This is Ford's own workshop manual for the Excursion, 6,567 pages in a single searchable PDF. Ford published it as one book for three vehicle lines that share a chassis, so every page header reads “2000 F-Super Duty/Excursion/Motorhome Chassis Workshop Manual” and the Excursion is named more than 8,500 times through the text. Ford's numbered section scheme is intact, so 303-01C is the 7.3L diesel, 307-01 is the automatic transmission and 502-02 is the full frame. The engine coverage is the launch powertrain: 5.4L Triton V8, 6.8L Triton V10 and the 7.3L direct-injection turbo diesel V8, described in the specifications as “7.3L, OHV, DI Turbo, V8, Diesel, F-Series/Excursion”.

Which vehicles this manual fits

• Fits: Ford Excursion, first and only generation. Two-wheel drive and four-wheel drive each have their own front suspension section, and the book carries Excursion body work including the liftgate, the third row seating and the running boards
• Covers years: 2004, 2003, 2002, 2001, 2000
• Engine options: 5.4L Triton 2-valve V8 (firing order 1-3-7-2-6-5-4-8), 6.8L Triton V10 (firing order 1-6-5-10-2-7-3-8-4-9) and the 7.3L DI Turbo diesel V8, the engine most owners know as the Power Stroke. Bi-fuel vehicles get their own fuel system and fuel tank sections
• Diesel note: the diesel documented here is the 7.3L, which Ford fitted to the Excursion from launch until 2002. Trucks built from 2003 carry the 6.0L diesel instead, and that engine is not covered in this book. Everything outside the engine bay applies across the whole run
• Gearbox: 4R100 four-speed automatic with its own cooling and external control sections, plus two manuals, the ZF S5-47 five-speed and the ZF six-speed, with clutch and clutch controls
• Axles and drive: Dana 80, Dana S135 and the Ford 10.50-inch ring gear rear axles, front drive axle, full floating wheel hubs in both Dana and Ford forms, and a four-wheel drive systems section with the transfer case
• Language: English
• Pages: 6,567 in a single PDF
• File type: PDF

Inside this manual

Every entry below is a section present in the document, and the numbers are Ford's own:

Sample pages from this manual

These are real pages taken from the document:

What you can repair with it

The three engines each get their own section, so you work from the one for the engine actually in front of you. Each carries its own specifications, in-vehicle repair, removal and installation, disassembly and assembly, with exploded views that number every component and list it by Ford part number underneath. The 7.3L diesel adds its own fuel charging and controls section, a turbocharger section and a glow plug system section, which is where most diesel work on these trucks starts.

Driveline coverage follows the axle, not the model. Dana 80, Dana S135 and the Ford 10.50-inch ring gear each get their own section, and full floating wheel hubs are covered in both Dana and Ford forms. The 4R100 automatic has separate sections for its cooling circuit and its external controls, and there are two manual gearboxes here, the ZF S5-47 five-speed and the ZF six-speed. Braking is split by system, with rear-wheel anti-lock and four-wheel anti-lock documented apart from each other, which matters because the two use different components.

Because this book was written for a chassis rather than one body, it goes further into structure than most SUV manuals. There is a full frame and body mounting section, front end body panels, body closures, and glass, frames and mechanisms. The Excursion-specific work is here too, from the liftgate and its latches through the third row seating to the running boards. Climate control runs to five sections including auxiliary climate control for the rear of the cabin, and the supplemental air bag system has its own section with the components illustrated and listed.

Manual language and format

This manual is written in English and downloads as one PDF of 6,567 pages. It carries a full text layer, so you can search for a section number, a part number or a torque figure and jump straight to it, and pages print individually. It opens on Windows and Mac computers, tablets and phones with any standard PDF reader.

Questions about this manual

Is the Ford Excursion a good SUV?
That is a buying question and this is a repair manual, so it does not answer it. What it does tell you is how much vehicle you are looking after. The Excursion shares its chassis with the F-Super Duty, which is why Ford issued one workshop manual for both, and why the book runs to a full frame and body mounting section, three engine choices up to a 6.8L V10, and rear axles as heavy as the Dana S135.

What engine does a Ford Excursion have?
One of three in the years this manual covers. The 5.4L Triton V8 fires 1-3-7-2-6-5-4-8, the 6.8L Triton V10 fires 1-6-5-10-2-7-3-8-4-9, and the diesel is the 7.3L direct-injection turbo V8 that Ford lists as “7.3L, OHV, DI Turbo, V8, Diesel, F-Series/Excursion”. Each has its own engine section, its own fuel charging and controls section and its own starting system coverage.

How many miles will a 7.3 Power Stroke last?
The manual makes no claim about engine life, and anyone who gives you a figure is guessing. What decides it is whether the service work gets done properly, and that is what this book is for: the 7.3L section covers specifications, in-vehicle repair, removal and installation, disassembly and assembly, with the turbocharger and glow plug system documented separately.

Why is the Ford Excursion so big?
Because underneath it is a Super Duty. Ford built it on the F-Super Duty chassis and documented all three vehicles in this one manual, which is why the header on every page reads “F-Super Duty/Excursion/Motorhome Chassis”. The frame, axles, brakes and powertrain sections you are reading are the truck's.

Which model years does this manual cover?
2000 to 2004. Ford dated the book to the launch year, so the header reads 2000, and the Excursion ran as a single generation from 2000 to 2005. The 5.4L V8 and 6.8L V10 in here were fitted right across that run. The one gap is the diesel: this book documents the 7.3L, which was fitted until 2002, and trucks built from 2003 have the 6.0L instead, which is not covered here. If yours is a 2003 or 2004 diesel, everything except the engine section still applies to your truck.

How you receive it

Payment is processed securely and the download link is issued immediately afterwards, so there is nothing to wait for and nothing shipped. The file is yours to keep and re-download within the link period.