What to look for when buying a gen 2 expy
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GAINMOB
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uhmmmmmmm....yeah...look for that...
tallsville
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i'd say check the rear AC, window up down motion. For the most part that is all that has gone wrong with my 2nd gen.
ELVATO
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Something I posted on F150online awhile ago to someone looking for buying advice:
Another issue, though this should be obvious, is the fading outer trim of the XLTs.
Also, some 05s may have injector issues. They may stick open or closed, resulting in engine damage. You would have to contact the dealership to see if the vehicle is affected. They extend the warranty on the injectors (and anything that might be damaged from a stuck injector) to 11 years or 120,000 miles, whichever comes first.
ELVATO said:For that price range, you shouldn't have any trouble getting something you like. If you're going to be towing, I'd get the 5.4 for the extra grunt. Also make sure the required trailer harness is in the back.
Things to check for:
1. Clicking/thumping from rear AC actuators. Turn on rear AC and switch between floor and roof, as well as between hot and cold. If there is clicking, one of the actuators has broken gears. Easy fix (though can be time consuming, depending on which one it is.) Might be good bargaining point.
2. Just like the F150s, the lighted window switches like to go out. They should come on as soon as the key is turned (kinnda hard to see in the daytime, so cup your hand over them.) Isn't a huge problem, more an appearance one. Again, another possible bargaining point.
3. Not sure if it's applicable with all years, or just 03's, but check the rear tailgate, especially around the plate area. There might be paint bubbling. Something about the aluminum oxidizing, something like that. Cosmetic, another bargaining point.
4. Check operation of the power mirror switch. I know of a couple where either some or all of the directions don't work. Mine, for example, doesn't wanna drive the mirrors down. The switch is only 15 dollars from Tasca, and is an easy fix, but not everyone knows that. Another bargaining point.
5. For higher mileage Expys with the 3V 5.4L, ask to see if the plugs have been changed. I'm pretty sure it's the same hassle as the F150 5.4L engine.
6. Check the headlights for spider webbing. Might need to turn on the headlights to see them (not sure if you can see it in the day, but you can see them at night, when the lights are on.) Seems it's heat cracks. My old ones had them, and the replacement ones I got off ebay have a couple small ones, though they aren't very noticeable. Hopefully running HIDs helps slows the process.
7. I know you said 04-06, but if you were to look at consider an 03, pull the fuse cover off and check the PCM relay (R203, the one next to fuses 22 and 36.) Check for burning at one of the prongs. The early 03s had a problem with the fuse box frying the PCM relay which can result in no-start conditions or the engine dying while driving (ask me how I know...)
Other than that, just push every button, turn every dial, and make sure everything works like it should. Check the tires for improper wear, check the engine for noises on a cold start up. Take a look under the Expy to make sure nothing is out of place. Check the fluids and their color/smell. If it's 4x4, make sure it works. Make sure the windows go up and down as they should. Check the power pedals. Check the rear wiper. Make sure all locks work, as well as the remote and keyless entry.
Hmm... I know I'm forgetting some stuff, but that's all I can remember for now. I'll post up if I remember something else.
Another issue, though this should be obvious, is the fading outer trim of the XLTs.
Also, some 05s may have injector issues. They may stick open or closed, resulting in engine damage. You would have to contact the dealership to see if the vehicle is affected. They extend the warranty on the injectors (and anything that might be damaged from a stuck injector) to 11 years or 120,000 miles, whichever comes first.
Big Ford Daddy
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I got some #3 happening on 04. upper right corner around the plate area is bubbling 
tallsville
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guess it good to live in the warmer dryer climates dont get as much of the rust issue as other parts of the country
Big Ford Daddy
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WHOISMOOTOO
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Sunroof! Lol elvato pretty much has everything covered
GAINMOB
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1 would think he's a FORD mechanic...but he's E/E
EMendoza93
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Make sure it hasn't been abused! I know I drove mine HARD.
imported_05expy
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cam phasers and tenisoner noise!! (i think 05 and 06)
sgtowing
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I have some #3 also on my 05. My windows can move slow. Other than that, so far so good.
ScottyDsntKnow
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Typical stuff you look for when buying any used vehicle. Motor and trans in these are pretty stout, when properly taken care of, the 5.4 will still be kicking strong when the body is falling off the frame.
All the problem areas have really been mentioned already so obviously look for those and test out everything. I was really into one Expo I test drove until the parking brake didn't work and the driver's seat motor would clunk and not move when I tried to make it go forward. Those motors are not cheap new and the owner kept trying to tell me that I was moving the switch wrong and that it worked lol.
In this market, I found it is actually better to buy from a dealer since NOBODY is going to pay KBB/Edmunds value for an Expo and the private sellers were way higher up than the dealers were. Not to mention they tend to get much angrier when you tell them their vehcile isn't worth KBB and they get insulted by a "lowball" that is actually a bit higher than what a local dealer was asking for the same vehicle with tax/title/tags already factored in.
All the problem areas have really been mentioned already so obviously look for those and test out everything. I was really into one Expo I test drove until the parking brake didn't work and the driver's seat motor would clunk and not move when I tried to make it go forward. Those motors are not cheap new and the owner kept trying to tell me that I was moving the switch wrong and that it worked lol.
In this market, I found it is actually better to buy from a dealer since NOBODY is going to pay KBB/Edmunds value for an Expo and the private sellers were way higher up than the dealers were. Not to mention they tend to get much angrier when you tell them their vehcile isn't worth KBB and they get insulted by a "lowball" that is actually a bit higher than what a local dealer was asking for the same vehicle with tax/title/tags already factored in.
Sierra Lima1470
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I'd say make sure the six disc changer works properly. I hear thats an issue. Also see if the climate controlled seat works fine on the Eddie Bauer models. And if it has the wireless headsets to the DVD system. Mine weren't there but since there won't be kids back there it wasn't an issue to me.
ScottyDsntKnow
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6 disc changer not working is really not a dealbreaker, just a negotiating chip. You can pull them and have them sent out for fixing (or DIY if you are a pointyhead) for something like $150-$200. Not cheap but not crazy either... Or just upgrade to a good aftermarket unit as ALL stock systems are junk compared to even a quality budget setup from someone who knows what they are doing.
ELVATO
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Just a suggestion, but I'd think this would be one of those threads you sticky, since these threads are what people usually look for when first buying a vehicle...
The same with the other threads for the other years.
The same with the other threads for the other years.
twisted
Member
first off 2nd gen has issues witht their frontend suspension as per dealer. check door switches for proper operation, cluster, the most important part is the tranny... i was told after mine blew that most 04-06 expys come in for new trannies so get it checked ahead of time, front wheel hubs...sigh typical ford. thats about it... imo and experiance.
I have an 06 and also have some bubbling of the paint on the rear tailgate - more or less below the rear wipers assembly.
Great post guys - wish I had seen this before buying my Expy, would have had a better idea what I was looking for. Fortunately, I lucked out in most of those scenarios except the rear bubbling of the paint and my $1,500 tune-up @ 74,000 miles. 6 of the 8 spark plugs were seized inside the engine and my friend spent a week and a half doing everything he could to take out the spark plugs without tearing the engine apart and pulling out the heads. A week and a half later with 2 broken specialty tools, lots of patience, and ingenuity he was able to get them out and complete the tune up.
I've read some stories of folks taking it to the dealer and having to pay something like $3,000+ to replace spark plugs because apparently FORD will just simply pull out the heads if a single spark plug seizes inside...
Great post guys - wish I had seen this before buying my Expy, would have had a better idea what I was looking for. Fortunately, I lucked out in most of those scenarios except the rear bubbling of the paint and my $1,500 tune-up @ 74,000 miles. 6 of the 8 spark plugs were seized inside the engine and my friend spent a week and a half doing everything he could to take out the spark plugs without tearing the engine apart and pulling out the heads. A week and a half later with 2 broken specialty tools, lots of patience, and ingenuity he was able to get them out and complete the tune up.
I've read some stories of folks taking it to the dealer and having to pay something like $3,000+ to replace spark plugs because apparently FORD will just simply pull out the heads if a single spark plug seizes inside...
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