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Why can't Ford put the DOHC 5.4L V-8, that has gotten rave reviews in the Navigator, into the Excursion? Seems like a great idea, and it would surely put those gm 5.3s in their rightful place: the dust of a Ford!
The Navigator version of the 5.4 has different heads...4 valves per cylinder, 32 total. Higher rpm potential but lacks the low end grunt of the V10. The V10 is the option of choice for those wanting more power in the SD's & Exc.
I don't know how many times I have asked the same question about engine options like why don't they put a SOHC 5.4L in the Mustang and give the customer the low end torque they want but the answer is never what it seems. I personally know this is possible to do, but.
Most of the Big Three are determined to develop their Brands and trying to keep them different from the other vehicle lines is tough. So, to keep the Navigator in a class all it's own they will not share vehicle components with other vehicle lines like Excursion. Also, they may not have the capacity to build 1000+ more DOHC 5.4L for other vehicle lines. Complexity in the assembly plants always drives up cost and it's passed on to the buyer so minimizing the number of engines and associated power trains helps reduce this complexity cost.