ford 5.4 excursion engine

What Years of Ford 5.4L Engine to Avoid and Why? (Reasons)

Ford offers a vast collection of Engine options, and 5.4 is one of them too. The Ford 5.4 is also popularly known as the 5.4L Triton V8 engine, and it is one of the most common engines used for the Ford full-size SUV and truck lineups.

However, the 5.4 engine is also infamous for having several major to minor troubleshooting issues, and some problems such as spark plugs, ignition coils, and the time chain failure are undeniably visible in some particular year’s Ford vehicles.

The following article will explain exactly why you should not consider the Ford 5.4 and if you must, then which year’s models you should avoid.

About Ford 5.4L Engine

The Ford 5.4 or 5.4L is a naturally aspirated V8 engine, which has been in the industry to power many vehicle models of Ford as well as other brands for a long time.

Originally Ford designed and developed the 5.4 engine to handle larger trucks or big SUVs , and it has been a member of the Ford Modular family .

Also, Ford first introduced the 5.4 engine in 1997 with their F series.

Later on, several other companies used the revised version of the 5.4 engine in their sports vehicle lineups too.

Many experts claim that the 5.4 engine is mainly a stroked version of Ford’s 4.6L engine since 4.6L and 5.4 both engines are developed by the same manufacturer and have similar architectures.

Ford 5.4 offered 235 up to 550 horsepower and 330 up to 510 torque. However, the output effectively varies depending on the year and model of the engine.

Which Ford Vehicle Series Particularly Feature Ford 5.4L Engine?

Mostly Ford used 5.4 engines in its old vehicle lineups, and you can still find them in some of the available old Ford vehicle models, mainly sold as Used vehicles. 

The following vehicle models are equipped with the 5.4 engine:

• Ford Expedition Models
• Ford E-Series Models
• Ford F-150 Models
• Ford Falcon Models
• Ford GT Models
• Ford Mustang SVT Cobra R Models
• Ford SVT Lightning Models
• Ford Shelby GT500/GT500KR Models
• Lincoln Blackwood Models
• Lincoln Navigator Models
• Lincoln Mark LT Models

Read Also: Which Grand Marquis Years You Should Avoid and Why?

Worst Years of Ford 5.4L Engine (List of Years)

Initially, the 5.4 engine was not built with lots of mechanical and electrical flaws since it is one of the longest-running engines of the Ford brand.

Reports claim that the initial era of the 5.4 was the best, but troubleshooting issues like spark plug failure were there in the 5.4 3-valve engines from the initial days.

However, other troubles kept adding up as the time passed, and problems got severely noticeable as well as disturbing due to their expensive repair servicing between 2004 and 2013.

If you are interested in Used Ford vehicle models, try avoiding the following years’ models:

• Ford Expedition Models From 2004-2014
• Ford F-150 Models From 2003-2007
• Ford Falcon Models From 2004-2007
• Ford GT Models From 2004-2006
• Ford Mustang SVT Cobra R 2000 Models
• Ford SVT Lightning 2004 Models
• Ford Shelby GT500/GT500KR Models From 2007-2012
• Lincoln Blackwood Models From 2004-2014
• Lincoln Navigator Models From 2004-2014
• Lincoln Mark LT Models From 2006-2008

Read Also: Which Ford Taurus Years to Avoid and Why? (Explained)

4 Major Problems of Ford 5.4L Engines:

In this section, I will address and elaborately discuss the four most common problems of the Ford 5.4, which made this engine infamous and kind of unreliable.

But before moving towards the main discussion, glance at the most common issues and approx. cost estimation of solving them-

1. Spark Plugs & Ignition Coils Failure

Spark plug and Ignition coil failure are the most common 5.4 engine problems that were highlighted in most consumer forums and expert reviews.

Mainly these two troubles are commonly visible in the 2-valve, 3-valve, and 4-valve 5.4 engines.

In general, spark plugs and ignition coils both have a standard timeframe after which they eventually start to wear and tear. So, making such failures such a huge matter is kind of unfair.

According to consumer complaint reports, sometimes they have noticed spark plugs blow out of the head in the 2-valve 5.4 engine-contained vehicles .

However, 3-valve and 4-valve 5.4 engine-powered vehicle owners have not mentioned such issues yet.

Users even mentioned encountering common symptoms such as engine stuttering, internal misfiring, rough idling, and significant power loss .

By the way, one can easily avoid experiencing such extra troubles by following the 5.4 engine standard maintenance like changing the spark plugs after each 80,000 to 100,000 miles and replacing the ignition coil after every 120,000 miles of operation.

Is This Problem Expensive To Fix?

According to RepairPal’s report, if you are repairing from any professional servicing center, the spark plugs replacement will cost between  $233 and $276 and the labor expense will be between $223 and $281 . The ignition coils replacement will cost between $200 and $276 and labor expenses might stay between $38-$48 .

Remember, 5.4 ignition coils are available at approx. $100-$200 and a new set of 5.4 spark plugs mostly costs between $50 and $100 . So, if you are fixing them by yourself, it will be pretty cheap.

Read Also: What Years Are Ford Diesel Engines to Avoid and Why?

2. Failed Driver Module Of Fuel Pump

Fuel pump driver modules or FDM failure is another most highlighted trouble of the Ford 5.4 engine. Originally it was a factory design error that the manufacturer neglected.

The engine fuel pump’s driver module was placed towards the rear side of the steel frame. This placement made the aluminum module to be exposed to all the external elements like water, salt, dirt, and others .

As a result, buildup debris or other similar materials directly enters the driver module, and eventually, the module fails. This failure forces the fuel system to cut off and the engine to shut down.

Users even reported common symptoms, such as engine sputtering or misfiring, no start, stalling, and DTC P1233 (fault code).

Fortunately, Ford was quick to realize the manufacturing defect, redesigned the parts, and mounted the module in the same previous location, but kept a safe distance so that it would not get direct contact with the engine’s steel frame .

Reportedly, you can fix the FDM issue at $772 up to $967 from any professional servicing workshop and the labor expense will stay between  $133 and $206 .

However, the fuel pump driver module replacement parts are available at $60-$100 . So, if you are fixing them by yourself, it will be pretty cheap.

3. The Timing Chain Tensioner Failure

The timing chain tensioners and variable valve timing or VVT are known trouble areas for the Ford 5.4 engines.

Since the timing chain is one of the crucial components that help the proper engine operation, if the problem is not fixed on time, it can lead to further severe engine damage, and you might end up replacing the engine.

Mostly the 5.4 timing issue occurs due to a loose or broken timing chain, and the VVT issue primarily arises due to cam phaser breaking.

Users claimed to notice common symptoms such as Rattling or knocking sounds coming from the engine and rough running or idling .

It is one of the most expensive repair servicing of 5.4 engines. Reportedly, you can fix the problem from any professional servicing center at $1,374 up to $1,643 , and the labor expense will stay between $1,027 and $1,295 .

Read Also: Which Ford Raptor Years to Avoid and Why? (Explained)

4. Engine Oil Pan Gasket Leakage

Oil pan gaskets are designed to take abuse, and as time passes, the gasket eventually starts to fail due to consuming unlimited abuse and heat cycle .

Ford 5.4 engine oil pan gasket has been reported as prone to fail and leak oil, even leading to potential engine failure . Reports claim that as soon as the 5.4 oil pan gasket fails, it starts leaking oil under the vehicle.

As the engine gets older several parts like rubber hoses, gaskets, plastics, and others must be wearing out.

Users have reported common symptoms like visible oil leaks under the engine and burning oil smells coming.

If you are taking your vehicle to any professional workshop for the servicing, it will cost you between $438 and $684 , and the labor expense will stay between $323-$437 .

How Long Will A Ford 5.4L Last?

According to the Vehq.com report, The Ford 5.4 V8 Triton engine can easily last between 150,000 and 300,000 miles if properly maintained. Remember, regularly scheduled maintenance is the key to keeping the vehicle engine active and energetic.

Which Are The Best Ford Engines To Consider?

According to the Fourwheeltrends.com report, the following Ford engines are the safest to consider:

• Ford Coyote 5.0L V8 Engine
• Ford Godzilla 7.3L V8 Engine
• Ford 5.0L H.O. Engine

Ford is one of those brands that most vehicle owners or enthusiasts desire and prefer. But not all Ford vehicle models are worth owning, and some models feature unreliable engines like the 5.4L.

Therefore, if you are planning to purchase a Ford vehicle and pondering which engine would be better, wait a moment to think wisely.

Read Also: Which Ford Flex Years to Avoid and Why? (Explained)

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• 1999-2007 Ford Super Duties
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5.4L in an Excursion?

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The wife wants more seats than her Supercrew offers. I am considering a 5.4 liter (I am fond of the one we have in the Supercrew) in an Excursion. Am I all wet by thinking this is adequate power for an Excursion? She will not be towing. The V-10 is only $500.00 more. This is a kid hauler, and any help with mileage would be a bonus, but I do not want her underpowered on the expressways. John PS. She will not go for the Diesel  

The 5.4 gets about the same if not worse than the V-10 in the excursion.  

I test drove an Excursion w/ the 5.4 and 3.73 axle last year -- it was, shall we say, sluggish? The $500 for the V10 buys more than the larger motor. It also includes a higher capacity radiator (2 cooling rows instead of 1), a stronger rear diff (3 pinion gears instead of 2), and a tighter TC (1.90 vs 2.10 in the Ex). I also think the TCC is stronger, but I can't find the specs... HTH, crewzer  

Crewzer, I need help with the abbreviations. I drove the 5.4L with the 3.73, and agree it's no rocket. The V-10 felt "heavier", yet stronger, but not a bunch more pep. I understand it will drink 2 mpgs more than the 5.4L. I am curious about the 4.10 gear 5.4L match. My past present success with the 5.4L makes me want it to be the better choice. I have no ownership experience with the V-10, and am cautious about the reliability. John  

Crewzer, Good stuff. Unloaded, can you hang with your brother's truck? Again, I have been very pleased with the 5.4, and she won't be towing. John No Mo, I have considered the Expedition, but with the $3,000.00 rebate for the Excursion vs the $1,500.00 for the Expedition, I see more value for the Excusion for essentially the same price.  

johnlyon where did you get your 2 mpg better info for the 5.4L? Everyone I have talked with get worse MPG than I do with the 3:73 rear end. I am getting 12.2 consistantly in the Dallas area around town and between 14 and 16 on the Highway depending on the speed limit.  

No problem. Stronger rear differential Tighter torque converter (1.90:1 nominal stall ratio vs. 2.10:1) TCC = torque converter clutch I'm happy enough with the 5.4V8 and 4.10 combo in my 4X2 crew cab Super Duty. I wanted to get the V10 + 3.73 when I bought my truck in March 2000, but too many dealers told me about long waits for factory orders, so I bought mine off the lot. One of my brothers ordered his truck with V10 a few months later; he's very happy with the performance, and has had *no* problems of any kind. We both tow 3,250 lbs trailers. His winter mileage around suburbia was ~9, and he's seen 15 mpg's on the highway. My 5.4's winter suburban mileage was ~10, and I've seen 16 on the highway. One adjustment I've w/ the 5.4 made is to use mid-grade (89 octane) when towing at low altitudes (<2,500 ft), and 87 when towing above 2,500 ft. The engine is much more responsive, and it'll stay in overdrive longer before downshifting while climbing a hill. crewzer  

I am biased too, and hate the V-10. Those who've been here a while know why! I am very impressed so far with the powerband on my new 5.4/3.73 and mileage is better for short/in town trips. Highway mileage is about the same as the V-10 was. Here's the kicker, though: Banks now makes a powerpack for the 5.4 that will put you up to about 10 more rear wheel horsies than a stock V-10. Plus, you should get some mileage improvement and it will sound sweet! I would definatley go with the 5.4 and 3.73. Break it in a while, then put a powerpack on it if you need more. I was quoted about $1200 for the Banks kit from Fuel Injection in Allen, PA. I want to get a couple thousand miles on first and then I'm going for it. Good Luck  

summitx: Although I like the 5.4L in my superduty and think it's a fine engine choice, I've not hear that many negatives of the V10. Did you experience a problem with it? or was its performance not what you were expecting?  

KXH, My V-10 had a severe flutter problem. Go to http://www.idrive.com/summitx and download the mp3 sound files to hear it. It took a year of heavy battle with FMC to get any help. Finally, they put me in touch with a young guy who is the area rep for the Northwest (James Edwards) and he took care of me. Basically, he gave me a more than fair buy back on my old one and a $2000 voucher for a new one. I went with a 5.4 supercab and, although I really miss the Crew-Cab, I'm happy with it. The powerband is smooth and it seems to have the power where I need it most ~ 3-4000 RPM is just as tourqey as the V-10 was. Granted, the SC is a little lighter than a CC but.... I never towed anything significant with the V-10 but I do pull a 2 place snowmobile trailer that is probably 2500# loaded. The V-10 would pull OK but would have to downshift on even the slightest little hill. I've driven the new Chevy 8.1 vortec and I don't think the V-10 comes close to it for low-end torque. As far as mileage, the V-8 does way better on in town driving but about the same on the highway at 75+.  

The little woman is starting to like the psd. She's even refering to it as her car now!!!!!!!!!!!!  

I have a 2001 excursion limited, V-10, 3.73 limided slip. I tow a 7500 pound boat on weekends in the hills of new england. The engine/axle combo does a great job. It is in no way over or under powered. When unloaded I consistantly get 14 mpg in town and as high as 17 on the highway, towing I get around 12 mpg. I feel that even with just the seats full, the 5.4 would be under powered and fuel economy would suffer. This is a heavy truck that's capable of doing a lot of work for you, why would you want to do it the injustice of under powering it. Resale would also suffer because most that are interested in the excursion have a job for it to do. Go for the V-10, you'll be happier later on.  

I demoed an Ex with a V10 in Y2k and even that was underpowered. Dealers here won't even order one with a 5.4L. If memory serves (as of 2001 models), only the 2WD version is available with the V8. With the Ex weighing in at almost 4 tons, that small block is going to be working way too hard just to move the vehicle, much less any cargo/passengers. Since my 2 day test of that Ex I have always stated that of the current crop of motors, the PSD is the only logical choice for the Ex. Finally, with a 2WD Excursion, the resale/trade-in will be a shocker. If you like that V8 in a SUV, an Expedition is better matched to that powerplant. My .03  

Don't se how you could hate the V10 and like the 5.4 it is a 5.4 with 2 more cylinders same bore and same stroke!!and in that big heavy excursion i bet under most conditions mileage is same fill that thing with a half dozen kids and gear i bet it is a slug with the 5.4 besides resale will be better because most people buy a truck like that with towing in mind!!  

Johnlyon Just a thought for you based on your Bio and location. The fuel savings are not great enought to warrent the penalty you will pay come trade in or resale time here in Texas. My V10 is only 3 months old and has moved from 12.5 to and from work to 13.7 mpg. Most of the dealers here in Fort Hood area won't even order v8. One dealer in Lampasas only orders PSD and they jump off the lot.  

I know many V-10 owners are happy with it - My MAIN point was that I am quite impressed with the 5.4 - More so than I thought I would be - And, I am one of a probable few who have actually owned a V-10 and switched to the 5.4 so I should know. I just think that the 5.4 is a little bit under-rated and the 6.8 is a little over-rated. If you need more towing power than the 5.4 has, go with a diesel, or get the 8.1 Chevy.  

As Dear old Dad said, "Give her everything she wants and just a bit more. It's going to end up that way anyway, so you may as well get credit for being a good guy". She got the PSD. Thanks guys, John  

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2002 Ford Excursion Engine

Options: 5.4l (vin l, 8th digit, sohc), egr valve.

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e-r-n_187-2

e-r-n_187-3

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* This item has multiple variations. Please Call for Proper Fitment

Remanufactured engines consist of the re-machined long block, and they include block casting. With any purchase, you can expect the following to come with the remanufactured engine:

• Connecting rods
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• New rocker arms, pushrods, and lifters
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• New oil pump

Our remanufacturing process entails that every part has been re-machined or replaced to meet or exceed OEM standards. Our remanufactured engines are among the highest quality in the industry today.

Our core return policy helps us manage the cost and supply to continue our remanufacturing process. The core is your old engine that is being replaced which needs to be sent to us. For core returns, we cover all shipping costs.

Please keep in mind that our FREE core return shipping is ultimately the customer’s responsibility. While we handle the cost, it is up to you to initiate the process and arrange for the core pickup. When your new part installation is finished, you can reach us by phone at (877) 343-7352 . You can also visit our core return page to arrange the core return.

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All 2002 Ford Excursion Engine Options

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2005 Ford Excursion Engine

Options: 5.4l (vin l, 8th digit, sohc), w/o egr valve.

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e-r-n_217-2

e-r-n_217-3

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* This item has multiple variations. Please Call for Proper Fitment

Our rebuilt engine includes engine elements such as the long block, the block casting with each necessary component including machining, crankshaft, connecting rods, new bearings (rod and main), pistons, rings, camshafts, and timing chain. The engine also includes new cylinder heads, which themselves include head casting with all the required machining, brand new valves, keepers, springs, and seals. Our remanufactured engines feature updated rocker arms, pushrods, and lifters to complete the engine build. The long block also arrives with a complete set of seals and gaskets as well as an updated oil pump.

In order to keep our prices low, we require your old part (core) to be sent back to us. For your convenience, we cover all shipping costs associated with returning your core. It’s important to note that the core return is something the customer is responsible for and needs to be initiated by the customer. Once your new part is installed, please contact us at (888) 412-2772 to set up your core pickup.

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All 2005 Ford Excursion Engine Options

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Ford 5.4L V8 Triton Engine Specs, Problems & Reliability

The Ford 5.4 Triton V8 is a part of Ford's Modular V8 engine family, a 5.4-liter naturally aspirated eight-cylinder gasoline engine, which was first introduced in the 1997 Ford F150. The 5.4 engine basically is a stroked version of the 4.6-liter version since the architecture of both engines is very similar. During the production history, there were three versions of 5.4L engine: 5.4 SOHC V8 with 2-valve heads or 3-valve heads, and more powerful, 5.4L DOHC 4-valve V8. 2- and 3-valve engines were used primarily in Ford F-Series pickups, while most famous Ford's sports cars (Ford GT supercar, Ford Shelby GT500, Ford Mustang SVT Cobra R) and luxury cars (Lincoln models) were equipped with 5.4L DOHC 4-valve engine.

The first engine, introduced in 1997, was a SOHC 2-valve 5.4L V8. It has a cast iron cylinder block. While the engine shared the bore diameter with a 4.6L version, the increased stroke demanded a taller engine block deck height - 10.079 in (256.0 mm) compared to 8.937 in (227.0 mm). The internal components include fracture-split powder metal connecting rods and light-weight aluminum pistons. Later, this engine will receive a forged steel crankshaft in some applications. On top of each cylinder bank, there is a SOHC aluminum head with two valves per cylinder. There are two timing chains at the front, one for each camshaft. The valvetrain features roller finger followers and hydraulic lash adjusters. The valve covers are aluminum and the intake manifold made of composite material. All 5.4L V8s were equipped with individual coil-on-plug electronic ignition system and electronic sequential multi-port fuel injection. The 5.4 2V engine was produced at the Windsor Engine Plant in Windsor, Ontario.

The 5.4 3V version was first introduced in Australia and used on the 2002 Ford Fairmont under the name Bara 220. On the North American market, that engine debuted together with the redesigned 2004 Ford F-150 model. Ford 5.4L Triton 3 valve engine has redesigned cylinder heads with two intake valves and one big exhaust valve per cylinder. Ford engineers also introduced a variable camshaft timing (VCT) system, which greatly improved power and torque over the 2-valve SOHC version as well as fuel efficiency. There are numerous small changes inside the 3v engine resulting in a higher 9.8:1 compression ratio and bigger oil capacity. From the beginning, the production and assembling of the 5.4 3V engine were at Essex Engine Plant in Windsor, Ontario. But the last 5.4 Triton 3-valve engine left Essex Plant in 2008 and then the production was moved to the Windsor Engine Plant.

Engine Specs

Ford 5.4 triton v8 engine problems and reliability.

Like Ford's 4.6L V8s, the Modular 5.4L Triton engine has similar common problems for their engine family, which included blowing spark plugs and spark plug threads stripping (1997-2003 model years), stuck spark plugs due to a gap between the plug and the cylinder head which gets filled with carbon deposits (typical for 2004+ model years), and intake manifold cracking and leaking (poor design of plastic intakes). But it should be noted that these problems cannot be called widespread, and 5.4 Triton V8s have earned a good reputation in terms of reliability and longevity among the majority of owners.

The problems listed above are well known and are at least repairable and will not empty your pocket. With proper fluid changes and regular, scheduled maintenance, any 5.4-liter Triton engine will serve well over 200,000 miles (320,000 km).

Modifications

Ford SVT Lightning 5.4L engine. This 5.4-liter supercharged engine produces 380 hp (283 kW) and 310 ft-lb (610 Nm) of torque. Ford F-150 Harley Davidson Edition. This 2002-2003 model was equipped with 5.4L supercharged and intercooled V8 engine. Power output: 340 hp (254 kW) at 4,500 rpm, 425 ft-lb (576 Nm) at 3,250 rpm.

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