I have an 03 expy and overall I have been happy with my purchase. I got the tsb taken care of for the vibration problem in 2 hi so after that everything has been great. The only 2 things that bother me at all are the engine and space behind the rear seat.
The 5.4 had been around for a while at that hp and torque rating and I was hoping for a more powerful engine. 260hp and 350 torque are ok but not great. I am the type of person who doesn't care so much about gas mileage but wants the thing to move when I step on it. Maybe I am too used to the speed of motorcycles.
The 2nd issue with behind the rear seat space I didn't notice until after I bought it. They should have given it another foot in length and then it would be great. What is the logic of having only 7ft behind the front seats anyway. So many things are 8' in length and it would have been nice to be able to fit them inside. Also, if you have stuff to carry you can't take more than 4 or 5 people with you because there is virtually no space behind the rear seat. You can't even fit a big cooler back there. You might say buy and excursion but that is a tank and in my opinion is not as good as a suburban. Besides I like the independent rear suspension, fold down seats, etc in the redesigned expy. The excursion is a little behind there.
Anyway, my questions are on what they are planning on changing in the coming years? Since the expy just underwent major changes after 5 yrs of being the same truck is Ford going to invest more $$$ in more changes and what will they be? I noticed a 5.4L 3V is getting put in the 04 F150s and was wondering if this is going into the expedition as well?

 

There are rumors of an Expedition XL being introduced as a supplement to the Expedition line once the Excursion ceases production. Supposedly, the back is stretched to Suburban standards.

No 5.4 3v in the Ex fpr 2004 according to Ford. Wouldn't want a lighter XLT out-accelerating the Navigator would we?

 

Ahh yes the good old politics holding the engineers back from creating a better vehicle. Not that my complaining about that would make any difference.
So when is the excursion going out of comission? When is the expy XL rumored to be offered? I assume the normal size expy would still be offered as well, right? Then I assume a diesel would be offered in the new expy XL and that they would use the new 6.0. How much weight do you think these rumors hold? We all know that some have substance but some are just someones dream.

 

Rumors come and go. Your guess is as good as mine if any of this comes about. I don't think the Excursion is going to see the 2006 model year unless Ford changes it's mind.