Did it look like someone's been in there before? This is almost worth pulling the passenger side valve cover to solve this mystery ! But if you see piston top damage, the motor is toast.
If you have a borescope camera take a peak at the top of the pistons and see if there's been any contact...
Probably quicker to just pop the valve cover off and inspect the timing chain. You didn't say how many miles were on the Expy. Did you get any maintenance records or history with it?
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Pull the cargo racks off the roof, especially on that side, and inspect for rust holes. If you find any you can wire brush the rust away and patch the hole with JB Weld then touch up paint. Expedition roofs are famous for their rust holes.
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Only thing I've been able to do is take a large hammer and punch and smack the shaft back down into the carrier . The column seems to get pulled out from people pulling themselves up into the vehicle by the steering wheel rather than the grab handle. Over the years it eventually works it's way...
Why not just fix the vacuum leak on the passenger side of the motor ?
Do you have the ability to use a mechanics smoke tester to blow smoke through the intake system?
That or a close inspection of all vacuum tubing and hoses and replace any that are allow unmetered air in.
The Cats are not...
Can you flash your high beams with the stalk lever ? Are you getting 12v power to the headlight switch ? Power out of the headlight switch ?
Headlight Switches at Rock Auto
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You can safely run a 180 degree thermostat without triggering a CEL for engine too cold. I would recommend buying or renting from your local autoparts store a cooling system pressure test kit and pressurize the system to find the coolant leak first, before you go spending money unnecessarily...
OEM Parts From Lakeland Ford Online
Gen4 Expedition Active Grill Shutter Parts Online
Is it just the lower half of the assembly? I assume the raccoon didn't jump up into the middle of the grill and damage the upper half assembly.
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If it's only happening when you use the turn signals that would point to the multi function switch that is the turn signal stalk / high beam stalk . Instead of disconnecting the battery you can pull the high beam relay there in the fuse box. You can also try swapping the high beam relay with...
If it's the original fuel pump it can be drawing so many amps it's frying the relay. Are you able to measure the amp load when you jump the fuel pump ? A new fuel pump will probably help.
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The fuel pump drive module should be on the frame behind the left rear tire. Did you replace your fuse box with one of the exact same part number? If not, go back to your original fuse box. But what you describe does sound like a failing fuel pump module.
2005 Expedition Fuel Pump Control...
Yes, to do it right you need to pull the intake manifold off. Inspect the coolant pipe that's under the intake manifold as well. There are O-rings that seal the small coolant pipe to the nipple on the water pump housing nipple.
Intake Crossover Gaskets ( Fel Pro ES-71213 ) at Rock Auto
Ford...
You getting fuel pressure at the fuel rail schrader valve ? If not, check the fuel safety inertia switch. It might've gotten triggered during all the swapping commotion. Getting spark ?
Use a mechanic's stethoscope to try and isolate where the tapping is coming from. Top end, or bottom end. Front or back of motor. Could be just a collapsed lifter, which is not a big deal to change. Hopefully nothing more serious than that.
Mechanic's Stethoscope on Amazon
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That's your front windshield washer line, and it should be plugged into the washer pump. One line goes to the rear washer, one line goes to the front.
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Somebody cut your hot water supply lines and made hamburger of everything. I can't tell if you have a vacuum supply line going into the firewall grommet or what. I assume you're not the original owner?
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