“Thunder” 1998 Expedition Build Thread

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MISTERgadget

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Inspired by the concept vehicle Ford built in 2000 and teased us with - following rave reviews in the press and then nothing from FoMoCo, I've decided to finally take this into my own hands and use my personal parts bin to make the SUV Ford should have! I have owned a Lightning since new in 2003 and accumulated a lot of the bits and pieces over the years as the setup on that truck has evolved.

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Our starting point - a 1998 Expedition EB, 2wd with just the right combination of options to get us the right hard parts we want - 5.4L, 4R100, 9.75" rear with 3.73s and a limited slip!

The truck has been in my family since new, and as pictured, you can see there's been just a few mods over the years - LED taillights, Xenarc Headlights with Lightning corner markers, and a basic stereo upgrade.

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From here, the goals and order of things are pretty straightforward.

  • Make it handle and stop well
  • Get the chassis and driveline ready for power
  • Reliable 500rwhp
  • Make it look the part
Of course, opinions on what the "right" answer is for each of those questions will vary.

I hope to be able to incorporate into the build some of the knowledge built up over years of modding the Lightning trucks and really make sure that good, practical solutions are for each one to ensure a fun, comfortable, and most importantly reliable ride.
 
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MISTERgadget

MISTERgadget

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Step 1 - put my Sportmachines.net 20" 03-04 Lightning Replicas to good use on the Expedition.

There are a couple of wrinkles in the install that are good to know

99-00 centercaps and 01-04 centercaps are different, the radius of the hole for the lugnuts changes. You need 01-04 centercaps which are marked with a "14mm" stamp inside, regardless of the lugnut size on the truck, so that the bores match the wheels.

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285/50-20 tires are much meatier than the OEM size!

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Can't wait to see how they look on all fours!

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mmm, much better!

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z168

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oh yesss... this is going to be good. Love the 20s

what did you replace your 3rd brake light with? looks different
 
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MISTERgadget

MISTERgadget

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oh yesss... this is going to be good. Love the 20s

what did you replace your 3rd brake light with? looks different

It's an LED 3rd brake light with a red lens I got off Ebay a few years back
 

z168

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Hows the lens right now? Is it still as shiny like the tail lamps?

I bought a Depo brand oem style brake lamp and theyre beginning to fade again
 
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MISTERgadget

MISTERgadget

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Hows the lens right now? Is it still as shiny like the tail lamps?

I bought a Depo brand oem style brake lamp and theyre beginning to fade again

I'd have to take a look, I honestly haven't looked at it closely in while.

Most headlight restorers/retrofitters will sand the outer lens lightly and coat them with 2k automotive clear, which has a UV protective layer that keeps them looking good for a long time.

https://www.amazon.com/Spraymax®-Glamour-Gloss-Aerosol-Usc-3680061/dp/B0043B7UQY
 
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MISTERgadget

MISTERgadget

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Next steps were to get started on handling and braking.

Unfortunately, I can't find any pictures of the belltech swaybar installation or the swaybars themselves. Belltech sells a swaybar set, part # 9921 for Expeditions.

The next mod was a full slate of parts for maintenance and to keep few other parts you would expect to degrade on an 18-year old truck in check, as well as a hydroboost upgrade and some lowering springs!

Used a junkyard hydroboost with a JC Customs adapter plate and a fresh coat of paint, along with raybestos brake rotors, pads and lines.

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Kwik SC

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How much did the stopping improve with the hydroboost upgrade? I know it works well on the L's and its definitely on my to-do list for that truck. But I drove my friend's Lightning swap Expy and that thing had zero brakes to stop with. Definitely needs a good solution.
 
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MISTERgadget

MISTERgadget

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How much did the stopping improve with the hydroboost upgrade? I know it works well on the L's and its definitely on my to-do list for that truck. But I drove my friend's Lightning swap Expy and that thing had zero brakes to stop with. Definitely needs a good solution.

The Hydroboost helped braking tremendously. One of my favorite upgrades so far.
 
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MISTERgadget

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Lowering was accomplished with Belltech 3" drop coil springs all around, #4804 in front and # 5308 springs in the rear. Now it's really starting to look like something! Stability, handling and responsiveness was greatly improved as well.

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Ok, so now she's looking mean with the new stance, time to complement that by completing the rear suspension upgrades. Added these PMT upper and lower trailing arms with poly bushings in the rear.

The OEM trailing arms typically rust into junk in northern states, mine didn't have that issue as the truck has lived in Miami its whole life, but these sure did make the rear feel much more sure-footed and will help keep everything square and planted with the planned power upgrades.

In addition to the PMT arms, I will have my fabricator build a custom panhard bar down the road to clear a TA Performance rear-end girdle.

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