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    Bad design of the spark plug port wells in the head

    'Can't see where you can drill dain holes without compromising the head. The boots for the COPs usually do a good job, but if this is an extreme use, you might want to remove them and swath tons of silicone grease on them. While you're at it, after blowing out the water, fill the wells with the...
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    Dead battery

    All I know is that I purchased an AGM for the Expy based on my experience with using them on motorcycles. Living up here in the rust belt, I would put my motorcycles away by November and take them back out in April, with an occasional ride on a rare, 50° day in January. I could do that because...
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    Dead battery

    Don't have the rear wiper problem, but there is definitely a parasitic drain on my 2005. I have a top of the line AGM battery that's been tested over and over and has been found to have no issues, but still, because I'm really done with this thing, it sits on the driveway and has to be started...
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    2005 A/C Stopped, Compressor not cycling on.

    Thanks for the diagram. It might look like that if it were elongated and turned 90° to a verticle rectangle. I don't have instruments to find static pressure. Just a recharge gauge that puts it in the RED. Perhaps I can ask the shop that did the 1 hour diagnostic where they said that the box was...
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    2005 A/C Stopped, Compressor not cycling on.

    Hi, want to know if the rectangular black box mounted to the driver side radiator support upright houses relays and fuses for the A/C? Opened it up to find 3 or 4 relays and a couple of fuses, all rusted and relays would have to be forced out. Ford says that this relay box is part of the wiring...
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    Air conditioner compressor

    Thank you, David
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    Air conditioner compressor

    Hi, I went to recharge the A/C on my 2005 Expy. Gauge is in the red zone, so didn't fill. Compressor doesn't cycle on and off. What do I look for? 90° here, any guidance would be refreshing:-) Thanks, Stephen
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    2006 Factory Roof Rack Rails Mounting

    They are called Wellnuts and can be purchased in a good hardware store. When removed, you can actually push through to the headlining, so it's just a simple hole drilled or punched through the roof at the factory. FYI, My first Expy was a '97 with the sliding track type roof rack. I had...
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    6.2 motor going in 2011 Navi

    I've asked about this swap years ago without any reply, so you might be the first one doing it. So please do document what you can. My concern was not because it will give more power and torque, truly a bonus, but was it a more reliable engine, with no issues like my 2nd Gen 3 valve 5.4. I...
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    You Guys With 33s & 34s--Where Are Your Spares?

    Keep the oversize tire and deflate it to clear the hitch. The reason I need to always carry a spare in ALL my vehicles is not an old school thing. It's simply that almost every time I needed my spare was because the sidewall was destroyed. For regular flats, I always carry some sort of inflator...
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    10W30?

    I highly respect and consult the Ford Tech Maculoco You Tube videos for my problematic '05 all the time. He too recommends changing to 10W20 for many of the same reasons stated here. The first owner used 10W30. When I got this truck at 46K, it was already making the cam chain whipping noise at...
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    Cold air intake?

    Yeah, and on a sadder note, many years ago a little kitten must've perched himself around the upper A arm of my '64 Olds parked under a carport when I lived in Northern California. I went out to leave, started the car and suddenly the generator light goes on and before I can open the hood, smell...
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    Cold air intake?

    Cold Air intake comes through the fender, just as Ford designers/engineers intended. So, even with the Gotts mod, to get any gain, and it will be minimal, you would have to set aside the grommet in the fender, enlarge that hole with a larger tube. But one thing I've learned, depending on where...
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    Rear cargo area floor tie down anchors idea

    You can make nylon straps with "D" rings, secure the other end with poprivets or 1/4 20 bolts and flat washers to the frame sides of the folding third seat. They are hidden under the floor when not in use and pulled up through the sides between the floor and rear side bulkheads when needed. Can...
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    Oil Filter Relocation Kit

    My first Expy, a '97 5.4, came with a remote oil filter / water to oil cooler combo as part of the tow package. My '05 has the filter screwed directly into the block. Never switched to that setup, but it's the ideal way to go and will fit all the 5.4 blocks if you could find all the components...
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    Melling oil pumps are a waste of time and money.

    You Tube's Ford Makuloco has some good points about changing to the Melling high volume pump. There are some inherent bad designs in the 5.4 3V that keep it from being a prefect motor. Cam chain tension relies on cheap plastic actuators that use oil pressure to push the tensioner slides against...
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    roof rack (complete removal)

    The rails are attached to the roof with wellnuts. Loosen and remove the wellnuts, remove the rails and re attach and tighten the wellnuts so the roof doesn't leak.
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    front bearings/hubs; any brands to avoid?

    I put Timkens in about 5 years ago on my 2005. Not sure if they were Chinese, but still holding up. ABS sensative to worn hubs, makes a good warning for that. ABS light was on, changed rear hubs, light went of.
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    Why code 345

    So, yeah, tricking the ECU is sounding more like the reason.
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    Why code 345

    Driving one day and a smooth idler pulley exploded it's bearings. The belt stayed on and I limped home without overheating or charging issues. While driving, the check engine light came on and I wondered what code there would be for the accessories drive failing. I was hoping it wasn't two...
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    Oil plug quick release

    I also would think so it doesn't snag anything protruding up from the road, especally if your 4 wheeling, which I know isn't done hardcore with most of these vehicles. But that would be my issue with a Fumoto. Too much stuff with the valve mechanism extending down that POSSIBLY can go wrong...
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    Fuel Milage

    2005 5.4, 24valve. Daily driver. 15.6 average on computer readout. Some highway, mostly rural, under 70 mph. 5W20 synthetic, 37psi in tires. Mileage drops down a couple of tenths in the winter.
  23. D

    Half a second chatter at startup

    On my '05 3Valve, it is as others mentioned, the tensioners not having enough oil pressure on startup causing the timing chain to rattle. This problem was addressed with tensioner upgrades that had improved O ring sealers. It has been recommended by the U Tube " Makuloco" channel, who I highly...
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    Gen 2 ticking

    I've had both two & three valve engines. What everyone is saying is a logical explanation for the ticking, but believe it or not, that "ticking" can be coming from a cracked exaust manifold, quite common with first gen 5.4. Ask me how I know. Manifold replaced, ticking gone.
  25. D

    My '05 3 Valve plug changing experience.

    That's good information about antiseize. I will compensate by going to the lower end of the torque range and by considering what extensions or U joints I'm using. 'Haven't had a problem in years, even with aluminum heads. If not comfortable with antiseize on the plug threads, with the early 3...

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