New 2003 owner. What are the first things you did?

[rickrick123]

I just picked up a mint condition 2003 XLT 4WD with 95k for $4800 bucks. And when I say mint, I mean mint (pics attached). 1 owner with perfect maintenance history. Only issues were power pedals (I manually adjusted to fix), a little back/forth play in the power drivers seat (plan to try the rail adjustment to fix), screw missing from the visor (already fixed), slightly out of front end alignment, and a small amount of surface rust and most of that is on the running boards.

I have ordered a replacement head unit to install (I have android auto in my other cars so it's a must for this one too) and I plan to add a backup camera.

What are the first things you did when you picked up your 2nd gen?

 

[kep5niner]

New headlights / fog lights
Weathertech floor liners
Swap the black wall side for the tires

Then pull all of the DTCs, to include EATC and cruise control to make sure everything’s on the up and up. Good looking truck.

 

[rickrick123]

New headlights / fog lights
Weathertech floor liners
Swap the black wall side for the tires

Then pull all of the DTCs, to include EATC and cruise control to make sure everything’s on the up and up. Good looking truck.

Funny you say that, I was searching last night for all the light upgrades. and floor liners

Already pulled the codes before I bought it and it was clean as a whistle.

 

[mbtech2003]

Lift it!!! Lol. 3” front 2.5” back. 1.5” whee spacers with 285-75r17 tires. Mine is a 05 tho. Gonna start looking for a new one. Cape cod rust is getting to it.

 

[GaryH]

I've had mine since '06, so not the first things I did. But I recently replaced the headlights. Makes a world of difference. Also, check to see if the rear washer is working. There seems to be several instances of the washer hose separating under the dash at the front kick panel. Your washer reservoir will seem to need refilling too often. Then one day it will drain overnight into the wiring harness that runs underneath the passenger door frames.

New headlights:

 

[rickrick123]

I've had mine since '06, so not the first things I did. But I recently replaced the headlights. Makes a world of difference. Also, check to see if the rear washer is working. There seems to be several instances of the washer hose separating under the dash at the front kick panel. Your washer reservoir will seem to need refilling too often. Then one day it will drain overnight into the wiring harness that runs underneath the passenger door frames.

New headlights:
View attachment 78628

Thanks, headlights do have some oxidation but I'll probably wait until they get worse. I was looking at smoke lens projector lamps and putting LEDs in and also smoke lens tail lamps already. No issues with the rear wiper.

However, now after filling the tank we did discover a leak. It gets parked on an incline and if heading downhill the tank leaks from the top drivers side corner. I have a guy who is going to drop it and find the exact leak. I see similar posts that mention the tank is not made anymore so hopefully we can fix without needing a new one.

 

[Broncoholic]

What are the first things you did when you picked up your 2nd gen?

Drive it, wash it, rinse, repeat. We bought our 2003 in 2004 with 32k miles on it, so we had many years of just driving it. Aside from regular maintenance, I started modding only about 6 years ago... Daystar lift, I've also added Rancho Quicklift with the Daystar lift; I had 2017 Raptor wheels, but bought a new wheel set with a little more offset; I'm on my 2nd set of 315/70R17 tires; added Hypertech 42000 to correct for oversize tires and program for premium fuel (not notable difference); added Flowmaster FlowFX dual in/single out for a little rumble, but not intolerable. I've also replaced the headlight and fog light assemblies (maybe considered maintenance since they were hazy), and the front seat leathers and bottom cushions from The Seat Shop (worth the investment over 5 years ago). Now it just really needs new paint from 20 years in the Florida sun on the Florida coast.

 

[Broncoholic]

However, now after filling the tank we did discover a leak. It gets parked on an incline and if heading downhill the tank leaks from the top drivers side corner. I have a guy who is going to drop it and find the exact leak. I see similar posts that mention the tank is not made anymore so hopefully we can fix without needing a new one.

If you're talking about the gas tank, I'll save you the money and tell you where it's leaking. There are 2 fittings (top front and rear) that are glued/plastic welded(?) into the tank. Those fittings crack at their mold seam. I found both of mine cracked when I replaced my fuel pump 4 years ago. I used some "fuel tank repair" Epoxy that kept them sealed for less than a year. Now I don't fully fill the tank unless I'm going to drive at least 15 miles after leaving the pump. And correct, the gas tank isn't available anymore. I check the internet every few months to see if 1 is available. I'd spend a few hundred on a new tank to not have to deal with the fuel leak/EVAP leak anymore.

Here's my post from another forum.

2003 fuel tank leaking at emissions vacuum ports, fixed! - Ford Truck Enthusiasts Forums

1997 - 2006 Expedition & Navigator - 2003 fuel tank leaking at emissions vacuum ports, fixed! - For years there has been a fuel smell when the tank is full/ near full. I dropped the tank today to replace the fuel pump and found these visual gems....

www.ford-trucks.com

 

[GaryH]

If you're talking about the gas tank, I'll save you the money and tell you where it's leaking. There are 2 fittings (top front and rear) that are glued/plastic welded(?) into the tank. Those fittings crack at their mold seam. I found both of mine cracked when I replaced my fuel pump 4 years ago. I used some "fuel tank repair" Epoxy that kept them sealed for less than a year. Now I don't fully fill the tank unless I'm going to drive at least 15 miles after leaving the pump. And correct, the gas tank isn't available anymore. I check the internet every few months to see if 1 is available. I'd spend a few hundred on a new tank to not have to deal with the fuel leak/EVAP leak anymore.

Here's my post from another forum.

2003 fuel tank leaking at emissions vacuum ports, fixed! - Ford Truck Enthusiasts Forums

1997 - 2006 Expedition & Navigator - 2003 fuel tank leaking at emissions vacuum ports, fixed! - For years there has been a fuel smell when the tank is full/ near full. I dropped the tank today to replace the fuel pump and found these visual gems....

www.ford-trucks.com

Thanks for that. I get the check engine light with OBD code P0442 (small evap leak) every 4 to 6 months. I just reset the code and I'm good for another 4-6 months. But I can always smell gasoline at the left rear tire after I drive it. Now I know why.

 

[Broncoholic]

Thanks for that. I get the check engine light with OBD code P0442 (small evap leak) every 4 to 6 months. I just reset the code and I'm good for another 4-6 months. But I can always smell gasoline at the left rear tire after I drive it. Now I know why.

Same code here. I carry the Hypertech with me because it also reads codes and can clear them.

 

[rickrick123]

Thanks all for the information on the gas tank. I may just deal with it. I really don't have the stuff to drop the tank myself and my shop is us busy AF lately and wouldn't be able to look at it for a couple weeks anyway. We'll just not fill all the way for now and for me I think it's only the front fitting since nothing ever leaks or smells from the back.

 

[Broncoholic]

If I could do it over, and I might 1 day, I'd use a fuel resistant sealant that should stay pliable. I suspect the epoxy didn't stay sealed because it didn't have give.

 

[GaryH]

Same code here. I carry the Hypertech with me because it also reads codes and can clear them.

True story. I'm on my way to get the required annual safety and emission inspection. About a mile from the inspection station, the CEL, SES, or whatever, light comes on. I head back home and reset the code (P0442), then right back to the inspection station. Failed the emissions test. Apparently it takes a drive cycle to actually clear the codes out of the computer. We are allowed one Not Ready as long as the CEL light is not on. I had two Not Ready sensors for some reason. Drove it around a few days, went back to the inspection station and passed.

 

[whtbronco]

My fuel pump failed last night. Sounded a bit funny when I left work, stopped at the chiropractors and it was failed when I went to leave. I already know the tank is leaking a bit when full so I will plastic weld the seam in the valve while I have it removed. The fuel tank valves are supposedly made of HDPE and so are most milk jugs so the plastic for welding is readily available.

I've successfully plastic welded numerous plastic items on our vehicles ever since I bought the Harbor Freight plastic welder. It's easy, though does take some getting used to, and it really works well. The most difficult thing can be finding the right plastic material to use for welding rods. I have started just going to the junkyard and buying and broken piece of trim when needed for most things, it ensures I have the right plastic. Generally I melt a V shape into the seam or joint with the iron and then go back over it with the iron and plastic to fill it back in. Once it cools it's welded and good as new or maybe better.

Here's the plastic welder I have, it's $20 now:
https://www.harborfreight.com/80-watt-iron-plastic-welding-kit-60662.html

Here's the symbol for HDPE so you can look for it around your house if you choose to.

 

[whtbronco]

I somehow missed how old this thread is. :-(

 

[Broncoholic]

I somehow missed how old this thread is. :-(

Not that old, and good info about plastic welding. Let us know how it turns out if you do the weld repair.

I had another P0442 code this week. It's annoying getting the check engine light every few months and having to plan my fuel fill ups.

 

[whtbronco]

The plan is to drain and remove the tank and fix the leak today and tomorrow, I'm slow due to rheumatoid arthritis. The new pump will arrive Tuesday.

On the P0442 this may not help, but maybe it will. It took me like 2 years to finally repair the issue on my daughters 2003 Monte Carlo. I smoke tested it time and time and time again and tested the sensors never finding an issue with the sensors. I found several very minor leaks or slightly loose fittings and repaired them and thought I had fixed it each time just to have it fail the evap self-test a few weeks or months later again. I had replaced every vacuum line, o-ring, the purge and vent valves, replaced seal on the tank pressure sensor. In the end I realized every time the CEL came on recently due to P0442 the tank pressure sensor had popped out a little which tore the seal each time. Previously I had swapped the seal and that seemed good. This time I swapped the tank pressure sensor and it finally resolved it. My theory is the tank pressure would get too high due to sensor intermittently failing and the sensor is just held in by the seal so it unseats itself. This sensor had been tested good several times.

I'm kinda lucky that we have 2 of these Monte Carlo's as daily drivers so parts swaps are easy for testing when I get stumped, but I also have tons of spare parts for them after 1 was totaled and another was bought for parts of course stripped everything I could save from both.

Anyway, it may be something that for some reason you're over looking like I was.

 

[Hamfisted]

The P0442 codes can be frustrating. The gas cap or dirt around the gas cap lock and seal area are common as well. Take a rag with WD40 on it and wipe the entire fill neck area clean, especially where the gas cap seal contacts. If you need a sealant for small cracks or holes that may come in contact with fuel, that Seal All sealant is fuel resistant and seals very well and remains flexible over time. It's available at Home Cheapo and Walmart.











.

 

[aeorn]

I have this same leak. Leaks when parked on an incline with a full tank of gas... i wish someone made an aftermarket tank that had a little more capacity. Didn't realize that even the stock one is out of production!

 

[aeorn]

Drive it, wash it, rinse, repeat. We bought our 2003 in 2004 with 32k miles on it, so we had many years of just driving it. Aside from regular maintenance, I started modding only about 6 years ago... Daystar lift, I've also added Rancho Quicklift with the Daystar lift; I had 2017 Raptor wheels, but bought a new wheel set with a little more offset; I'm on my 2nd set of 315/70R17 tires; added Hypertech 42000 to correct for oversize tires and program for premium fuel (not notable difference); added Flowmaster FlowFX dual in/single out for a little rumble, but not intolerable. I've also replaced the headlight and fog light assemblies (maybe considered maintenance since they were hazy), and the front seat leathers and bottom cushions from The Seat Shop (worth the investment over 5 years ago). Now it just really needs new paint from 20 years in the Florida sun on the Florida coast.
View attachment 78637
View attachment 78638

How are your ball joints holding up with the Daystar + Rancho? Your lift looks great. This is exactly what I want to do, but the naysayers are giving me doubts about reliability.