I hope that this is a very short lived period of bad luck with our 2005 Excursion. We bought our excursion new and have never had any issues with it. At the end of June, I took it in for a 90,000 mile service before leaving on a camping trip up to Westport, CA. When the service tech called, he told me that the Hydro Boost was leaking and that there was an oil leak from the bed plate. The good news was that it would be warranty work, the bad news was that they might not have it ready in time for our camping trip. Not good since I just dont have an extra truck standing by to tow our travel trailer with. The ford guy came through and had it ready the day before were we scheduled to leave. I was very worried about them taking the engine completely out and getting everything back together right before leaving, but they assured me that I had nothing to worry about. Towed the trailed up to Westport had a week of greating camping and family time, then decided to take a trip a little farther up Hwy 1 to visit a little town up the coast a ways. With the wife and all three kids in the car we headed out. About fifty miles out in the middle of nowhere, the excursion just shuts down. Hwy 1 is very narrow and very windy, luckily we were able to get mostly off the road. I looked under the hood and there is oil everywhere!!!! Looked under the car and there is oil covering everything from front to back! Did I mention that there was NO cell service in the area! After hours and hours of waiting, we managed to get the excursion towed back to town and the family dropped off back at the campground thanks to a very nice CHP officer. After over $500 in towing to the nearest ford dealership, they diagnosed the problem as a major crack in the oil pressure sensor. Somehow Ford seems to believe that the major crack in the oil pressure senor was totally unrelated to the prior warranty work. That seems like a total load of crap considering it blew out exactly seven days after the bed plate repair was done!!! After my father-in-law made the eight hour drive to come and get my family of five and our trailer, I had to drive all the way back out there to get the excursion after it was repaired again.

To add a little icing to the cake, about three days after getting back, I noticed that the AC no longer worked! Back to the Ford dealership yet again. Of course this also had nothing to do with the prior repairs! Apparently our helper springs had crushed the AC lines at some point. I cant believe that after years of worry free service, our excursion could suddenly have so many issues all at once! Guess when it rains it pours!

 

I don't know if the 2 problems were related but it certainly is odd. At least its under warranty. Mine only has 34k on it and I'm towing my jeep liberty from South Florida to Hilton Head tomorrow. I have never towed with it and don't expect any problems.

The only thing I worry about is that since it has so few miles and very few on the highway, what kind of issues could arise. I'll keep my fingers crossed. :-)