Ford Excursion Throttle Position Sensor (2000-2005): A Complete Guide
Fix your Excursion's dead pedal, erratic shifting, or stalling issues by understanding this critical part.
- First, confirm if you have a gas or diesel engine; the parts are completely different and not interchangeable.
- For this specific part, spending more for an OEM (Motorcraft) sensor is highly recommended by experienced owners to ensure reliability.
- Symptoms like a 'dead pedal' or erratic transmission shifting are classic signs of a failing TPS/APPS on an Excursion.
- Replacement is a simple DIY job for both gas and diesel models, typically taking less than an hour.
Is It a Throttle Position Sensor or an Accelerator Pedal Assembly?
Stop: Gas & Diesel Engines Use Different Parts
Before buying, you must know what engine your 2000-2005 Ford Excursion has. This is the most common mistake owners make.
- Gasoline (5.4L V8 & 6.8L V10): You need a Throttle Position Sensor (TPS). This is a small, relatively inexpensive sensor that mounts to the throttle body on the engine.
- Diesel (7.3L & 6.0L Power Stroke): You need an Accelerator Pedal Position Sensor (APPS), which is almost always sold as a complete accelerator pedal assembly. You cannot typically buy just the sensor. This part is located inside the cabin under the dashboard and is significantly more expensive.
Symptoms of a Failing Sensor
A bad TPS or APPS can cause major drivability problems. The symptoms will get progressively worse until the truck is unreliable to drive. Here’s what to look for:
- Hesitation or "Dead Pedal": You press the gas and nothing happens for a second or two, then the power kicks in. This is a classic symptom, especially on the diesel models. 🎬 Watch: Troubleshooting a diesel engine with no throttle response
- Erratic Transmission Shifting: The transmission may shift harshly, at the wrong times, or seem to hunt for gears. The computer needs a clean signal from the TPS/APPS to command shifts correctly.
- Poor Acceleration & Power Loss: The truck feels sluggish and weak because the computer doesn't know you're asking for more power.
- Rough or High Idle: The engine may idle poorly or surge unexpectedly.
- Stalling: The engine may stall when you come to a stop or let off the gas.
- Check Engine Light: A failing sensor will often trigger a Check Engine Light. Common codes include P0120, P0121, P0122, and P0123.
Choosing the Right Aftermarket Part
For electronic sensors on these trucks, brand choice matters. Many owners report that cheap aftermarket sensors fail quickly, sometimes within weeks, leading to the same problems all over again.
A Mechanic's Advice on Brands
For critical sensors like the TPS and APPS, spending a little more on a quality part saves you headaches later. The general consensus among Ford truck enthusiasts is to use the OEM Motorcraft part if possible. Aftermarket parts can be a gamble.
Brand Quality Tiers
- Tier 1 (Best Bet): Motorcraft (OEM)
This is the original part your truck was built with. It offers the best guarantee of compatibility and longevity. Forum users overwhelmingly recommend sticking with Motorcraft for sensors to avoid problems. - Tier 2 (Reputable Aftermarket): Standard Motor Products (SMP), Delphi, NGK
These brands have a solid reputation for producing quality electronic components. If an OEM part is not available or is too expensive, these are your next best options. - Tier 3 (Use with Caution): Dorman, Value Brands
Dorman has a very poor reputation for this specific part among enthusiasts, with many reporting premature failures. However, for some diesel pedal assemblies, Dorman may be the only available aftermarket option if Ford has discontinued the part. Use these brands if you have no other choice, but understand the risk.
Typical Replacement Costs
Costs vary significantly between gas and diesel models due to the different parts involved.
| Part & Engine | Part Cost (Aftermarket) | Part Cost (OEM) | Shop Labor Cost |
|---|---|---|---|
| TPS (Gas 5.4L/6.8L) | $34 - $90 | $50 - $70 | $50 - $100 |
| APPS Assembly (Diesel 7.3L/6.0L) | $150 - $390 | $450 - $800+ | $75 - $150 |
Frequently Asked Questions
Do I need to calibrate the new sensor?
For the 2000-2005 Excursion, a formal calibration with a special tool is not usually required. However, it is best practice to disconnect the battery's negative terminal for about 15 minutes during the installation. This resets the engine computer and allows it to 'relearn' the new sensor's parameters 🎬 Watch: How to recalibrate your Ford 7.3 accelerator pedal when you first start the truck.
Is this a difficult part to replace myself?
No, for most DIYers this is a very feasible job.
- Gas TPS: Very easy. It's located on the throttle body and held by two T20 or T25 Torx screws. The air intake tube may need to be moved for access. The job takes less than 30 minutes. 🎬 See this walkthrough for replacing the gas engine sensor
- Diesel APPS: Easy to moderate. You will be working in the footwell under the dashboard. The entire pedal assembly is typically held on by three bolts. The main challenge is the awkward position. The job takes less than an hour.
Are there any recalls for the throttle position sensor on my Excursion?
No. Searches of the NHTSA database did not find any recalls specifically for the throttle position sensor or accelerator pedal position sensor on the 2000-2005 Ford Excursion. A recall for a speed control deactivation switch on 2003 models exists, but it is an unrelated part.
Why is the diesel pedal assembly so expensive?
The diesel versions use a 'drive-by-wire' system where the pedal assembly is a complex electronic component containing the sensor, wiring, and pedal mechanism. Ford does not sell just the sensor for most of these assemblies, requiring you to buy the entire unit. The high cost reflects the complexity and the fact that it's a much larger and more involved part than the simple sensor used on gas engines.
Helpful Videos
Technical Specifications
OEM Part Numbers: F4SZ-9B989-AA (Gas Engines) DY-967 (Gas Engines) 1C3Z-9F836-BA (Diesel without adjustable pedals) 699-200 (Aftermarket for Diesel)
For gas engines, the part is a 3-pin sensor mounted on the throttle body. For diesel engines, it is an integrated sensor within the accelerator pedal assembly.
We Have This Part in Stock
The information in this article is provided for general reference and educational purposes only. Vehicle specifications, procedures, and part compatibility can vary by production date, trim level, and region. Always consult your vehicle's factory service manual and verify part numbers before purchasing or performing repairs. Safety-critical components such as airbags, seat belts, and braking systems should be installed by a qualified professional.
- Ford Excursion: