What to look for when buying a gen 2 expy

Yes, Gearwrench really does come out with some good tool ideas. Their magnetic swiveling spark plug socket is the best I've ever used. You'll appreciate the Flex Head tools the more you use them too.

I've had all kinds of issues with my '03 three most of his little stuff... Except changing the flex plate .. that was a major issue. PATS issues a couple of times. Fuel pump went out... 350 bucks please..(just for the fuel pump)

Test highway speeds up through 65 mph listening for differential noise. This is a known problem. My EB differential emits a low volume wine at 58mph, tapering off in volume to zero above and below 58mph. It's a little bothersome to hear but I'm putting up with it. If it doesn't get any worse I'll just deal with it as a minor annoyance and continue to avoid cruising at 58mph.

I bought my 04 EB after only driving it a few blocks on the neighborhood streets. I discovered the differential wine taking it from Coral Gables to Fort Lauderdale on I-95.

When you fill up are parked nose down a bit? My 03 did the same. I forgot the explanation from the shop, but we didn't fix anything. I just back it in so it is parked nose up a bit.

thebuckaman said:

Just registered to say thanks for the checklist. I used it to pick up a 2004 XLT with 108k. Really in nice shape. The list was an awesome help. I do have a fuel smell when I filled it up and noticed some fuel on the front of the tank when I got it in the garage. I will need to investigate this.

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On my 03 getting the 2nd row center seat folded down is difficult. I have to get in there and kneel on the seat to tug on the cable hard enough to get to get it to release.

Again on my 03. On one of the second row side seats: After folding down the seat back, I can push it down level with the floor without difficulty. But it takes a lot of effort to pull the release to get it back up.

On a truck from the north east or where salt is used check the radiator mount, well known to be rotted out. Wifes expy garage kept still rotted out. Can do it yourself if you have time and a welder. not real easy but doable

Great thread!

I just bought a 2006 72k miles. Used to be a Fire Vehicle so it's as basic as it can be while having lots of weird excess. Well maintained. Whisper quiet. Radio, CD player & Cassette Deck no Aux plug in or Bluetooth ... Might just say it all. Key had no chip in it. It's rather weird to know I can go make copies for $5 vs $75



Have put about 300 miles on it since purchase and it stalled while driving. Thankfully I was in a safe place. And all the security stuff went out - auto locks, clicker, rear hatch opens randomly - lots of fun.



This forum has helped me narrow down some potential Why's. I'm leaning towards ground wires that have jiggled lose, and fuse box/relays that need replacing.

I haven't dived into mechanical since about 1995 and not had a Ford since my parent's collection. Dusting off the knowledge. Hoping some might still have value. I think this 9ne is simple enough, aka not much computer on it, that it's in my basic range of aptitude.

This is not covered by many people, but listen for a rattling on all the 2005-2014 model year expedition as well as the 2004-2011 f150 and some f250's have the 5.4L 3V that has oil pressure and timing issues with the cam phasors for VCT, if it sounds like the f150 in this video. ford 5.4 3v triton cam phasor ticking yt video. The 4.6 3V and the 5.4 and 4.6 2V motors arent troublesome aside from some issues with the spark plugs blowing out of the holes (if you arent a pro yourself, get a pro to change them for you, you'll thank me later) Now 98-04 navigtors have the 32V Non-VCT heads from the factory, but later ones have the 3v turd engine.

Captainjerky said:

Here's my new-to-me 2005 EB. Thanks again for the advice; this truck is really growing on me!
View attachment 54495

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I have an 06 Eddie Bauer the only thing I've done to it is rebuilt the transmission and put all the timing phasers and gears on there 226,000 still gets good gas mileage and a go across the country fast

Passenger/right side exhaust manifold. Mine is an '06 XLT. While troubleshooting passenger bank noise, saw telltale signs of leakage from #4 (aft cyl., pass side) exhaust manifold. I replaced it, turned out it was warped per my straight edge, with the #4 port being about 0.025" pulling away from cylinder head.

Speaking of noise, mine has a tap/dink noise while warming up. At times it goes away as fast as flipping a switch, then it comes back and grows louder slowly. Quiet when warm and no noise during or immediately after start. Only starts dinking about 20-25 sec after start. Been doing this for the last 2500 mi. Phasers, tensioners, guides, oil pump, chains, roller followers and lash adusters all replaced 22K miles ago (at 100K miles).