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  1. BlackCoffee

    Rattling noise

    Same thing happened to me. I should have remembered the converters. If you have a lift, or are doing this under the car, I can give you a little bit of an edge on removal and installation. You will find it fun trying to get the pipes installed. Support the transmission, remove the transmission...
  2. BlackCoffee

    Rattling noise

    You can place a remote microphone on each side and see if you can isolate the sound when it occurs. I am not sure the rattle is connected with the 4H problem. A rattle sounds more like a mechanical problem, like a bearing going bad. Does the rattle occur when you are in park. Sometimes the...
  3. BlackCoffee

    Rattling noise

    Are you sure it is from the wheel. If so, it could be the hub which contains the wheel bearing. You can replace it yourself, but it involves removing the knuckle from the ball joints. The hub also controls 4-were drive.
  4. BlackCoffee

    Error when Calibration Steering Angle Sensor (SAS)

    Thanks, time to learn something new and take the next step. I have seen references to FORScan before, but never had the need to flash one of the systems. I have used engine loaders like SCT Livewire to put a tune on, but not had the need to go further. I will download the program, get the OBD...
  5. BlackCoffee

    Error when Calibration Steering Angle Sensor (SAS)

    OK, time to get into the weeds. I lost all communication with my old ABS module. Got it back momentarily, but now it won't talk with the scanner. It is accompanied by the flashing AdvanTrack skid marks. So, as any red blooded American male on holiday, I went to visit my favorite junk yard dog...
  6. BlackCoffee

    Error when Calibration Steering Angle Sensor (SAS)

    Did the whole front end on my 2003 Ford Expy EB. Needed an upper ball joint, so I did upper, lower, strut assemblies. While there, I did the speed sensors. Now I have the C-1998 calibration and C-1730. I will do the pinpoint tests on the C-1730 which appear to look at the pressure sensor (should...
  7. BlackCoffee

    Tuners

    I rebuilt the engine and got a couple tunes from 5 STAR loaded with the SCT Livewire. Not really sure they made all that much difference. I had to replace the OEM cams with a CompCam since they are pretty much unavailable. They have a little more lift (advertised as close to stock). The engine...
  8. BlackCoffee

    Power Window Dead 1/2 Way Down

    OK, it's been a couple day so I will jump in. Since you know there is a kid's lock, of course the power to the other windows goes through the driver's master. You can check this by turning it on/off and seeing if the other windows react the same as the the rear PAX window. If with the kids lock...
  9. BlackCoffee

    Click from starter Relay No start

    If the starter is turning, it is not the starting circuit or the security module. If the engine is not turning it could be the starter is not engaging or it is the ring gear. If the engine turns, I would look into a fuel condition. Check fuel rail pressure and make sure the fuel cutoff switch is...
  10. BlackCoffee

    Click from starter Relay No start

    I can 't tell from your description if the starter is turning or not. If it is turning, but the engine isn't turning, you may have lost teeth on the ring gear and it is just spinning. If the starter is not turning it is either power to the solenoid, or power to the armature. Put a voltmeter...
  11. BlackCoffee

    Click from starter Relay No start

    I would do a pinpoint test on the starter circuit. It looks like you have a short and the relay took the brunt of the problem. Hamfisted makes a good point. When you say jumping the relay turns the starter, does the engine actually start? If not, maybe the secondary fuel pump relay overheated...
  12. BlackCoffee

    20 year tune up questions.

    The pedal going all the way to the floor doesn't right. I have an 2003 EB with 270K miles. I have done several brake jobs and each time the pedal travel is good. I have tried several aftermarket pads, calipers, and rotors. Other than the pads themselves, good stock rotors and calipers work...
  13. BlackCoffee

    New engine or new vehicle ?

    When I rebuilt the engine and transmission, replaced a few air conditioner parts, and did a lot of updating it ran about $5K with my own labor. Just a couple of things I worry about. First, just because you live in the south doesn't mean you don't have rust. Most of the rust is from water that...
  14. BlackCoffee

    New engine or new vehicle ?

    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...
  15. BlackCoffee

    Difficult to Start - Problem with shifter

    This may help you. It is from the 4R70W rebuild video for adjustment of the Transmission Range Sensor (TRS) and how to align. Fast forward to 59 minutes and you will see the mounting and adjusting of the TRS. If it is aligned, you may need to replace the TRS. Not a big project. AODE 4R70W Class...
  16. BlackCoffee

    2003 5.4L - Transmission cooler + other upgrades for towing?

    This might help you find the connectors on the harness. The brake controller is C2142 near where the ODBII connector is mounted. The 7-pin Trailer connector comes out of the harness next to the 4-pin and is C4099 .
  17. BlackCoffee

    2003 5.4L - Transmission cooler + other upgrades for towing?

    The 2003 Eddie Bauer has a connector just above the gas pedal to hook up a brake controller. My EB Bauer came with the Towing Package so the 7 pin connector at the hitch was installed. As for the connectors, I am not sure, but I would think they are part of your harness. I don't think they had...
  18. BlackCoffee

    Engine fan always on plus new oil leak

    This engine does not have a valley pan similar to an push rod engine. Under the engine is the valley between the cylinders, but no place for oil to leak. I doubt it is a head gasket, more likely the valve cover gasket or the oil pan. If the head gasket were leaking that much oil, you would also...
  19. BlackCoffee

    Engine fan always on plus new oil leak

    Do you have a 4x4 or 2x4? There is more room to work underneath if the front axle is not in the way. It is hard to get all the bolts out if you don't remove the power steering pump, but it can be done. When you get the adapter off, sometimes it is a little corroded and needs have the surface...
  20. BlackCoffee

    Coolant pressure

    I would vote for a bad head gasket as well. Although, the coolant cap should allow the pressure to bleed off when the coolant cools down. How far do you drive to work and do you get an overheat lights at all? If coolant is flowing back into the cylinder because the head gasket is leaking, you...
  21. BlackCoffee

    Engine fan always on plus new oil leak

    A couple of things. With the amount of oil you have, it probably has been leaking for years. Some of your build up is not from just the last six weeks. Oil filter adaptor. You can replace the oil filter adaptor gasket, but be ready for a job. Coolant also flows through the adaptor and you will...
  22. BlackCoffee

    03 ford expedition Transmission support

    Doesn't sound like a transmission mount. Not sure what you mean by "drags real hard." If it is not accelerating, you may have a problem in the transmission. If it is just vibration, you may want to check the U-Joints. The bell housing bolts the transmission to the back of the engine. There is...
  23. BlackCoffee

    Service engine light on

    Go back to Autozone and find someone that knows what they are doing. "Check Engine Light" is a generic term. On the Ford Expo it is labeled "Service Engine Soon." Plug the code reader into the connector under the dash by your right knee. The code may be something minor, or your engine could...
  24. BlackCoffee

    Losing transmission fluid.

    I like my 18V Milwaukee, but it does seem to max out at about 140 ft-lbs. Had to take off the front drive shaft from the transfer case when I did the tranny. It took soaking the bolts, heat, and an air impact to get them off. Two of us, and it still took an hour for six bolts.
  25. BlackCoffee

    2003 Expy possible Heater Core, how to make sure

    Just a thought on Evans. Make sure you do a good flush before hand. I used Valvoline Zerex, Radiator Super Cleaner, ZXC02 for a complete flush. For antifreeze I used Valvoline MAX LIFE AntiFrieeze, G05. Happy with products The last time I rebuilt my 5.4 (2003) there was a lot of buildup inside...

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