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    Body mount area rust on '03

    Here's my tragic Expy frame story if you care for some light reading and commiseration: Tragic Bad Frame Expy story
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    Not starting.

    Battery sounds good. Pull the terminal connections make sure the posts and inside of the terminals are clean and bright. Use a battery post and terminal cleaner tool. Check your terminal connections to the cable to ensure they are crimped tightly and have full contact with clean copper. When you...
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    Body mount area rust on '03

    The front radiator mounts are as notorious for rusting out as are the rockers. I'd also make sure they check the rear mounts which are up underneath the rear quarters and easily missed. Rarely do just the front mounts rust out alone. The others will likely be showing some flaking. If they are...
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    Blown spark plug repair

    As promised Link to How-To Calvan kit installation video Amazon replica kit I used Amazon Calvan replica kit The real deal Calvan kit Calvan Kit on Amazon
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    Blown spark plug repair

    Follow-up: After I installed the insert I eagerly started up the Expy. The result was underwhelming. It wouldn't hold idle, and was misfiring like crazy. Codes were P2195 and P2197.. both banks too lean. Plus a few misfire codes on 1 & 6. WTF? I immediately thought I forgot to reconnect a...
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    I just replaced my air compressor for the second time less than 2 months 2004 expedition it was blowing cold air now the air compressor not working

    Im guessing you mean A/C compressor? Few more details would be helpful. Like did you do it, or was it a shop? Did they use OEM or aftermarket parts? What problem led to you replacing it, etc. Thanks!
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    Blown spark plug repair

    For BigOleFordFan: 2004 XLT 4.6l Triton 2V V8 Short story: If you pull a sparkplug in your used Ford Triton 2V V8 and discover that cylinder has been repaired with a cheap auto store (HeliCoil, Save-A-Thread, Carquest, etc) kit then do yourself a favor, bite the bullet and order the Calvan or...
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    Triton eating #4 spark plug

    Most likely solution is also the simplest, under torqued, non-OEM plug. Pick up a MC plug from a reputable auto shop or dealership. Amazon, et al, are notorious for selling Chinese knock-offs as OEM. Makes sense, #4 is a biyatch to get to torque down properly. I'd get a MC plug and make sure...
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    Blown spark plug repair

    Hi crew, Lemme tell you story... about the Expy-man blues.. So I got a check engine light and rough idle the other day peoples, I checked the code and it was cylinder 3 misfire. Figure bad plug or coil or both, I don't know...so I went to work and pulled both. Discovered the problem...
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    Battery dying while driving

    Woah! 4.2 Amps draw, is that with the engine running or off??? If the engine is off 4.2A is a pretty hefty draw. That's definitely not any kind of single dome light, clock, stereo, etc. Do you have any aftermarket accessories installed that may be drawing that? CB Radio, aftermarket stereo amp...
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    Expy died with no warning and then revived itself. Thoughts?

    All great replies: 99WhiteC5Coupe - just cleaned and lubed about 2k ago at last oil change. Didn't know about the oil pressure switch, you could be on to something. Going to research that one, any help on where it is and how to test it? FastCar: my thoughts also. One of the 278 electrical engine...
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    Expy died with no warning and then revived itself. Thoughts?

    Hi all, Yesterday on my way to a job site, after a 45 min drive, 20 of it in stop and go traffic, I just got off the highway and started up a slight incline when the Expy shut down. No power, revs to 0, Red Check Gauge light came on, Oil Pressure was at Zero (!), still had electrical power...
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    What to look for when buying a gen 2 expy

    if the buyer chooses to purchase a rotted out POS that might drop the rear end out at the first hard speed bump it hits thats between them and their state laws, or lack thereof. I'm just pointing out the fact that if you are planning the purchase of an older model Expy that there is a possible...
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    What to look for when buying a gen 2 expy

    Of all the things mentioned here the #1 issue you MUST look for is: RUST I'm not talking about surface rust or the little bits of flakiness here and there and especially not the rocker panels which we all know will probably be either completely rotted away or just a paint shell. I'm talking...
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    Bar's Leaks to mend a 5.4L crossover coolant leak at intake-head joint?

    I've used Bars on a very worn (310k miles) Dodge 3.8l V6 that had a slight head leak. Oil in the coolant and seepage. It helped some and didn't wreck the engine but I know I'm on borrowed time. I will limp it along until it finally lets go but it's an occasional use vehicle and not a daily...
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    5.4l Coolant Manifold crossover leak

    Hi Mako, yup, nearly the exact same experience I had. If you are lucky, it could just be the rubber gasket that failed. Pulling the manifold is a pretty big job but doable if you are a DIY kind of guy. Not sure why Ford chose to make a connection that is prone to fail (heat cycling plastic to...
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    5.4 vs 4.6.. thoughts and impressions

    Not to beat this dead horse too bad... :) I see this issue come up often, and now that I have owned and daily driven both I have a few thoughts on this for those considering a 4.6 or 5.4 2V Triton. Power: 5.4 wins hands down. I noticed the difference immediately when test driving the 4.6 Expy...
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    5.4l Coolant Manifold crossover leak

    I know this is a thread res but just an update. Unfortunately I let this truck go. I was going to do a write-up but given all the issues I had with this truck plus the rusted frame/body mounts that would never pass inspection without thousands $$$ in repair I decided it was not worth the time or...
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    New to me 2004 Expedition maintenance?

    Hello team, I picked up an high mileage (248k) 04 XLT 4WD 4.6L back in August for a real good price. Not in the best shape but the frame, motor, and drivetrain were solid. Have driven it daily to 10k (now 259k), enough to know it's fairly reliable and have decided to hold on to it. I've done...
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    2004 Ford Expedition - Best Recommendations to improve night time driving

    I agree with others regarding plastic lens glazing. If your lenses are even slightly yellowed or glazed over it can greatly affect your beam pattern and brightness. Polish or replace glazed lenses and leave them stock. Even driving on pitch black rural roads with deer, downed trees, and other...
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    5.4l Coolant Manifold crossover leak

    It's been a while but just now getting back into fixing the Expy. The top end is literally completely apart and I'm assembling the parts I need to get it back on the road. Trying to source the intake, has anyone ever tried this brand? ATP brand intake I know, I know, OEM is the best bet but...
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    5.4 3V Engine Timing Chain Replacement walkthrough video

    To my understanding, Expeditions had the 5.4L 2 valve V8 until late May of 2004. After that they used the 3V 5.4L V8, hence the confusion. Ford swapped engines in the middle of a production year. If you have an 05 then you have the 3 valve version.
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    5.4l Coolant Manifold crossover leak

    Tech Note about Valve Covers: Despite the intake manifold and all the lines and Tubes being out of the way, there were still some gotchas that are worth noting. Driver side: this was the easiest side but I still had to remove the bracket that holds the power steering fluid reservoir. I also...
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    5.4l Coolant Manifold crossover leak

    Cleaned up the engine (mostly) and pulled the valve covers this weekend (pics to follow). Far easier without everything in the way! The cams and everything in there look pretty good. The passenger side has more color than I would really like but not sure how I could clean that other than a wipe...
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    5.4l Coolant Manifold crossover leak

    Was able to pull the plugs today, that was a lot easier with everything out of the way. BUT I made a truly horrific discovery. See the pic.. warning! If you are squeamish you may want to scroll past it... NOOOOOOOOO! Oh the horror! The humanity! Why God, whyyyy??? Really though, why? The OEM...

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