I came across what seems to be a good deal on a 6.0 excursion, but while I’m considering the purchase I wanted to get some info on maintenance and fuel costs associated with these trucks. I get that it varies based on where you live and who your mechanic is, and I also want to exclude any major issues or failures from the maintenance portion (even though I’m sure they can be prevalent with the 6.0). Having never owned a diesel, I also wanted to get an idea of the kind of fuel economy you get using one for a 12 mile round trip work commute daily, but also running it longer in the highway frequently. My first step before I actually purchase the truck will be to take it in to a well regarded diesel mechanic that specializes in fords to get his opinion on if the truck is in decent shape and what he thinks it will take to maintain it, but figured I’d ask here first to get a general idea. So, what’s your take?

 

Do your homework

https://www.dieselworldmag.com/diese...-power-stroke/

Perhaps no other diesel engine in recent memory has burdened its owners more than the 6.0L Power Stroke. Thousands of roadside repairs, expensive tow bills, and repeat failures plague the ’03-’07 Super Duty.

 

Did you forget about the crap-tastic 6.4L PSD??? Yeah, the 6.0 is a turd, but you can polish that turd somewhat while keeping the short block bolted in and the cab still on the truck. To fix (or at least attempt to fix) the 6.4, the engine has to come out (because the pistons crack), which can be done cab-on, but is actually easier and less time consuming to do cab-off.

To the OP, unless you are a long-time gear head with a lot of general automotive know-how and experience, don't buy a 6.0. They were turds new and now they're 20-year-old turds. They will absolutely drain your bank account with repairs if you have to take it to a shop. And they are not tolerant at all of neglect. If you're not a gear-head and you really want an Excursion, go for a gasser one.
...

 

Half is the mechanic the other half is the owner. (Previous and current)

Who did the repairs when it needed it?

Did they do things right or cut corners?

Did they use Ford parts or aftermarket?

Did they stick to the maintenance schedule or just do things when they got around to it?

I stuck to the severe maintenance schedule and my 2005 6.0 Excursion never had a problem. When I deviated that's when problems came. I could tell the difference in the engine and I knew it wasn't happy. You have to listen to how it runs with certain oils and fuel. Make sure the programming isn't up to date because the further you go along, the lazier it gets. It always got Ford parts when it needed something and alway ran its best.

When I first got mine October 2013, I ran through the maintenance battery to both clean things up and develop a good cadence. The PO neglected the engine and it only got love when it left his wife on the side of the road. The time and money I put into mine was totally worth it.

Monitor the engine oil temp and coolant temp. If you notice a 15 degree or more delta between the tow cruising at 65 or 1900rpm, it's cooling system flush and oil cooler time.

A good mechanic should also have an IDS to more accurately diagnose these trucks too. There's a lot the IDS can tell you that a normal code reader or diagnostic tool will not.

Bottom line: you can't beat the power and towing capability of the 6.0 even stock. It has a better and more robust transmission than the 7.3 and has better towing technology. If we'll cared for, it will serve anyone well. If abused or neglected, expect repair bills.

 

I have a 2005 with 305,000 miles. Blew heads at 150,000, new heads, studded and deleted. The egr goes out and she got hot. All deleted now, put another set of head gaskets in about 275,000 but heads were still good. We have one of the best diesel shops here so i am confident in keeping it going. Probably put $14,000 in it in since 2011.

 

No amount of modding a 6.0 will add the missing head bolt/studs. 4 per hole is obviously not enough...

 

I have an 05 2WD 6.0 with 258k that I bought 3 years ago from a guy who was the 3rd owner. This guy had all the receipts from all of the repairs done to the truck over the last 10 years. Deleted and studded, turbo, Sensors, 2 injectors, 4 glow plugs, FICM, Alternator and batteries, Diff seals, Front pads, rotors, calipers, hoses, Fuel pump, 2nd fuel pump when he put on a Airdog pump. I get the truck and in 3 years I am on my 3rd Airdog pump (they have changed harness design), Added a fuel pressure gauge, 4 glow plugs, rear pads, rotors, calipers, hoses, shocks all around, 3 door latch repairs, Crank sensor and harness repair, Oil cap cracked going down the road (that was fun cleaning 9+ qts of oil off the engine and back of truck), U-Joints, Tires, and I am now having a code for the Electric fan clutch,
I say all of this because if you dont know diesels or have a buddy that works on them I would stay away from the 6.0L. Repairs are almost always over $500 and will go well into the $1000s. Oil changes are $130 if you do it yourself. Filters once a year. Diesel fuel is running $4.00 plus. The only advantages I would say is the torque, and fuel mileage as I avg 19-20 mpg driving mostly interstate. 15-16mpg city. Long road trip I got 22mpg with some mountains in NC/TN. If money is no object to you and you pull campers or trailers I would say diesel. If not then I would go with a gasser. V10 not the 5.4L.

 

Ill be the guy to disagree with the majority here! I LOVE my 2003 6.0. Can they have problems, sure, but what cant? Seems like most problems are from guys putting on a 100HP+ tune and expect it to last!

I got a 2003 Excursion 6.0 diesel... just turned 306,000 miles. Its NOT studded, still has factory EGR and factory oil cooler. I frequently pull a 9500 pound camper without issues. I have a Atlas 40 FICM and a 50HP tow tune from 5 star. But, I also maintain mine. My deltas are no higher than 13 degrees even when pulling. I change my oil every 5000 miles and only run Mobile 1 Delvac 5W40, and Motorcraft filters. Change fuel filters once a year/15000 miles. Installed a coolant filter system and change that filter every 6 months. Am I lucky? Sure... But. I believe that the ones that dont last and haven't lasted are beaten! Id buy another 6.0 in a heartbeat, but would have to invest some $$ to get it right, and would not stud it if it didnt need it!

 

I was in your position in December (minus the foresight to ask questions, or get it looked at, or really do any homework at all) and bought a 2004 Eddie Bauer edition w/ the 6.0 psd. It's my first diesel, first Ford, first HD platform, but not my first big SUV I've owned several suburbans and currently have an Avalanche (based on the suburban chassis). It's been a learning curve I'll say that. I found a good shop locally to get it reliable (for the most part) and did my usual used vehicle routine (replaced all the fluids, had them fix the critical items, including the egr, and they added a coolant filter) I was also introduced to diesel prices, and has some sticker shock (did I mention I didn't do any homework before buying). But even with the benefit of hindsight, I'm VERY happy with it. I've been having a great time learning all about diesels, and just how capable an EX can be.

To directly answer your questions:

• I also wanted to get an idea of the kind of fuel economy you get using one for a 12 mile round trip work commute daily, but also running it longer in the highway frequently.
  • My commute is 17 miles on the highway and 4 miles city and get just under 15mpg. When road-tripping (not towing) I can push it to 16.5 if I keep it around 60.
• Info on maintenance/fuel costs.
  • These are old vehicles, if you pay a mechanic to do everything it will add up quickly (very quickly), and I'm sure you've learned even poking around here, the 6.0's have issues, and those issues are magnified by poor maintenance. The oil is asked to do a lot, so staying on top of that is the most important thing you can do, you literally can't change it too often. Most recommend (including Ford) every 4,000 miles, but the rig certainly won't complain if you change it early. Unfortunately, it takes a LOT of oil compared to a gas engine, 15 quarts per change, and adding some Archoil Friction Modifier with each oil change isn't a bad idea. And that's just for the oil, there's a ton of other maintenance these need (all well documented on this site). Ultimately, the cheapest part of owning an Ex is the purchase price.

I can't find the post but I remember reading a great line on here, I don't remember word for word but: "Think of the Ex as a 60's or 70's muscle car, you'll never be able to justify the purchase or the time or money, but once you fall in love with them, you don't need any justification". Of course, that logic only refers to you the owner, not to your spouse, or friends or anyone else, because keeping a 20 year old land barge alive is a big, never ending, job.