In October 2020, we decided to swap our 2013 Ford F-150 for a 2002 Ford Excursion. We outlined our reasoning and initial assessment of the vehicle based on our research of the model in our introduction to the project. The short of it, we wanted an affordable, durable, capable tow rig to better handle lugging our growing family and Rockwood Roo around the country.
A break in the cold weather this November prompted us to get one last trip in before officially calling it off for the winter. Naturally, I had already winterized the camper in mid October when we sold our F-150 as I was sure I would not have another tow vehicle until spring. Worth breaking it back out for a fun filled weekend and opportunity to test the new tow rig? Absolutely!
Our drive was 4 hours each way to the gorgeous Echo Bluff State Park in Missouri. Outside temps were in the mid 70’s for the high and 50’s for the low. All tires on the truck and trailer were aired up and the Excursion just came off a successful safety inspection and oil change. What could go wrong?
Hitching the Trailer
Like many RV owners, I am obsessed with tow vehicle squat. Every time I see a bumper pull trailer run down the highway I am checking it out and silently judging the driver based on how far the back end is sagging. Our F-150 rode relatively level when hitched and I expected the Excursion would as well. I was slightly disappointed to find the nose of the truck pointed a bit more towards the sky than anticipated. A pretty amazing feet considering the massively heavy ranch style bumper on the front acting as a counterweight of sorts. Measuring the rake of the vehicle the back end was about a half inch to an inch to lower than the front. Don’t get me wrong, I’ve seen far worse and the truck performed well enough on a brief 4 mile interstate loop to proclaim camping season back open.
Engine
We were thoroughly impressed with the legendary 7.3 Power Stroke’s capability. The engine never struggled to pull our trailer and returned an astounding 10 – 12 miles per gallon on our drive. This is nearly double that of our gas Ecoboost F-150! Our Excursion came to us with an Edge programmer, intake, and performance exhaust. None of these upgrades are uncommon as owners will try to awaken the engine which is hilariously slow to accelerate when stock. It did take a bit to get used to the amount of throttle required to maintain speed on hills. The reason for my initial hesitation was the deafening roar the diesel made through its 4 inch MBRP exhaust under load. It made me doubt whether I was breaking something as the truck sounded like a ticked off T-Rex. Seriously, it actually made our 18 month old daughter cry at one point. Even when in full “Jurassic mode”, it maintained perfect temps and never displayed a sign of stress.
Transmission
Initially the transmission was our big worry. The 4 speed 4r100 is known to give owners problems as it was never quite up to the task of handling the power strokes 500 lb ft of torque. Any performance upgrades the the engine increases probability of failure. Overall I would give the transmission a C+. It got us to where we needed, however, did seem to slip a few times on the highway and when creeping uphill at the campground. No slippage unhitched or hitched on the way home. I’ll have to pull the trouble codes and see what the problem is.
Suspension
This was perhaps the most surprising revelation on our initial test as the truck drove relatively well unhitched. Hooked to the Roo, the Excursion handled so poorly that we nearly turned around after 15 miles on Interstate 70. I started to get the hang of it and once off the crowded interstate and nerves settled but it was not ideal. The biggest issue was steering wander. This is where the rig sways from side to side when trying to stay in a straight line. Steering input at center was sloppy and when correcting, it was easy to overcompensate and swerve out of the lane. The way back was far worse as wind gusts blew our rig all over the road. By the time we arrived home every individual in the car had taken a turn yelling, crying, and/or having a panic attack. It will absolutely need an overhaul before spring camping.
Comfort
The Excursion is a massive SUV inside and out. The seats are super cushy which is great, but, a bit more support would be nice on the 4 hour stint. Leg room was fantastic in the drivers seat. Lindsey did point out the footwell is unfortunately shaped and obtrusive to the front passenger. In the back the kiddos had plenty of room and car seats installed with ease. At about 6’5″ I can put Olivia’s rear facing seat behind me and not feel cramped up front. Behind the 3rd row we had our two labs who never seemed to long for additional space. If we took the 3rd row out we probably could fit another 4 labs back there.
The biggest complaint of the rig was noise. That 7.3, as mentioned above, is loud. Unless coasting downhill or on a flat where I could keep RPM’s low, Lindsey and I could barely have a conversation. My decibel app on my phone registered around 85. That is like rolling down the highway with a blender running in the passenger seat! I am quite sure that aftermarket exhaust is at play and something will need to be done ASAP.
Conclusion
Overall the first drive was stressful due to the worn suspension and loud exhaust drone on the interior. We never expected a truck this old to be perfect though so in perspective it was not a terrible first run. We got to where we needed to go and were able to get an idea of what work needs to be done to get the Excursion in fighting shape this spring. We will continue to document our project as we address the issues identified on this initial shakedown. First on the list will be suspension diagnosis and repair as it is a safety concern. Once we get that squared away I’ll turn my attention to the rest of the systems to get them ready as well as address the noise.
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