; Low-range ratio: 2.72:1; Low-range: planetary design; Fluid type: ATF
Repair operations: transfer case: removal and installation; transfer case: overhaul; front output shaft oil seal: removal and replacement; rear output shaft oil seal: removal and replacement; rear extension housing bushing: removal and replacement; manual shift lever assembly: removal and installation; electronic shift: removal and installation.
Other manuals: cooling, heating and air conditioning systems; fuel and exhaust systems; engine electrical systems; emissions and engine control systems; driveline; brakes; suspension and steering systems; body; chassis electrical system; wiring diagrams. All 1999-2005 Ford Excursion repair manuals are written specifically for the do-it-yourselfer.