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Ford · Known Issues

2002 Ford Excursion Problems: 2 Known Issues

2002 model year · 680+ owner reports · Updated September 2026

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Issue summary

According to Au7o's analysis of 680+ owner reports, the 2002 Ford Excursion has 2 documented known issues, with 1 rated critical. The most serious is BorgWarner 4405 Electric Shift Transfer Case Failure (V10 Models) ($350-$5,000 repair). The most commonly reported issue is BorgWarner 4405 Electric Shift Transfer Case Failure (V10 Models) with 680 owner reports. Across all issues with published estimates, repair costs range from $250 to $5,000. DIY maintenance guides at au7o.io.

In This Article

  • Excursion Drivetrain2
  • Recalls11
  • FAQ
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In This Article

  • Drivetrain2
  • Recalls11
  • FAQ

All 2 Known Issues

Filter:
ALL YEARS200520042003200220012000
Community reported
680 owners

On the 2000-2005 Ford Excursion 6.8L V10, the 2000-2005 Ford Excursion equipped with the 6.8L V10 engine and BorgWarner 4405 electric-shift-on-the-fly transfer case experiences multiple failure modes including transfer case shift motor failure, false neutral conditions, and GEM (Generic Electronic Module) control issues. The electric shift motor can become stuck in intermediate positions between 2WD and 4WD, causing a false neutral condition where no drive torque reaches the wheels. The GEM module that controls 4WD engagement can fail or lose communication, preventing 4WD operation entirely. JustAnswer.com and Ford Expedition Forum document cases where the transfer case shifts to neutral unexpectedly. RepairPal estimates the transfer case shift motor replacement cost between $346 and $420, but complete transfer case overhaul or replacement can cost $3,000-5,000.

Common Symptoms

  • Transfer case stuck between 2WD and 4WD (false neutral)
  • 4WD indicator light flashing or not illuminating
  • No response when shifting from 2H to 4H or 4L
  • Grinding or clunking when engaging 4WD
  • Vehicle loses all drive torque unexpectedly
  • GEM module 4x4 fault codes
  • Transfer case shift motor running but not completing shift
  • Difficulty shifting from 4L back to 2H

How to Fix

Diagnose using GEM module DTCs first - many issues are electrical (shift motor or GEM) rather than mechanical. The shift motor (Dorman 600-805 or Motorcraft) is the most commonly replaced component at $200-350 plus 1-2 hours labor. If the GEM module has failed, replacement and programming ($300-600) is required at a dealer. For mechanical transfer case issues (grinding, worn chains), a complete rebuild ($2,000-3,500) or remanufactured replacement ($2,500-5,000 installed) is needed. Change transfer case fluid every 30,000 miles with Mercon V.

Typical repair cost:$350 - $5,000

Research This Issue

Based on 680 owner reports

GoogleRedditYouTubeNHTSA
Community Reported
Medium Confidence680 owner reportsLast reported by owners Feb 2026Reviewed Feb 2026

On the 2000-2005 Ford Excursion, the front hub bearings wear prematurely due to the vehicle's extreme weight (7,600+ lbs GVWR). Symptoms include humming noise that changes with speed and steering wheel vibration. Common on both 4x2 and 4x4 models.

This issue also affects: Ford Explorer, Ford Five Hundred, Ford Flex

Common Symptoms

  • Humming noise at highway speed
  • Noise changes when turning
  • Steering wheel vibration
  • ABS light on

How to Fix

Replace the hub and bearing assembly. Use premium bearings rated for heavy-duty applications. Torque to spec (175 ft-lbs axle nut).

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • Wheel Bearing and Hub Assembly
    Cross-refBR930420

    Fitment confirmed against the ShowMeTheParts catalog for this vehicle's year and engine.

    eBayAmazon

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Typical repair cost:$250 - $500

Research This Issue

GoogleRedditYouTubeNHTSA
Community Reported
Medium Confidence
NHTSA Recalls11 recalls

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 DEALERS FOR CERTAIN 2004 THROUGH 2011 MODEL YEAR RANGER TRUCKS, 2002 THROUGH 2005 MODEL YEAR EXCURSION VEHICLES, AND 2002 THROUGH 2007 MODEL YEAR F-250, F-350, F-450, AND F-550 TRUCKS FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THE MULTI-FUNCTION SWITCH WAS SHIPPED WITH A SUBCOMPONENT (SLIDER) THAT MAY EXPERIENCE DEFORMATION. A MULTI-FUNCTION SWITCH WITH A DEFORMED SLIDER MAY MALFUNCTION CAUSING THE TURN SIGNAL, TAIL LIGHTS, HAZARD WARNING SIGNAL FLASHERS AND/OR BRAKE LIGHTS NOT TO ACTIVATE.

Campaign #11V35200013/07/2011

VEHICLE SPEED CONTROL

ON CERTAIN TRUCKS EQUIPPED WITH SPEED CONTROL, GASOLINE OR NATURAL GAS ENGINES, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT.

Campaign #06V28600001/08/2006

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 EXPLORER, 1997 AND 2002 MERCURY MOUNTAINEER, 1995-1997 AND 2001-2003 RANGER, AND 1994 F53 VEHICLES EQUIPPED WITH THE TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCH (SCDS). THE SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.

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Frequently Asked Questions

What are the most common Ford Excursion problems?

According to Au7o's analysis of 680+ owner reports, the 2002 Ford Excursion has 2 documented issues. The most frequently reported are: BorgWarner 4405 Electric Shift Transfer Case Failure (V10 Models), Front Wheel Hub and Bearing Assembly Failure. Of these, 1 is rated critical and should be addressed promptly.

Is the Ford Excursion reliable?

The 2002 Ford Excursion has 2 known issues documented across 680+ owner reports. 1 issue is rated critical: BorgWarner 4405 Electric Shift Transfer Case Failure (V10 Models). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Ford Excursion problems?

Repair costs for known Ford Excursion issues range from $250 to $5,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, BorgWarner 4405 Electric Shift Transfer Case Failure (V10 Models), typically costs $350-$5,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 2000-2005 Ford Excursion BorgWarner 4405 Electric Shift Transfer Case Failure (V10 Models)?

The 2000-2005 Ford Excursion equipped with the 6.8L V10 engine and BorgWarner 4405 electric-shift-on-the-fly transfer case experiences multiple failure modes including transfer case shift motor failure, false neutral conditions, and GEM (Generic Electronic Module) control issues. Repairs typically run $350-$5,000. Severity: high.

What is the 2000-2005 Ford Excursion Front Wheel Hub and Bearing Assembly Failure?

The front hub bearings wear prematurely due to the vehicle's extreme weight (7,600+ lbs GVWR). Symptoms include humming noise that changes with speed and steering wheel vibration. Common on both 4x2 and 4x4 models. Repairs typically run $250-$500. Severity: medium.

Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.

Data sourced from 680+ owner reports, NHTSA recalls, TSBs, and automotive forums.

Campaign #09V39900013/10/2009

ENGINE AND ENGINE COOLING:ENGINE:DIESEL

ON CERTAIN HEAVY DUTY TRUCKS EQUIPPED WITH 7.3L DIESEL ENGINES, THE CAMSHAFT POSITION SENSOR LOCATED ON THE ENGINE OF THE VEHICLE MAY FUNCTION INTERMITTENTLY, POSSIBLY RESULTING IN AN ENGINE STALL.

Campaign #07V55300005/12/2007

WHEELS:HUB

CERTAIN FEDERAL-MOGUL REPLACEMENT WHEEL HUB ASSEMBLIES WITH THE BRAND NAMES: NATIONAL, CARQUEST P/NOS. 515020, 515021, 515025, 515053, 515054, 515059, AND 515060, SHIPPED BETWEEN JANUARY 23, 2006, AND DECEMBER 20, 2007, SOLD FOR LIGHT DUTY AND MEDIUM DUTY TRUCKS. THE INBOARD RETENTION NUT USED TO MAINTAIN HUB BEARING ASSEMBLY CAN LOOSEN RESULTING IN AN ABS LIGHT INDICATION, NOISE, AND/OR WHEEL SEPARATION.

Campaign #07E10600017/12/2007

+ 6 more recalls. Check all on NHTSA.gov

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