2003 Ford Excursion Towing Problems
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2nd Gear
Joined: Nov 2025
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2003 Ford Excursion Towing Problems
Hello, I have a 2003 Ford Excursion 6.0 Powerstroke with an 8-inch lift and 37-inch tires, 4.56 gears, and kill devil diesel heads. Bulletproof EGR, bulletproof oil cooler, Odawg Intake S2R, a fast pump 140, S&B air intake, Banks intercooler, KC Turbo Stage 1, SCT Programmer by GearHead (had it under 'Unlimited Towing'), Blessed Performance, Fuel Pressure Regulator with Fuel Bowl Delete, Adrenaline HPOP, 4-inch exhaust straight pipe, and ARB studs.
The transmission is still stock, and I was running a GearHead tow tune while keeping the RPMs in the 2,200–2,600 range on climbs. Fuel pressure holds steady at 64 psi, and boost peaks between 18 and 20 psi under load. We don’t have an exact trailer weight yet —just an estimate of around 14,000 lbs —so that could also be a factor in how the truck feels on grades.
I have a 26 ft tow hauler (weekend warrior) with an estimated weight of 13,000-14,000 lbs. It has pedal clearance to the floor, and I can only get up to 45 mph on Route 8 going to Glamis. The truck handled the load fine but lacked the pulling power, and was passed by a Toyota Tundra with the same toy hauler. My EGT is at 1,200 ECT, the highest 210 EOT at 190.
What do you think I can improve? Any suggestions? I want a better towing capacity when going up a hill.
The transmission is still stock, and I was running a GearHead tow tune while keeping the RPMs in the 2,200–2,600 range on climbs. Fuel pressure holds steady at 64 psi, and boost peaks between 18 and 20 psi under load. We don’t have an exact trailer weight yet —just an estimate of around 14,000 lbs —so that could also be a factor in how the truck feels on grades.
I have a 26 ft tow hauler (weekend warrior) with an estimated weight of 13,000-14,000 lbs. It has pedal clearance to the floor, and I can only get up to 45 mph on Route 8 going to Glamis. The truck handled the load fine but lacked the pulling power, and was passed by a Toyota Tundra with the same toy hauler. My EGT is at 1,200 ECT, the highest 210 EOT at 190.
What do you think I can improve? Any suggestions? I want a better towing capacity when going up a hill.
Lead Driver
Joined: Aug 2022
Posts: 5,079
Likes: 1,417
From: Oologah, OK
first thing is to leave the OD off...
and let the engine RPMs climb up higher,
I don't know zilch about your truck model or add ons.
my 7.3 slowed down to about 25 mph going over Loveland Pass in Colorado, OD off, stock engine... 4R100 auto tranny.
I just let the RPMs go up as much as they could, which was not enough.... it has a boost leak
and let the engine RPMs climb up higher,
I don't know zilch about your truck model or add ons.
my 7.3 slowed down to about 25 mph going over Loveland Pass in Colorado, OD off, stock engine... 4R100 auto tranny.
I just let the RPMs go up as much as they could, which was not enough.... it has a boost leak
Last edited by John in OkieLand; Nov 3, 2025 at 11:55 PM.
Logistics Pro
Joined: Mar 2010
Posts: 3,533
Likes: 497
From: NC
I have a stock 6.0L and have pulled the Appalachians, Rockies and Sierra Nevada's. Excursions are capable but are not rocket ships on long pulls, let the RPM's rev and let the truck tell you what it likes and it will tell you. Keep an eye on temps, back out of it as needed.
Fleet Mechanic
Joined: Mar 2023
Posts: 1,587
Likes: 930
Your boost ( which you state "boost peaks between 18 and 20 psi under load"), seems pretty low to me. When I was still running a 6.0 I'd hit 25 psi, maybe touch 28 psi sometimes if I held it, on flat Texas roads with just a canned SCT (no EGR) tow tune and stock turbo.
Don't know much about the KC stage 1, but I would assume its at least as capable as my old 2005 stock turbo was. Perhaps the tow tune your were using is just VERY conservative, so much so that it cuts the power drastically. Since obviously you have gauges (otherwise you wouldn't be able to tell us all the parameters you did), switch to a higher tune, keep an eye on the gauges and try again.
The stock intercooler's plastic end tanks would blow out at around 30 psi or so, but you have a Banks unit, which I assume will hold more pressure (my Mishi intercooler takes 50 psi all day long, I'd imagine the Banks one would too).
...
Don't know much about the KC stage 1, but I would assume its at least as capable as my old 2005 stock turbo was. Perhaps the tow tune your were using is just VERY conservative, so much so that it cuts the power drastically. Since obviously you have gauges (otherwise you wouldn't be able to tell us all the parameters you did), switch to a higher tune, keep an eye on the gauges and try again.
The stock intercooler's plastic end tanks would blow out at around 30 psi or so, but you have a Banks unit, which I assume will hold more pressure (my Mishi intercooler takes 50 psi all day long, I'd imagine the Banks one would too).
...
Last edited by Antonm23; Nov 4, 2025 at 09:45 AM.
Frmr Ford Trans Engr
Joined: Aug 1999
Posts: 24,730
Likes: 2,658
From: SE Florida
How does one leave the OD off? This is a 6.0L truck with the 5R110W TorqShift transmission. It doesn't have an OD OFF button. It has a tow/haul button, which does NOT turn off the overdrive.
Lead Driver
Joined: Aug 2022
Posts: 5,079
Likes: 1,417
From: Oologah, OK
I know Zilch about the 6.0 truck models, period.
Fleet Mechanic
Joined: Mar 2023
Posts: 1,587
Likes: 930
Some say it boosts transmission line pressure, some say it just changes shift points, some way it changes when the TC will lock, some way it doesn't really do anything in the transmission at all and that it changes engine tuning ( pulls injection timing and pulls fuel just prior to every shift) and of course some say that everything mentioned earlier is wrong. IDK what to think or who to believe
Can you please tell us what the tow/haul button actually does?
...
Last edited by Antonm23; Nov 4, 2025 at 12:41 PM.
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Lead Driver
Joined: Jun 2006
Posts: 5,675
Likes: 996
From: Near Yosemite CA
Couple of things... unless things have really changed, OR you managed to cram a lot of shtuff in your WW, a 26' TH rolling at 13k #'s seems a bit high.. my 27' Rage'n with 100 gal water, 100 gal fuel, 2 quads, 1 Ktm 520 and all the coolers, food for a week+ I was touching 10,5-11k #'s and that was stuffed with riding gear, helmets, tools and more, was the Tundra's TH loaded the same as yours, probably not...
Also, as said, your boost seems a bit low, on my Ex/4x/7.3/3.73's and 35's, only mods were 4" straight pipe turbo down/out, Air filter and Hypertech Heavy tow tune, I would be in the upper 20's+ pulling the Grapevine and depending on traffic I'd be 26-3000rpms. Now when I had to let off due to a semi or some nimrod cutting in front of me and I lost my momentum, it'd take me a bit to get back up to speed...
Are you blowing black smoke at all up the grade? Is your TC locked up...
Heaviest I've towed with my 02 F350/7.3/4x/4.10's and 33's was a huge effing 5'ver we bought for the kiddos to live in a few yrs ago, 39 foot beast w/5 slides, dry weight was ~13k #'s and going up Cuesta grade out of SLO I was in 2nd at about 45mph, I wasn't going to push the old girl, but she was working hard...
Also, as said, your boost seems a bit low, on my Ex/4x/7.3/3.73's and 35's, only mods were 4" straight pipe turbo down/out, Air filter and Hypertech Heavy tow tune, I would be in the upper 20's+ pulling the Grapevine and depending on traffic I'd be 26-3000rpms. Now when I had to let off due to a semi or some nimrod cutting in front of me and I lost my momentum, it'd take me a bit to get back up to speed...
Are you blowing black smoke at all up the grade? Is your TC locked up...
Heaviest I've towed with my 02 F350/7.3/4x/4.10's and 33's was a huge effing 5'ver we bought for the kiddos to live in a few yrs ago, 39 foot beast w/5 slides, dry weight was ~13k #'s and going up Cuesta grade out of SLO I was in 2nd at about 45mph, I wasn't going to push the old girl, but she was working hard...
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Frmr Ford Trans Engr
Joined: Aug 1999
Posts: 24,730
Likes: 2,658
From: SE Florida
Here's my perspective on what the tow/haul does. And I'm writing from the perspective of the guy who programmed it (along with a coworker) for the 2005-2007 6.0L trucks.
The main function is to change the shift schedule for towing and hauling. It makes the upshifts at higher RPMs, and makes the downshifts a bit earlier. It also provides engine braking and forced downshifts by using the brake pedal. That is it.
It doesn't add pulling fuel during a shift. That happens with or without tow/haul engaged.
Logistics Pro
Joined: Mar 2010
Posts: 3,533
Likes: 497
From: NC
If you don't know anything, why do you offer advice? If you don't know anything about a subject, there is no reason to reply to that post.
Here's my perspective on what the tow/haul does. And I'm writing from the perspective of the guy who programmed it (along with a coworker) for the 2005-2007 6.0L trucks.
The main function is to change the shift schedule for towing and hauling. It makes the upshifts at higher RPMs, and makes the downshifts a bit earlier. It also provides engine braking and forced downshifts by using the brake pedal. That is it.
It doesn't add pulling fuel during a shift. That happens with or without tow/haul engaged.
Here's my perspective on what the tow/haul does. And I'm writing from the perspective of the guy who programmed it (along with a coworker) for the 2005-2007 6.0L trucks.
The main function is to change the shift schedule for towing and hauling. It makes the upshifts at higher RPMs, and makes the downshifts a bit earlier. It also provides engine braking and forced downshifts by using the brake pedal. That is it.
It doesn't add pulling fuel during a shift. That happens with or without tow/haul engaged.
Cross-Country
Joined: Aug 2025
Posts: 70
Likes: 18
Hello, I have a 2003 Ford Excursion 6.0 Powerstroke with an 8-inch lift and 37-inch tires, 4.56 gears, and kill devil diesel heads. Bulletproof EGR, bulletproof oil cooler, Odawg Intake S2R, a fast pump 140, S&B air intake, Banks intercooler, KC Turbo Stage 1, SCT Programmer by GearHead (had it under 'Unlimited Towing'), Blessed Performance, Fuel Pressure Regulator with Fuel Bowl Delete, Adrenaline HPOP, 4-inch exhaust straight pipe, and ARB studs.
The transmission is still stock, and I was running a GearHead tow tune while keeping the RPMs in the 2,200–2,600 range on climbs. Fuel pressure holds steady at 64 psi, and boost peaks between 18 and 20 psi under load. We don’t have an exact trailer weight yet —just an estimate of around 14,000 lbs —so that could also be a factor in how the truck feels on grades.
I have a 26 ft tow hauler (weekend warrior) with an estimated weight of 13,000-14,000 lbs. It has pedal clearance to the floor, and I can only get up to 45 mph on Route 8 going to Glamis. The truck handled the load fine but lacked the pulling power, and was passed by a Toyota Tundra with the same toy hauler. My EGT is at 1,200 ECT, the highest 210 EOT at 190.
What do you think I can improve? Any suggestions? I want a better towing capacity when going up a hill.
The transmission is still stock, and I was running a GearHead tow tune while keeping the RPMs in the 2,200–2,600 range on climbs. Fuel pressure holds steady at 64 psi, and boost peaks between 18 and 20 psi under load. We don’t have an exact trailer weight yet —just an estimate of around 14,000 lbs —so that could also be a factor in how the truck feels on grades.
I have a 26 ft tow hauler (weekend warrior) with an estimated weight of 13,000-14,000 lbs. It has pedal clearance to the floor, and I can only get up to 45 mph on Route 8 going to Glamis. The truck handled the load fine but lacked the pulling power, and was passed by a Toyota Tundra with the same toy hauler. My EGT is at 1,200 ECT, the highest 210 EOT at 190.
What do you think I can improve? Any suggestions? I want a better towing capacity when going up a hill.
01 E 4wd limited, Hydra, pusher intake, Mishimoto intercooler, Kc stg1, Bostek Hpop, Swamps 175/146 injectors, 4" diamond eye, tru cool trans cooler, spal electric fans, mechman 320, built transmission, ranch hand/bodyguard bumpers, ebpv delete, ... S&B,, 18x9 wheels, 35x12.5 bfg bug sqaushers.
Last edited by Texmax; Nov 4, 2025 at 05:29 PM.
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