Advice for aging 05 Expy

Hey all, my 05 Expy is going to try and let me down, if I don't start helping it. It only has 185K miles, but a list of rather major concerns.
Its starting the 5.4 rattle...camshaft phasers, so I'm figuring of doing the timing set thang.
A/C took a dump on me 2 years ago. The mechanic said the compressor is shot and one of the lines was leaking as well.
Lower radiator support is darn near rusted through on the right side.
Has never had spark plugs replaced, nor the tranny fluid changed
Although I have replace lower ball joints, after 5K they have gone south. Looking into Motorcraft replacement.
I also want to do the timing using Motorcraft parts as well, after viewing some YouTube videos on that subject.
Repair or upgrade?
Can't really afford to repair, or replace, but cannot afford to be with out 4X4 vehicle where I live.

Wow your heading for a world of hurt. The biggest thing besides the rust is the tranny. If it's gone the full 170k without changing fluid,leave it alone. Changing it this late in the game is a recipe for disaster. You've got so many things that are broke or are going to, are you sure you want to put good money after bad. In the end it's up to you, but if you could sell it as is, and find another one in better condition, you'd be better off.

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From an 05 expy 4x4 owner to another 05 expy 4x4 owner...

Ok bro you're basically in the same road I was in two years ago, except after replacing my timing phasers and chains i found out the motor bottom end was in a worst situation than my top end was to begin with anyways!

Anyways I been there... done that, if the rattle is present and you're positive your engine is still strong then replace the phasers, chains and oil pump all in one blow (est. $900 in parts using all motorcraft items + a melling oil pump) amazon has a kit for $800+ for all motor craft timing set plus vct's, I bought it and been a happy camper since.

If you dont think your motor will make it then look for a replacement motor, some people ask 3k for a used motor, some ask 300 for an identical motor, you just gotta look and expand your search if need be (after I realized my bottom end was gone I found after an extensive search a 5.4L 3V for $400 delivery included with a confirmed 99k miles on it)

My AC took a shit on me too but it did it with vengeance, the clutch froze solid and ripped 3 belts in the process, I replaced it with a used unit from a junk yard pulled from an F150 and it's been working flawlessly since (this is 2 years old talk now) the leaking line you can find and replace by yourself using uv dye Kors readily available in all auto parts stores.

The radiator support isn't a nightmare to replace, it is a PITA to find cheap but labor wise it isn't a super extensive job that you couldn't take care of the same day you take care of your ac compressor, if you need the truck as bad as you do then you're willing to turn a wrench for it to keep it running another 200k after all this is said and done.

Get yourself a lisle 65100 (I think) tool for spark plug removal, it isn't as bad as they make it to be when you have that tool beside you, I did it and yes I cursed alot in the process but in the end I got 8 spanking new plugs in my motor.

The first 120k of my truck's life it had ONE oil change and no trans fluid change, I drained my fluid and kept original filter in, then replaced all fluid minus 2 quarts which I instead added 2 quarts of Lucas stop slip fluid in for reassurance that I dont get any surprises soon.... 2 years later no surprises yet!

Anyways dont listen to Steve aka @1955moose , he's dealing the old man cards now... everything to him Is a world war 3 soon to happen kinda effect lol, anyways with all said and done you're looking at estimated $1200 for parts and labor 100% covered by you.... in the end you get a relaiable truck you can count on for another 115k at the minimum and it'll cost you less than 4 payments on a new car payment for an eco shit box like a dodge dart or a honda fit... think about it before you make a decision bro...

(Ps. Please for the love of God don't pull the I'm too old to do my own work card on me, cause if you do I'll be more than happy to buy gasoline for you to burn the truck, I'll even buy an extra gallon for you to douse yourself in it too)

Now if I misspelled anything then I'm sorry I'm using my phone while being partially tipsy to replay to this thread...

Habbibie, thanks for all the useful info. Yeah, I'm approaching 60, but the only thing stopping me from starting to work on it is, lack of a place to do it. I got damn near all the tools I need, plus, next week, Harbor Freight is opening a store in my town. Second thing holding me up is, no wheels to use while I'm doing the repairs. My thinking was, If I was to replace the lower radiator support, that means I'd pretty much have to remove everything in front of the radiator, including it. With all that out of the way, It would be easier to get to the compressor and line, with that out of the way I could get to the timing shit easier, then attack the plugs.
Another thing on them plugs, did you try the chemtool or seafoam thing, running a couple cans through in a couple tanks of gas?
I also view some of Fordtechmakuloco videos. He put a video out there on having the engine nice and hot then using the impact on them. Not sure I wanna go that route. I more prefer to stick with the Lisle tool.
I guess I'd better start looking up parts and ponder what the hell I wanna do.
Thanks again.

Habbibie, It now takes me all night what I used to do all night! And yes world war 3 is coming, hopefully not in our life time. And you know I'm all for keeping these old relics on the road. Nothing ****** me off worse than another saveable vehicle heading to the boneyard. Its like kids in school, if a teacher can reach even one, that's a good day!

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