New to me 2000 Expy

I just got done doing some major overhaul on a 2000 Eddie Bauer that I bought for my son. I'm currently sitting at around $5,800 on it, still needs some work and will need paint. Most of what is left is cosmetic.

I paid $1000 for it. What I thought was the a windshield leak turned out to be run holes in the roof from something the PO installed and removed and half ass fixed. What I've done to mine and can give you any variety to tips on since its very fresh in my mind:

Reman Promar 5.4L engine.
Replaced temp and oil sender, TPS, timing sensors, knock sensor (damn thing fell apart). Cleaned everything else when it tested out ok.
Rebuild fuel injectors.
New intake (it already had the dorman and I didn't know it, but the PO's mechanic used RTV on all the water jacket seals.)
Bought a complete set of ECCPP COP's and they seem to be just fine.
Replaced all the swaybar bushings with Energy Urethane
Replaced outer tierod end caps with energy urethane.
I have a complete set of KYB Monomax shocks on the way.
I used Bosch Platinum +2 plugs (got them on a killer clearance at Wal-mart)
New brakes all the way around, turned front rotors, backs had to be replaced.
New Lower ball joints. (Moog)
New upper control arms/ball joints (was cheaper to buy them that way then the joint itself)(Moog)
Had alternator bearings and brushes replaced.
New PS Pump
New water pump
New water bypass tube.
New Fan clutch (would love to have to electric but couldn't justify the money)
New Headlights and fog lights.
New Arnott Air Springs

Short of the transmission and rear end this thing has been basically rebuilt. PO had already put a new radiator in it.

The 5,800 includes an engine stand and engine lift, plus a few tools I needed. Honestly though I could have spent that on a decent used car with nothing replaced. I know exactly what I have with this thing now. Its easy to work on, can cross parts to the F150 if I need to and it ride just fine. My only real complaint is dealing with rust.

Anything else anyone knows of that typically goes out on thee that should be looked at? I've noticed the AC acting a little odd so I'm thinking about pull that and doing the o ring fix. I'm half tempted to keep this thing for myself, its pretty sweet. My wife can drive the 2015 Explorer.....love me some V8.

Also, anyone wanting any tips on pulling the motor or other odd things I discovered working on this thing let me know. Pulling the motor wasn't that bad and when I put it back in it fired up on the first try.

Hi - what did you use to replace the headlights? I have a 1999, and replaced the headlight glass with an aftermarket glass kit and put in HID bulb / ballast kit, to improve as the stock lights were not that good, and still having issues with the new glass's pattern? How are your replacement headlights?

Wow. Lots of work but not to bad of a deal, right? Do you have pics of what you did, like a build thread?

Shaggy said:

Wow. Lots of work but not to bad of a deal, right? Do you have pics of what you did, like a build thread?

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Not really but I should have. Had anticipated my son would have helped more and I could have had more pics. I do have pics though I could likely consolidate them.

desertman said:

Hi - what did you use to replace the headlights? I have a 1999, and replaced the headlight glass with an aftermarket glass kit and put in HID bulb / ballast kit, to improve as the stock lights were not that good, and still having issues with the new glass's pattern? How are your replacement headlights?

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http://www.ebay.com/itm/380429334173?_trksid=p2057872.m2749.l2649&ssPageName=STRK:MEBIDX:IT

These are the headlight/turn signal kits I used. I like them. Good light pattern. I also got the fog lights there as well. So far no leaks either.

Great job!

The only things I could suggest looking into (which have been the only two major things for me) is the blend door and intake manifold.

The blend door has a major design flaw and will flop around or get stuck.

The manifold will eventually spring a leak. Mine leaked at 140,000 miles...not a bad run, but still ended up cracking.

Hi-I just picked up (this week) an excellent condition '00 EB 2WD with 4.6L/4R70W and 170K. It runs tight and has been very well maintained. All electronics work (except overdrive button). I'm concerned with repeated mentioning of this leaking/cracked intake manifold. Could you elaborate? Is it on both 4.6 and 5.4 mod engines? If it's a given that she'll blow, I'd prefer to do some preventative maintenance. Thanks.

You know normally you'd want to look for a low mileage version, and pay extra for that part, but being able to spend the time with your son, and teaching him is priceless. Good deal!


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Did the promar engine have thread inserts in the spark plug holes?


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1955moose said:

Did the promar engine have thread inserts in the spark plug holes?


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Ya know, I never checked or thought to ask. These guys rebuild tons of Tritons and with the 3 year unlimited mileage warrant you would htink they would. Not even sure how to tell if the inserts are there.