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  1. BlackCoffee

    2003 Expy possible Heater Core, how to make sure

    The Expo has a problem with the heater hoses being above the water bottle. If there is a leak, a bubble can form in these hose while the car is sitting overnight. Coolant leaks out, and when the car is started, the bubble prevents coolant flow. What generally happens is the temp rises, sometime...
  2. BlackCoffee

    Intake Manifold -5.4L 2v

    If you are getting codes on the number one cylinder, you may have a different problem. Depending on your level of mechanical ability, it is not much more work to pull the heads. Sure, you may be getting coolant in because it is entering the intake manifold, but it could also be a breakdown of...
  3. BlackCoffee

    Transmission?

    At first, it sounded like a fuel problem. But, it the engine runs and idles fine, just won't move, it is the drive train. I rebuilt my transmission at 252K. It wasn't as bad, just lost overdrive. It could be the torque converter, but you need to remove the transmission. So, it's time to make a...
  4. BlackCoffee

    Rotors at 23k miles?

    I think you should give some thought to what warped the rotor. It may be from overheating the brakes because the pads or rotor aren't dissipating the heat. This could be loads and braking technique. Better pads and rotor may help in this area. Or, at one point, you mentioned it sat for a couple...
  5. BlackCoffee

    Fuel data error

    Sounds like your float has gone bad. The fuel level sending unit is part of the fuel pump. If you show no other symptoms, it sounds like an indication problem. It's time to drop the tank and check the pump/sending unit. if you remove the pump, you can check the resistance across the float as it...
  6. BlackCoffee

    2005 Eddie Bauer - front A/C stops blowing air - Looking for some advice

    If you run the A/C in the garage for any length of time, you should see a puddle of water on the floor where the drain is located. Just under the firewall, in front of the PAX. If you get under the car, you can locate the drain. It does sound plugged. The good news is that all the expensive...
  7. BlackCoffee

    Door Ajar

    WD40 works if the plunger is stuck in and doesn't come out when the door is actually ajar. This is usually what happens when the radio won't shut off. When the door opens, the plunger closes the circuit. If you have a constant door ajar, that means the switch has shorted internally and WD40, to...
  8. BlackCoffee

    Fluids 07 new motor break in?

    I rebuilt last year, got 15K on the engine now. Same thing, since you're in Arizona, I would go with 30W oil for the break-in. I used 30W for 300 miles, changed oil and filter refilled with 30W for another 700M (total 1000), then went with 5-30 full synthetic. For cooling, I went with Valvoline...
  9. BlackCoffee

    2003 EXPEDITION NO AUTOLAMPS,INTERIORLIGHTS, RADIO STAYS ON

    Search under door ajar sensor. Some people solve this by replacing the door ajar sensor. In my case it turned out to be the ETAC box putting bad info on the UDP buss. Another symptom is the chimes for the key in and lights on. Here is the thread...
  10. BlackCoffee

    Door Ajar

    If the door ajar is always on, it is not the plunger pin getting stuck, it is probably a switch failure. This will help a little. Plunger out, door ajar, relay is closed. So, if you have a failed switch, it could be a switch or the wires to the switch are shorted. If you disconnect the switch...
  11. BlackCoffee

    Brake Pedal Sinking to floor

    It's time to find a reliable junk yard that will let you pull parts. The good news is that when you pull it yourself, they usually only charge 15-25 bucks depending on the part.
  12. BlackCoffee

    Door Ajar

    Having just gone through a related problem, the door ajar lights feeds the vehicle security module. Always on, may not be as bad as always off. There are systems that respond to the door ajar switch like the radio, lights/key chime, seat adjust, and anti-theft system. If you can still adjust the...
  13. BlackCoffee

    2003 Cranks but will not fire

    I replaced the control board relay and it was not hard. I used this video for reference. If it is bad, it should be obvious on removal of the board. It will look burned. Anyway, with the age of your Expedition, it can't hurt. Here is the video: I got the relay of Amazon...
  14. BlackCoffee

    Brake Pedal Sinking to floor

    Since you did replace the brake booster, did you orient the rod correctly. If the booster rod had an offset, it must be orient down. If that is not correct, the booster will not operate correctly. Here is the booster check.
  15. BlackCoffee

    Its almost time for new tires. Oh no!, a tire thread!

    I am also a Michelin guy, you can usually find a buy three get four deal. I like some of the Goodyear tires for my passenger cars, but you really have to pick the correct tire. Not a fan of the wrangler or kevlar tires. I usually look at road noise and wet performance ratings. Road noise is...
  16. BlackCoffee

    Door Ajar Switch and 4x4 Flashing

    See you on on the Straygoose page. Go Maynard!
  17. BlackCoffee

    Brake Pedal Sinking to floor

    I reread and it sounds like you get good brake engagement initially (after the car was running and the booster was working) and then the brake pedal continues to travel to the floor. You suspect a leaking hydraulic valve in the ABS unit. If it were a leaking valve, you would eventually lose...
  18. BlackCoffee

    Brake Pedal Sinking to floor

    Pedal going all the way to the floor is usually an indication of a bad brake booster. They are not hard to replace, I did one at the beginning of the summer on my 2003 EB with 262K. You won't have to bleed the brakes again, just detach the new master cylinder, replace the booster, and put the...
  19. BlackCoffee

    Window Regulator

    There are a few sizes used. They will be metric. You can stop by a good hardware store and grab a few different sizes and threads for comparison. You can also go to some of the Ford Parts sites, or your dealer, and they have parts diagrams that list the bolts. From what I can tell, they are 6mm...
  20. BlackCoffee

    Door Ajar Switch and 4x4 Flashing

    Finally, I may have the solution. It looks like a bad DEATC was taking out everything on the UDP buss. Indications got worse and consistent. Finally, advance track wouldn't come on. I was suspicious of the VSM, but starting looking at other boxes on the network. I had a spare EATC that I picked...
  21. BlackCoffee

    Door Ajar Switch and 4x4 Flashing

    Thanks, AF Spec Ops 1982-2002 Retired at 20.
  22. BlackCoffee

    Door Ajar Switch and 4x4 Flashing

    Thanks Hamfisted, I knew you would weigh in on this problem. I just put the new door ajar sensor in. Let me get a few cold morning before I know it is fixed. As for the 4x4 flashing. I checked and no primary or secondary codes are set. The other interesting thing is that when I get rid of the...
  23. BlackCoffee

    Door Ajar Switch and 4x4 Flashing

    I have two problems that seem related, but don't know why. The radio won't turn off when the key is removed and door opened. The chime does not work for lights or key. This seems like the door alarm switch on the driver's door. But there is more. The seat adjust and exit does not work. The seat...
  24. BlackCoffee

    what IS this thing

    Not all original torque converters can be drained. It depends on which one Ford installed.
  25. BlackCoffee

    Engine Replacement Option/Decision

    Here is the corrosion around the lower radiator support. You don't notice it unless you are looking for it.

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