1999 4x4 - Overland/off-road build

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Overland_Expy

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Hi everyone,

I recently bought a 1999 Expedition. It's a XLT 4x4, I think it's pretty close to a base model. It has the 4.6 and came with a factory 8.8 with 3.55 gears and the LSD. I scored it with 102k miles and this will be my (slow) build thread to document what I'm doing.

I am coming from my previous rig which I just sold, a 1994 F150 5.0 with a pretty nice sleeping setup in the back. I took that truck through every western state in the 5 years I owned it, and this Expedition is designed to continue the adventures.

Eventual plans: 34-35" tires, re-gearing, rear selectable locker and front limited slip, winch, torsion bar crank & rear spring spacers, rock sliders, and a sleeping platform, plus some aux lighting. Your basic off-road starter kit build. :)

In the less-distant future, I'm planning to do some restoration on the truck. Simple stuff like painting the grille and roof-rack (which is peeling), fixing what I think is a driver's side exhaust manifold leak, figuring out a check-engine light and a weird vibration the truck has at about 1500rpm in neutral/park and at low RPM in gear. I'm guessing that this is a misfire but I'm not sure yet. Also has an annoying metallic rattle sound going over bumps that I haven't figured out, but I'm guessing might be a sway bar related issue.

This is how I got the truck. I drove to Vancouver from Spokane and picked it up then drove it home. My cruise control doesn't work which made the drive a pain, but went well otherwise. I manged to get 18.5 MPG through the second half of the drive which was surprising.

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My first step was to remove the third row seat. I am married with no kids, so having this many seats does me no good and I can't sleep in the back with it in. :)
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Next I removed the running boards. This was a lot more annoying than I expected as there were around 30 bolts total, but pretty easy. Free ground clearance!
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I haven't had a chance to do anything else with the truck yet, but I will upload the results when I do. I did take it 4 wheeling at my local OHV park after work and was impressed with how well it did for a stock, 5000+ pound vehicle on old all terrains.
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AZShawn

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Great looking truck, nice find with only 102k miles! I'll definitely be interested in seeing your build as it progresses. Good luck!
 

ExplorerTom

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Nice truck. I’d still have my 2000 if it weren’t for that weird electrolysis eating radiators quickly. I took mine on MANY offroad camping trips. I never slept in mine though.

check out the link to mine below.
 
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Overland_Expy

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Hi guys,
back with another update. I didn't think my last post had even posted (guessing it probably had to be approved by moderators) but happy to see that it did :D. Thanks for all the kind words.

Not a lot of pictures but I've done some work on the truck since last time. Cleaned the MAF and throttle body (didn't take it off, just used cleaner and a rag w/ screwdriver) and did the dreaded spark plugs/plug wires job and changed the coils at the same time. Used all motorcraft parts, the old plugs were autolite so thankfully I know they have been changed at least once! The amount of extensions I had to use to get the rear plugs was ridiculous.
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Also swapped the headlights to some Amazon special lightning knockoffs. Fairly happy with them though the driver's side turn signal bulb housing sucks and the bulb doesn't sit flush. I think the ring that holds it is broken but whatever, I'm gonna run it for now lol. New bulbs are Sylvania Ultrastars which I have been impressed with in the past. Also swapped in LED reverse bulbs.

This weekend was the first camping trip with the Expedition. Went into north Idaho and found some pretty scenery.
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Visited the ghost town of Burke and camped at a nearby lake. Was really hoping that it wouldn't be fenced off, but oh well :(
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We slept in the back of the truck after unloading all our crap. With an inflatable sleeping pad it was alright, not great, not terrible. I think in the future I'm going to cut a piece of plywood to cover the third row attachment wells (not sure what to call them) in the back. Also might try to find some padding to throw back there.
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Overall, the truck did well. We went on some more difficult stuff and I had no complaints besides that the factory shocks suck.

As far as issues with the truck, I have a code p0401 that I was hoping would be fixed by cleaning the throttle body but no such luck. Not sure where to turn next in regards to DPFE or EGR valve, etc, so if anyone has advice on how to diagnose specifically what might be wrong with my EGR I would appreciate it :)

Also, I still have a vibration at idle in gear that gets worse when under load, IE turning the wheel, running the A/C, etc. Could this be a symptom of the EGR or should I be looking elsewhere?

Hope everyone has a good weekend :)
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hypercardriac

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Definitely gonna be following this. I have been building on mine a couple years and I love this machine. Have fun, don’t be afraid to be different, and be ready to build some shit yourself. The aftermarket is pretty limited for first gens, more visual than anything.. Have any questions, I can probably help.. If not, I will be here to learn from someone who can.. Located about 75 miles southeast of you, can’t wait to see what a local (WA local anyhow) does to his truck..


Sent from my iPhone using Tapatalk
 
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Overland_Expy

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Definitely gonna be following this. I have been building on mine a couple years and I love this machine. Have fun, don’t be afraid to be different, and be ready to build some shit yourself. The aftermarket is pretty limited for first gens, more visual than anything.. Have any questions, I can probably help.. If not, I will be here to learn from someone who can.. Located about 75 miles southeast of you, can’t wait to see what a local (WA local anyhow) does to his truck..


Sent from my iPhone using Tapatalk
Thanks! Good to know someone else is in the area :) More coming soon. Done lots of other small things...
 

OK98EXP

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I have a 1998 EB. Inherited the truck awhile back and rarely drive it. But I recently started to bring her back to life, so to use it for lake trips and other outings. I also experienced similar engine issues. My codes were telling me EGR, DPFE, O2 sensor, and a #3 misfire. I started with a EGR and DPFE replacement, and I also gave the engine a good throttle body cleaning and a Seafoam intake treatment. Unfortunately, I just received about 10 pct improvement and the engine hesitation and shuttering while under load continued. My next step was a to replace the coil packs and give it a round of spark plugs. At 163k, the truck had never had a spark plug change. Now it runs so much better. Now I am going to tackle a lifter tap that happens when accelerating and a faint whistle sound. A mechanic suggested it a exhaust manifold gasket that needs replaced.

Great post. I look forward to following your journey!
 
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