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We have the 5.4 in the Expy and we average 11.5 mpg around town. I also have the 5.4 in the SuperCrew and average around the same. The Excursion so far is registering 11.3 mpg. I have not had to purchased gas yet, so I figure I will not be able to calculate a more accurate rating for a couple months.
The 5.4 seems to be strong engines in the Expy and SCrew. I have never driven an Excursion with the 5.4 and cannot give you a comparison. I owned an '88 Bronco with the 302 and from that point on, I said I will never own the smallest engine available in any auto. I am on the north side of Atlanta and the hills were killer on that 302. I can say that the V-10 is one of the smoothest engines I have ever driven and I have no complaints with the acceleration of this beast.
Like you the PSD was not an option for me because 90% of our trips are less than 10 miles and 50% of those are probably <5.
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