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2002 EXCURSION
INDEX
Subject Page Number
Model/Series/Trim Availability 2

Seating Capacity And Standard Equipment Specifications 2-3

Technical Specifications:
— Axles 4
— Brakes 4-5
— Cooling System 5
— Fuel System 5
— Steering 5
— Suspension (Frame/Shocks/Springs) 6
— Tires and Wheels 7
— Transfer Case/Transmissions 7

Payload/Weight Ratings 8-9

Base Curb Weights 10

Special Applications (Trailer Towing) 11

New or Revised 7/27/01 2002 EXCURSION 1

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2002 EXCURSION
MODEL / SERIES / TRIM AVAILABILITY
Trim Level
Model XLT Limited
4-Door Truck Wagon ■ ■

SEATING CAPACITY AND STANDARD EQUIPMENT SPECIFICATIONS

Model Excursion
Series / Trim - 137.1” WB — 2WD / 4WD XLT Limited
Passenger Pkg. — STD OPT STD
Passenger Capacity 9 8 8
SEATING ARRANGEMENTS INCLUDE:
Captain’s Chairs — Dual front ■ ■
Bench — 3-Pass. front - 40/20/40 ■
— 3-Pass. rear - 60/40 ■ ■ ■
— 3-Pass. rear - folding ■ ■ ■
Passenger/Cargo — Lbs.- maximum 2WD — 2185 1945
Cap. and Options 4WD — 1740 1800
GVW RATING: — Lbs. (Computer selected - 2WD — 8600, 8900 8600, 8900
not to be advertised) 4WD — 8900, 9200 8900, 9200
GAWR: — Lbs.
2WD Models Minimum Front 3950
Maximum Front 4400
Minimum Rear 5250
Maximum Rear 5250
4WD Models Minimum Front 4100
Maximum Front 4700
Minimum Rear 5250
Maximum rear 5250
POWERTRAIN: 2WD / 4WD
Engine — Application Refer To Preferred Equipment Packages For 50 States Usage
— Type (Ford) 4x2 - 5.4L (330) SEFI V-8 Triton
4x4 - 6.8L (415) SEFI V-10 Triton
— Air intake - hot/cold Thermostatically controlled
— Fan clutch Viscous type
— Exhaust System Stainless Steel
— Ignition - EEC V Solid State
Transmission — Type - 4-Speed Automatic Overdrive 4R100
— Low/High gear ratios 2.71:10 /.71:1
Transfer Case — Type - BW 44-06 Rotary knob Control Trac 4WD center disconnect mechanism
— Low/High gear ratios 2.72:1 /1.00:1
AXLES:
4x2 Front Axle — Type Twin I-Beam IFS
— Make and capacity Ford - 4700 lbs rating @ ground
4x4 Front Axle — Type Monobeam
— Make and capacities Ford - 5200 lbs rating @ ground
Rear Axle — Type Ford - 7000 lbs. rating @ ground
BRAKES:
Front Disc — Type Dual Piston Pin Slider, Bolt-on Anchor Caliper
— Size 12.13” Diameter
Rear Disc — Type Single Piston Pin Slider, Bolt-on Anchor Caliper
— Size 13.20” Diameter
Power-Assist Unit — Type Vacuum Boost w/gas engines (Hydro-Boost with 7.3L Diesel)
— Effective Diameter 9.84”
Anti-Lock System 4-Wheel ABS
Parking Brake (Rear Brakes) Foot-Operated, Hand Release

2 2002 EXCURSION New or Revised 7/27/01

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2002 EXCURSION
SEATING CAPACITY AND STANDARD EQUIPMENT SPECIFICATIONS
Model Excursion
ELECTRICAL:
Alternator — Rating 6GIF - 130 Amperes, 1950 Watts
Battery — Type Maintenance-Free (Battery Saver System Standard)
— Rating 78 Amp-hr., 750 CCA
FRAME: — Type Ladder type w/BlockerBeam, 36,000 psi Steel
— Section Modulus 4.16 cu. in.
FUEL TANK: — Capacity 44.0 Gal. (167L)
— Location Aft-of-Axle W/Skid Plate. Includes inertia cut-off switch
JACK: — Capacity 2.0 Ton
STEERING: — Make Power assist, Ford XR-50 Recirculating Ball — Includes power
steering fluid cooler
— Ratio 17.0:1 Gear
— Turning diameter 4x2 = 46.8 ft. — 4x4 = 50.4 ft. (curb to curb)
SUSPENSION:
Springs, Front — Type: 4x2 Coil, Computer Selected - 3950 lbs @ ground (Min.)
— 4x4 Leaf, Single-Stage, Constant Rate - 4100 lbs @ ground
Springs, Rear — Type: 4x2 Leaf, Single-Stage, Constant Rate
4x4 Leaf, Single-Stage, Constant Rate w/Anti-Windup Leaf
— Rating at ground (min.) 5250 lbs.
Shock Absorbers — Gas - Type 1.375”
Stabilizer Bars — Front — 4x2 Steel Bar 1.36” Diameter
— Front — 4x4 Steel Bar 1.42” Diameter
TOW HOOKS: — 2 Front — frame mounted.
TIRES: — No./Type XLT- Five, Steel-Belted Radial, All-Season OWL
Limited - Five, Steel-Belted Radial, All-Season OWL
— Size LT265/75Rx16D
WHEELS: — Type XLT Trim: Chrome Styled Steel w/full wheel cover/Std steel spare.
Limited Trim: Premium Forged Aluminum/bright appliques/.5-trian-
gular type holes/Std. steel spare.
— Size 16” x 7.0” K
— Spare Tire Located inboard LH rear quarter trim with carpet cover and stow-
age pouch
WIRING HARNESS: — Type Trailer Tow Class IV bumper, 7-pin wire harness
NOTE: Refer to the end of this section for Preferred Equipment Package content and option availability.

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2002 EXCURSION
TECHNICAL SPECIFICATIONS
Axle
FRONT AXLE SPECIFICATIONS
Model/Series 2WD 4WD
Make/Type Ford Twin-I-Beam w/Ball Joint Dana 50 Monobeam, Live Spindle
Max. Rating @ Ground (lbs.) 4850 5200
Drive — Hotchkiss
Housing — Type — Unitized
— Cover Attachment — Bolted
Gears — Type — Hypoid
Ring Gear — Pitch Diam. (in.) — 9.00
Pinion — Mounting — Above Center
Differential — Type — 2-pinion
— Bearings — Tapered Roller
Axle Shaft — Minimum Diam. (in.) — 1.59
— Diam. over Splines (in.) — 1.30
— No. of Splines (Hub End) — 30
Axle — Material Nodular Cast Iron Cast Iron

Radius Arms — No. 2

— Material Stamped, High-Strength
Low-Alloy Steel
Ball Joints Lubed-For-Life
Spindle — Material Nod. Cast Iron Body w/Forged Stl
Stem
Wheel Bearings — Type Tapered Roller

REAR AXLE SPECIFICATIONS

Model/Series 2WD 4WD
Make Ford Standard and Limited Slip
Max. Rating @ Ground (lbs.) 6830
Type Full-Floating
Drive Hotchkiss
Housing — Type Cast Center
— Cover Attachment Bolted
Lubricant Capacity (pt.) 7.0
Wheel Bearings — Type Tapered Roller
Gears — Type Hypoid
— Material Alloy Steel
Ring Gear — Pitch Diameter (in.) 10.50
Pinion — Mounting Overhung
(1)
Differential — Type
— Bearings Tapered Roller
Axle Shaft — Minimum Diameter (in.) 1.36
— Diameter over Splines (in.) 1.50
— No. of Splines (Hub End) 35
(1) 2-pinion with 5.4L (330 CID) SEFI V-8 engine and 6.8L (415 CID) SEFI V-10 engine. 3-pinion with 7.3L (444
CID) V-8 Turbo Diesel engine.

Brakes
HYDRAULIC BRAKE EQUIPMENT SPECIFICATIONS — FRONT / REAR
Total
Caliper Gross Swept
Axle Brake Area (sq. in.)/ Piston Lining Area Area
Usage Rotor Dia. (in.) Lining Width (in.) No./Dia. Per Axle (sq. Per Axle
Type (lbs.) OD ID Segment Thickness (in.) (in.) in.) (sq. in.)
Disc 4850 - 2WD 13.03 9.06 Outboard 12.40 / 1.89 /.47 Dual/2.12 49.60 264.48
Front 5200 - 4WD Inboard 12.40 / 1.89 /.47 Dual/2.12 49.60 264.48
Disc 6830 - 2WD 12.83 9.06 Outboard 8.68 / 1.76 /.47 Dual/1.75 34.72 244.81
Rear 6830 - 4WD Inboard 8.68 / 1.76 /.47 Dual/1.75 34.72 244.81

4 2002 EXCURSION New or Revised 7/27/01

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2002 EXCURSION
TECHNICAL SPECIFICATIONS
Brakes (Cont’d)
BRAKE MASTER CYLINDER SPECIFICATIONS
Type Model/Series Bore Diam. (in.)
Dual System, Dash-Mounted All 1.375

BRAKES BOOSTER SPECIFICATIONS

Effective
Make/Type Series/Model Diameter (in.) Booster Type Diaphragm Type
Dash Mounted Gas Engines 9.84 Vacuum Boost Dual
Diesel Engine 1.56 Power Piston Hydro Boost —

Cooling Systems
COOLING SYSTEM SPECIFICATIONS
Cooling
Core Size (in.) System Fan Specifications
Frontal Rows Fins Capacity Blade
Trans. Area of Per (approx. No. of Dia.
Engine Cooling Usage (sq. in.) Height Width Thick. Tubes Inch qts.) Type Blades (in.)
5.4L (330) Std. All 802 26.49 30.27 1.02 1 15.0 26.4 (25) Plastic 10 19.38
SEFI V-8
6.8L (415) Std. All 802 26.49 30.27 2.20 2 12.5(1) 28.5 (27) Plastic 8 20.00
SEFI V-10
7.3L (444) Std. Man.(2) 802 26.49 30.27 2.20 2 12.5(1) 30.6 (29) Plastic 9 23.25
V-8 Turbo Std. Auto 802 26.49 30.27 2.20 2 12.5(1) 30.6 (29) Plastic 9 23.25
Diesel
(1) Revised to 11.3 fins per inch in April, 1998.
(2) Includes in-tank transmission cooler.

AUXILIARY AUTOMATIC TRANSMISSION OIL COOLER APPLICATIONS

Model Engine Transmission Standard
ALL Gas 4R100 26
Diesel 4R100 18

Fuel System
FUEL SYSTEM DATA
Electronic Fuel Injection Gas Engines Sequential Multiport Fuel Injection
7.3L V-8 Turbo Diesel Hydraulic Electronic Unit Injection
Fuel Pump Gasoline Engines Single Electric-In-Tank High Pressure (One Per Tank)
Fuel Filter Gasoline Engines In-Line Large Capacity (One)
7.3L V-8 Turbo Diesel Full-Flow, Disposable Plus In-Line Water Separator
Fuel Tank All Engines 6 Layer Co-Extruded HDPE
44 gallon usable capacity
Air Cleaner All Engines Dry Element, Replaceable

Steering
STEERING SPECIFICATIONS
Power Steering Turning Diameter (ft.)(1)
Model/Series Wheelbase (in.) Gear Ratio Overall Ratio Curb-to-Curb Wall-to-Wall
4x2 137.0 17:1 19.6:1 46.8 49.6
4x4 137.0 17:1 18.4:1 50.4 53.0
(1) Average of left and right turns using standard tires.

New or Revised 7/27/01 2002 EXCURSION 5

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2002 EXCURSION
TECHNICAL SPECIFICATIONS
Suspensions
FRAME SPECIFICATIONS
Maximum Side Section Yield
Model/Series Wheelbase (in.) Box Section (in.) Modulus (cu. in.) Strength (psi)
4x2 / 4x4 137.1 7.27 x 2.82 x .201 4.16 36,000

SHOCK ABSORBER SPECIFICATIONS

Front Rear
Model/ Wheelbase No. Piston No. Piston
Series (in.) Usage Used Dia. (in.) Type Used Dia. (in. Type
4x2 / 4x4 137.0 Std. 2 1.375 Gas-Pressurized 2 1.375 Gas-Pressurized

SPRING SPECIFICATIONS — FRONT COIL

Combined Rating Height of Spring @ Inside Dia. Wire Dia. Deflection Rate @ Ground
Series/Model @ Ground (lbs.) Design Load (in.) (in.) (in.) (lbs. per in. ea.)
4x2 3950 12.0 4.0 .799 572
4100 12.0 4.0 .819 610
4400 12.0 4.0 .831 647

SPRING SPECIFICATIONS — FRONT LEAF

Combined Rating Number of Total Thickness Length Width Deflection Rate (lbs.
Series/Model @ Ground (lbs.) Leaves (in.) (in.) (in.) per in./ spring)(1)
4x4 4100 2 1.15 55.63 3.00 330
4300 2 1.15 55.63 3.00 350
4700 2 1.15 55.63 3.00 380
(1) Single-stage, constant rate springs.

SPRING SPECIFICATIONS — REAR LEAF

Combined Deflection Rating Each
Rating @ Number of Total Thickness Length Width Rate (lbs. per @ Pad (lbs.
Series/Model Ground (lbs.) Leaves @ Pad (in.) (in.) (in.) in./ spring) per spring)
4x2 5250 6 2.5 58.08 3.00 410 2275
4x4 5250 7(1) 3.16 58.08 3.00 410 2275
(1) 7th leaf is an anti-windup leaf.

6 2002 EXCURSION New or Revised 7/27/01

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2002 EXCURSION
TECHNICAL SPECIFICATIONS
Tires and Wheels
TIRE SPECIFICATIONS
Load
Limits @
Maximum Maximum Static
Rim Section Inflation Inflation Loaded Revolutions
Width Width Ply Load Pressure Pressure Radius Per Mile @
Size (in.) (in.) Rating Rating (psi) (lbs.) (in.) 45 mph
LT265/75Rx16 A/S BSW 7.0 10.51 10 D 65 3000 14.7 658
LT265/75Rx16 A/S OWL 7.0 10.51 10 D 65 3000 14.7 658
LT265/75Rx16 A/T OWL 7.0 10.51 10 D 65 3000 14.7 653

WHEEL SPECIFICATIONS
Max. Wheel
Nominal No. of Bolt Capacity Load
Wheel Type Wheel Size Offset (in.) Studs Circle mm (in.) (lbs. @ ground)
Styled Steel 16” x 7.0” K 25 8 170 (6.7) 3415
Chrome Styled Steel 16" x 7.0" K 25 8 170 (6.7) 3415
Chrome Styled Forged 16" x 7.0" K 25 8 170 (6.7) 3415
Aluminum
Premium Forged Aluminum 16" x 7.0" K 25 8 170 (6.7) 3415

Transfer Case
TRANSFER CASE SPECIFICATIONS
Make and Model New Venture 273
Application Electric Shift (Rotary Control)
Series/Model 4x4
Type 2-Speed Planetary Gears
Lubricant Capacity (pt.) 4.0
Gear Ratio — High 1.00:1
Gear Ratio — Low 2.72:1
Case Material Aluminum

AUTOMATIC TRANSMISSION SPECIFICATIONS

Ford 4-Speed Automatic
Make/Type Overdrive (4R100)
Ratios (to 1):
1st 2.71
2nd 1.54
3rd 1.00
4th — OD 0.71
Reverse 2.18
Converter (1)

Lubricant Capacity (pt.) 32.0

Helical Gears All
Oil Cooler Water
Converter Size & Type 12″ Controlled Clutch Apply
(1) 2.10 with 5.4L engine, 1.90 with 6.8L and 7.3L engines.

New or Revised 7/27/01 2002 EXCURSION 7

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2002 EXCURSION
PAYLOAD/WEIGHT RATINGS
Option Worksheet
(Front/Total)
Option Weight (lbs.)
ENGINE/TRANSMISSION COMBINATIONS:
5.4L (330) SEFI V-8 with 4-Speed Auto OD (4R100) (4x2)/(4x4) (0/0)
6.8L (415) SEFI V-10 with 4-Speed Auto OD (4R100) (4x2)/(4x4) (97/96)/(99/103)
7.3L (444) V-8 Turbo Diesel with 4-Speed Auto OD (4R100) (4x2)/(4x4) (545/588)/(545/590)
Rear Axle with Limited Slip (0/5)
California Emissions (gas engines) (7/5)
TIRES
LT265/75Rx16 All-Season BSW (0/0)
LT265/75Rx16 All-Season OWL (0/0)
LT265/75Rx16 All-Terrain OWL (0/0)
OPTIONS:
Air Conditioning — Rear Auxiliary (-1/-41)
Cladding - Lower Bodyside Delete (-5/-16)
Engine Block Heater (Gas Engines) (1/1)
Floor Mat Delete (-3/-8)
License Bracket - Front (1/1)
Luggage Rack - w/o Crossbars (-2/-10)
Mirrors, Electric - Non-Bright Trailer Tow (10/11)
Pedals - Power Adjustable (1/1)
Radio — AM/FM Stereo/6-CD/Clock (CDX6) (4/5)
Radio — Rear Radio Controls (0/1)
Rear Seat Entertainment System (2/5)
Reversing Aid (0/4)
Running Boards - Illuminated (2/3)
Seats — 40/20/40 Split Bench — Cloth Power Driver’s Seat (0/0)
Seats — Captain’s Chairs — w/o Power Driver’s Seat (9/19)
Seats - 2nd Row Dual Buckets (8/16)
Seat - 2nd Row Bench Delete (includes weight of passengers) (-137/-656)
Seat - 3rd Row Bench Delete — removable (includes weight of passengers) (-6/-537)
Seats, Heated (RH/LH) (2/3)
Seat - 6-way Power Driver Seat (5/8)
Skid Plate Package — (4x4 Transfer Case only) (11/18)
Trailer Tow Prep Package (0/0)
Trim, XLT (0/0)
Trim, Limited (15/32)
Wheels - Argent Steel - 16x7.0 in. (4 wheels) (-14/-27)
Wheels — Bright Aluminum — 16x7.0 in. (4 wheels) (-44/-88)
Wheels — Premium Forged Aluminum — 16x7.0 in. (4 wheels) (-41/-82)
Windows, Power Rear Quarter (0/2)
Sub-Total: Front/Total ____/____
Sub-Total: From 1st Col. ____/____
Line A) Total Actual Option Content/Weight: ____/____

Front/Total
1) Minimum Cargo Capacity Rating 0/
2) Plus Actual Content Weight (from Line A, Cargo Worksheet) +
3) Equals Combined Option Content Weight and Minimum Cargo =/
Capacity Rating
Maximum Cargo Capacity Rating can be computed at right.
The actual GVW rating will be the lowest GVWR listed with allowable front/total
weights (above right) exceeding the combined option content weight and
minimum cargo capacity rating.

8 2002 EXCURSION New or Revised 7/27/01

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2002 EXCURSION
ACCESSORY RESERVE CAPACITY
TABLE "C" — VEHICLE CAPACITY CALCULATION
Total
Allowable Total Option Weight (from Table "B")
Less Total Actual Option Content Weight (from Line A, Cargo Worksheet)
Equals MAXIMUM VEHICLE CARGO CAPACITY RATING
Plus passenger weight
5-pass.=750 lbs.
6-pass.=900 lbs.(1)
8-pass.=1200 lbs.
9-pass.=1350 lbs.
Equals TOTAL VEHICLE CARRYING CAPACITY (cargo plus passengers)
(1) Front Split Bench Seat includes weight of additional passenger

MAXIMUM ALLOWABLE WEIGHT (lbs.) (Regular Production Options &

Aftermarket Equipment)
7.3L (444) Turbo
Model GVWR 5.4L (330) SEFI V-8 6.8L (415) SEFI V-10 Diesel V-8
4x2 8600 350
8600 362
8900 641
4x4 8900 413
8900 413
9200 652

TOTAL ACCESSORY RESERVE CAPACITY CALCULATION

Maximum Allowable Weight (RPO & Aftermarket
Equipment)
Less Actual Regular Production Option Content —
Weight (from Line A, Payload/GVWR Worksheet)
Equals Total Accessory Reserve Capacity(1)
(1) The weight to be added to the Ford completed vehicle should be less
than this figure, as explained in the foregoing text. This Accessory
Reserve Capacity figure approximates the figure which will be
computer-printed on the Safety Compliance Certification Label
located on the driver's door latch post.

New or Revised 7/27/01 2002 EXCURSION 9

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2002 EXCURSION
Base Curb Weights
Model Front (lbs.) Rear (lbs.) Total (lbs.)
4x2 W/5.4L V-8 3262 3388 6650
4x4 W/5.4L V-8 3524 3563 7087
4x2 W/6.8L V-10 3359 3375 6734
4x4 W/6.8L V-10 3575 3615 7190
4x2 W/7.3L V-8 Turbo Diesel 3782 3415 7197
4x4 W/7.3L V-8 Turbo Diesel 4062 3626 7688

10 2002 EXCURSION New or Revised 7/27/01

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2002 EXCURSION
SPECIAL APPLICATIONS
Trailer Towing Information
NOTE: Refer to the TRAILER TOWING SECTION in this book.
Snow Plow Information
NOTE: Not recommended for Snow Plow Applications.

New or Revised 7/27/01 2002 EXCURSION 11