2003 Expedtion 250k suspension rebuild

tigernation653 · Apr 14, 2015

All original OEM suspension, 2WD, Non-Air. The ride is getting real loose and there is a lot of bumping, knocking suspension travel sound at low speeds. I want to start replacing components to restore handling and safety. The vehicle is in great shape otherwise (one owner, well maintained), only uses 1 quart of oil every 2k miles, so I plan to keep it another 100k miles. I don't want to replace everything at once, so where should I start and how much should be replaced. I know shocks and struts, but what about springs, ball joints, tie rod ends, sway bar bushings and so forth?

GAINMOB · Apr 14, 2015

Yes...all of what u mentioned....and prices vary pending ur source of procurement...nothing drastic....I buy my parts off ebay...others like oem from rock auto in vendor section

2004XLT · Apr 15, 2015

Like 6K said, at this mileage do everything. You said you don't want to replace it all at once, generally the only items you can replace without alignment are struts, sway bar links, and the lower ball joints. Everything else in the front end has the potential to effect alignment and should all be done at once.

If you're in the northeast, I would do springs as well as struts, I had pieces of spring breaking off of my 04 at only 115k due to rust. Also good to take a look at all bushings. I do like Rockauto and I would say stick with Moog or OEM parts for a front end rebuild...btw Moog lower ball joints are only $17 over there at the moment. Another item to look at would be front wheel bearings (hub assembly) while you're in there.

tigernation653 · Apr 20, 2015

Thank you

Thank you for the great advice.

99BlackEx · Apr 24, 2015

Yeah, I'm having to do the same thing but at 150K the rust belt sucks....

Mine definately needs shocks and springs and I can see through the rear trailing arms so I think it's time to replace them as well lol. I got a pretty good price to have them replaced, I could do it in a couple months but it needs done now and I don't have the time.

If you run into any crazy problems let us know, I am trying to get a list together of tools and parts needed for when I do finally get underneath her so I can get it done in a weekend possibly. Good luck.

2007EXPYBLUEEB · Jul 11, 2015

At 140k, I want to replace my struts; not necessarily a full rebuild.
Looking at KYB, Bistein as they seem to be the most available.
I have seen a set of four quick struts for under $400 but I am wary of the quality.
Have not checked out Rock but I will replace them all.

I have not confirmed the below sizes as I have not undertaken as of yet. I will try to repost to confirm and get to the front well, eventually

Rear Struts
Tower Top 15 mm (little clearance at rear need ratcheting wrench)
Tower Bottom 1" 1/16 bolt; 1 3/16 nut(or 29mill?)
Toe Adj Link 241 and 24 mil
Sway Bar Link 15 mil

If your rebuilding the stut assembly you may need additional sizes for the retention nut, as well as any ball joints that are spinning as you try to remove them. I do not know these sizes.

2003 Expedtion 250k suspension rebuild

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