UAV Urban Assault Vehicle - 17 Ex Wreck Rebuild

[HawkX66]

Someone had screwed up the A/C plug at the back of my console so I had to replace it. I couldn't find the correct one on-line which is DS7T-19G247-AC. The one called out in all of the Ford diagrams is wrong.
Instead of hunting one down I decided to create one that is a little more robust which isn't saying much. The factory plug is a complete joke. Here is what I came up with. I opened the factory plug, cut a hole to match the new plug, cut the factory terminals down and soldered two wires to the new plug so I could still use the factory harness without cutting it. It's not perfect, but it will be a lot stronger than the original.

 

[HawkX66]

I finally got around to swapping out my front differential. What a *****... In the end I had to drop the EPAS to get it back in. I was laying on my back doing this. If I were on a lift I could probably have gotten away without removing the steering rack. It was only two extra bolts and two plugs so it didn't really make a difference. I kept the gears. You never know if someone will need a good set of front 3.73s. They're my favorite ratio.
For sale: One gently used low mileage front differential from a 2017 Expedition. 3.73 gears and well maintained. Make an offer. ;-)

 

[HawkX66]

Much better. Glad to get the a/m grill off there. I think the factory grille looks a thousand times better than what I had on there. I just need to install the grille inserts now. It actually came with them. I didn't think the one I bought was going to. They weren't pictured in the ad. $240 including shipping for a brand new 2017 grille. I think I made out pretty good this time.

 

[JExpedition07]

Glad you got a proper grille hawk, I’m not a big fan of the aftermarket options

 

[HawkX66]

I just added the spacer that Iron Bull forgot to weld on. They sent the piece later which meant I had to bolt it on instead of it being welded. Looks wise it didn't make a difference bolted or welded. Now I'd like to find some black annodized bolts instead of the stainless ones I used. They don't look bad, but I want them blacked out.
Now on to lengthening the parking sensor and driving lights wire harness.

 

[Munkiebunz3]

@HawkX66 What was the spacer? I think they forgot mine too. My grille connects to a whole lot of Noth down there.

 

[HawkX66]

@HawkX66 What was the spacer? I think they forgot mine too. My grille connects to a whole lot of Noth down there.

It's the piece that goes between the bottom of the grille and the top of the bumper. If you look at the close up center pic you can see the stainless pan head bolts holding it to the grille. It was actually a blessing they forgot it and I had to attach it. I don't think I'd like the grill solid mounted to the bumper. I have it so it's laying on top of the bumper and that is plenty secure because of the curve of the bottom of the grill and spacer piece. It's nice and solid, but if the bumper gives at all it won't break the expensive grille...

 

[HawkX66]

Another piece of the puzzle knocked out. I installed a new passenger side airbag trim cover. I finally found one for $80 with the airbag. Anyone want to buy a cheap airbag? They're all over ebay for $300... Insane as that's what they cost new. There's a part number for the cover, but it's not sold separately from the airbag.
Now the interior is completely finished. All I have left to do are really a couple of small things and to wire the front parking sensors. It already drives like a 17 Expy Platinum with 25,000 miles should. Zero complaints from me. I love it. I'm still all in for less than $25k including buying the Expy and all the parts.

 

[Langer]

Another piece of the puzzle knocked out. I installed a new passenger side airbag trim cover. I finally found one for $80 with the airbag. Anyone want to buy a cheap airbag? They're all over ebay for $300... Insane as that's what they cost new. There's a part number for the cover, but it's not sold separately from the airbag.
Now the interior is completely finished. All I have left to do are really a couple of small things and to wire the front parking sensors. It already drives like a 17 Expy Platinum with 25,000 miles should. Zero complaints from me. I love it. I'm still all in for less than $25k including buying the Expy and all the parts.


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Looking great, did you have any luck with the glove box piston?

 

[HawkX66]

Looking great, did you have any luck with the glove box piston?

Thanks. No, no luck yet. I'm going to empty it and take a look again tomorrow. It can only be in so many places. I have to be missing a hole in something that it snaps in to.

 

[HawkX66]

Four hours! That's what it took my last night to wash and wax my rig. I didn't even make it to the roof... I'll start there next time. I did notice a spot the size of a pen tip that looks like rust... My 07 had the same thing in exactly the same spot. Pretty sad. It's between the moon roof and the windshield. I kept it waxed and it never got any bigger on the 07. I'll probably clean it and hit it with a little touch up paint.

 

[Munkiebunz3]

@HawkX66 sounds like you are missing the white plastic clip doohickey.

 

[16plati]

Four hours! That's what it took my last night to wash and wax my rig. I didn't even make it to the roof... I'll start there next time. I did notice a spot the size of a pen tip that looks like rust... My 07 had the same thing in exactly the same spot. Pretty sad. It's between the moon roof and the windshield. I kept it waxed and it never got any bigger on the 07. I'll probably clean it and hit it with a little touch up paint.



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Spent 9 hours on a friends Sequoia two days ago. Hadn’t been detailed in 10 years. Looks brand new now thanks to my favorite chemicals

 

[HawkX66]

@HawkX66 sounds like you are missing the white plastic clip doohickey.

You nailed it. Thanks!

 

[G213]

This project is incredibly impressive; very nice work. I know you've put a ton of time into this, but for 25k, you've built a 50k truck. That's one hell of a ROI.

 

[HawkX66]

@HawkX66 sounds like you are missing the ]

I was just looking at my part and I realized that I do have the white "doohickey." Your pic showed me where it needs to go though so thanks for that!

This project is incredibly impressive; very nice work. I know you've put a ton of time into this, but for 25k, you've built a 50k truck. That's one hell of a ROI.

Thanks a lot. That was exactly my intention. If I had my garage built after moving last year I would have cut the time spent in half. I'm real happy with how it's turned out.

 

[HawkX66]

When you put the a/m bumpers on an Expy with parking sensors, you have to figure out how to mount them. I didn't want to half ass it and I didn't want to waste my money buying sensors and retainers not knowing if they'll work.
Last night I was able lock down what I need to do. It was more than I wanted to spend on the retainers ($38), but I got the information I needed and they'll look awesome. I wanted to use the ones off my original bumper, but I was missing one that I couldn't source and I was going to have to epoxy them on. I didn't think they'd hold in the long run because of the bumper coating. They also might have had issues because they didn't stick out enough. You can't buy them separate from the bumper cover apparently.
I ended up with the following part number. There are actually four different numbers for the four front retainers. FL3Z-15K861-AA (AB, AC & AD)
In the end, these will match my bumper perfectly and, more importantly, will work correctly. The only thing I had to do to my bumper to make them fit was sand the coating out of the edge of the hole in the bumper.







These are what the factory retainers look like:

 

[Munkiebunz3]

Thick enough layer of the adhesive will work, just make sure you did a good job cleaning off the dirt first. It doesn't need to finish flush. Great job!

 

[HawkX66]

Thick enough layer of the adhesive will work, just make sure you did a good job cleaning off the dirt first. It doesn't need to finish flush. Great job!

Using the ones that I bought takes the adhesive out of the mix thankfully. They snap into place. I'd love to have used the factory one, but these will do just fine. Another box checked off... Now to extend the wiring for the fog lights and sensors. No problem. Just need it to stop raining.

 

[HawkX66]

Hit the Outer Banks this weekend for some R&R. We camped out in the Expy and I was surprised to find it was perfectly comfortable. A full mattress/pillow top fits nice. Did a lot of beach driving etc.
I also installed a couple of the new sensor retainers. They weren't exactly plug and play, but it didn't take too much to get them to fit nicely.