New engine or new vehicle ?

No way was I going to drive my 2003 on long distance trips nor would I do an expensive repair that's worth more than the vehicle itself. So I bought a nice 2014 for travelling and kept the 2003 to drive local. I keep it alive and safe. Best of both worlds.

Where I live ... the $weet $pot is from 2 years to 13 years old.

MATT CONTI said:

I agree with your take: it's not worth putting $6k into an 18-year old SUV with 200k+ miles. But when you find: a newer than 2003 Expedition 4x4 with 170k-ish miles for $3000-3500, please send them all my way. I'll take them all, then possibly double my money reselling them.

Here the cheapest 2004+ on Craigslist currently is a 2008 with 241K that needs exhaust manifolds for $4000. On marketplace, the cheapest legitimate one (not "needs work" or "new engine" or junkers in a 'hood you wouldn't drive thru, much less shop for a car listed 38 weeks ago) is a 2005 with 184k for $4500 out in the boonies. Next is a 2008 XLT with 173k on it, for $5000. That's the one I'm picking up tonight. They go up from there...sharply. And they all have rusted-out rockers.

Click to expand...

Funny - 4 hours later, a 2004 with 155k shows up...for $3800.

Lol. They're out there. I was actively looking for another until a few weeks ago and saw quite a few on the market. I was specifically looking for 2003-2004 EB 4x4. Nothing newer, nothing less.

I agree with the other posts. The rebuilt engines are not perfect out of the crate either. Rust is another huge factor. And what you already replaced and the overall condition of vehicle. The used and new market is ridiculous right now. If you really like the vehicle then go for it... I did any engine replacementay 102k with a ford rebuilt with 3yr warranty and I needed the warranty!

Did you consider a junkyard engine? It might be significantly cheaper. New/Used trucks are selling at premium at the moment. You might be paying $2-4k more than what you would have (relatively) paid for a couple years ago.

This one's interesting. I think the decision really depends on the overall condition of your Expy, and how much you like it. OP lives in San Antonio, so I doubt rust is an issue. You said you've spent money on maintenance, so if you've spent money on parts other than the engine those are things you may still have to do on a used F150. You know your car's history, and if it's gone over 200k you're doing pretty well with maintenance, buying some other guys used car with 130k of abuse might end up costing you much more than the sticker price.

I don't think I would drop $6000 into a full rebuild, but I certainly would drive it until it needs an engine and swap out for a lower mileage one from a junkyard. Sure you don't know how well maintained it is but it beats spending $15k for the same gamble. If you're doing work yourself you can also get a rebuilt long block for under $3k.

Many good points here. I am in the minority apparently, but I would keep it running for two main reasons: 1) the price of replacing it with late-model used is high (often > $25k), and with new is outrageous (often >$50k). Used may or may not have been maintained well, you probably won't know. So you could end up spending even more. 2) I do all the upkeep myself, so the $ pencils out and I know that it has been well maintained throughout its lifetime (single owner). However, if you have to have work done by the pros, it is a lot more expensive and might not be worth it. 3) The rest of my truck is good - no rust, always garaged, no towing or abuse, trans is good, interior good, etc.
Just a few points for you to consider. I have thought a lot about this too as my Exp gets old. Again, the outrageous pricing of new or late-model used Expeditions is a major factor with me. Good luck.

So, I rebuilt the tranny and engine at 250K in my 2003 back in 2019. I would not do that now. Even though the vehicle may appear reliable, parts are getting harder and harder to find. I have spent some time in the junk yard pulling little things since the rebuild and fewer and fewer Expo's are showing up. One thing that may make up your mind is a good look at the undercarriage. Check the radiator support around the mounts, probably needs to be replaced. Water sits in mount around the rubber mounts and rusts it out. Before I took it apart, things looked great on the body. I have included what I found.




Another spot are the rocker panels, inner and outer. They may look fine, but the running boards hide a lot and they rust out from the inside. When you see rust poking through, it is too late. Check the cross member just behind the tranny that runs under the front seats as well as behind the rear wheel wells. There are some body panels that are sandwiched together behind the rear lights that are spot welded. When water gets between the metal lips, they rust out.

There are other parts that will make your life miserable as well. There is a Ford buss that connects to the green info display in the dash. If anything on that buss goes bad, you get all kinds of problems. My 4x4 was flashing indicating a transfer case code, it also took out the seat positioning and radio delay and autolock. Turned out to be the EATC for the AC and heater. The board inside was messing with the network buss. Can't buy a replacement, so I grabbed the last two at the junk yard.

I've been contemplating the same thing with my 2003 XLT 5.4L @ 197K miles. Still runs great, only expected maintenance so far. We still use it for road trips. (8 - 10 hours one way) One minor fender bender late last year resulting in a new left front fender, bumper cover and related bits (covered by the other driver's ins. )

I understand that from a pure $ value point of view that it may not be worth it to rehabilitate and old car. The sell-value after the repair is less than the current sell-value + the cost of repair.

The main problems I have with spending crazy amounts on a newer model is the cost of repair of the newer vehicle. Knock a mirror off with lane assist or something else with embedded electronics and it is thousands to fix rather than a few hundred. That and the car transmits to the manufacturer every few minutes. Your data is only as safe as the least trust worthy employees with access to the information.

So I'm thinking about a different approach.... what do you think it would cost for a more complete re-fit. Not quite a full blown customization, but I guess that is close. Doesn't need to be a straight replacement of existing parts/spec either. 1. Engine, Transmission, the whole drive train. 2. Possibly an Interior replacement / re-fit. Would $20K essentially give it a full make-over? -- say I was planning on driving it another 10 years.

PS... I live in the south. I haven't inspected for rust. It was kept in the garage up until about 5 years ago.

I'm in the same boat as you, Dmpsix. My 05 will be turning over to the 200K soon. The list of issues probably outweigh its worth. But then, you hear and read of the doom and gloom in the truck market (especially new), with the chip shortage.