Recent content by engineer1

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    New member 2003 Expedition

    I'll second the plastic weld process. Both of my top vents had cracked and leaking badly. That's how I repaired it, and I had posted some photos and procedures I used about 3 - 4 years ago. Definitely use HDPE welding rods.
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    Cold Water Leak

    Because of your description and water in the valley it sounds like a top of engine issue. I would look vary carefully under the front passenger side of the intake manifold. These manifolds are plastic, and in the front of each side a metal crossover pipe mounts, from the under side of the...
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    Is my issue fuel pump or wiring?

    I would put a high probability on the fuel relay, which is notorious for intermittent, progressively worse failures. There are lots of postings and ways to jumper around it for testing. It requires removal of the main fuse box on the passenger side to replace it with the newer, higher amperage...
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    Cylinder 8 misfire under high acceleration

    I posted this on another (broken valve spring query) and thought you also might be interested. - Just a thought from a whole different direction. My EB is a gen 2, so may not apply to your situation, but I was having a similar problem and decided to replace the coil packs. When I removed #7 I...
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    Broken valve spring?

    Just a thought from a whole different direction. My EB is a gen 2, so may not apply to your situation, but I was having a similar problem and decided to replace the coil packs. When I removed #7 I noticed it was wet on the bottom, but did not have a coolant smell. I came across a thread on this...
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    2003 Fuel tank, EVAP assembly, power drivers side seat track…

    Good advice from BlwnAway to COMPLETELY eliminate any trace of epoxy before welding. Be sure to use HDPE rod (high density polyethylene). I successfully welded my '03 tank a few years ago. The info with photos is in this link. Good luck...
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    Fuse panel

    Check this link https://www.expeditionforum.com/threads/newbie-here-dead-ins-cluster-radio-windows.24952/page-8 I have a factory wiring service manual for my '03 ED, and this matches my book. Open the pdf and circuit 3049 is the first cluster of info - you will see that number on the circuits...
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    Fuel smell outside vehicle

    Back in 2021 I had a problem with my '03 EB leaking fuel from the 2 cracked vent fittings on top of the fuel tank, but I would only see liquid if the tank was full and it was parked on a slope. There have been several threads discussing the failures on the polyethylene tanks. My solution was to...
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    Raining coolant

    Be prepared when you remove the intake manifold that you may find more than a gasket issue. My '03 EB had the same leak, but I discovered the gasket is more of a formed O ring seal that sits in a channel molded into the plastic manifold. My manifold had cracked/broken so it no longer contained...
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    Low oil pressure

    If you continue to have a problem you may want to consider installing an economical mechanical pressure gauge to monitor it. This will tell you If really have low pressure, for any reason, or whether you have an electrical problem. When I rebuilt my EB at 187K I screwed my pressure tester into...
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    2004 fuel pump failed and replaced(long story with tech info)

    You're welcome. Good luck.
  12. E

    2004 fuel pump failed and replaced(long story with tech info)

    This thread from 2021 may help some of you with the repair of the plastic vent leaks. The repair I described starting on page 2 is still holding up fine and there are still no leaks in the tank. https://www.expeditionforum.com/threads/need-to-replace-my-fuel-tank.47332/
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    How to unfold 3rd row

    dlcorbett was correct about early '03 buttons on the driver side rear quarter panel. My "03 EB has them, and they work well.
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    Need To Replace My Fuel Tank

    Thanks, Trainmaster. Yeah - while researching I've found several other posts with this same problem, and they seem to fail in different ways. Hope this process helps someone else.
  15. E

    Need To Replace My Fuel Tank

    SUCCESS! The welded areas all held pressure OK using the soap bubble detection method. I only tested at 2 psi because the vents both opened at about 1/2 psi. (I had a balloon on each vent to observe that they were working OK so I removed them & installed rubber caps) I figured 2 psi was 400% of...
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