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  1. whtbronco

    Seat covers - real replacement covers

    So we have finally worn through the outside edge of the driver seat on our 2004. At 316k miles it's no surprise, even more so considering I had to slide out for about 10yrs due to substantial physical issues. The rest of the leather looks nearly new. The vinyl on the outside of the driver...
  2. whtbronco

    2004 DATC driver side blend door actuator failure write up

    The driver side blend door actuator, the lower one, failed on my 2004 recently. The typical knocking noise was the telltale and impacting the driver side it was obvious which one. There’s excellent write-ups and videos on the passenger side already, which by the way is much easier to get to and...
  3. whtbronco

    Idler pulleys, just some bearing observations

    My 2004 Expedition with 5.4L developed a light engine speed vibration about a week ago. It's primarily noticeable in gear. Anyway, today I decided to check the pulleys and accessories. I didn't actually finish checking them, I checked the alternator and the 3 idler pulleys. Having found that...
  4. whtbronco

    Rusted A pillar

    I decided to take a few days and repair the driver side rocker panel on my truck. The lower B pillar support had rusted similar to the passenger side so I figured it would be a fairly easy repair. I was shocked when I stuck my endoscope in the opening I had cut out to find the C pillar in...
  5. whtbronco

    Timing set and a startup anomaly question

    I've heard light chattering from the timing chains at startup for a while on my 2004 5.4L 2V, 299k miles. 42 days ago I started it and immediately it revved to 2300-2400rpm. By the time I looked at the tach it stopped increasing and dropped back to 1200-1300 like normal at cold startup and then...
  6. whtbronco

    Gen 2 Body Mounts and info

    While replacing the passenger side rocker panel I found the #2 passenger side lower body mount bushing was dry rotted. I ordered a replacement and when I pulled it apart much to my surprise I found the inside of the upper body mount was pretty much rusted away. So I've been looking for a...
  7. whtbronco

    Replacing a rocker panel

    My passenger side rocker panel rusted out. I intended to replace it October 2023, but it got put off due to an accident and vibration issues. Now it's finally back to the top of the list. I got started today and found what appears to be a support bracket that goes from the B pillar to the...
  8. whtbronco

    SOLD: BW4416 rebuilt transfer case for sale

    I have decided to sell the transfer case I rebuilt for my 2004 Expedition. The rebuild description and pics start on page 4 of the thread noted below if there's any interest. It works fine after the rebuild and I ran it for a few weeks. Had the front seal not leaked a little, 1/2-5/8" spot...
  9. whtbronco

    Not so Good Vibrations

    So I've been chasing vibrations in my '04 Expedition for quite a while, 288k miles. One I was certain was the A/C compressor, and had made plans to replace it. I'm totally lost on this, but after replacing the fuel pump my wife said the engine was running smoother and the vibration was gone...
  10. whtbronco

    2004 Expedition - help me identify this rusted box driver side rear corner

    Seriously what is this box for in the driver side rear corner just below the tail light? I can't figure out what's in it. Can't get to it from the tail light recess. Ford generally doesn't produce something like this for nothing and it's not the same on the passenger side. There is a formed...
  11. whtbronco

    2004 fuel pump failed and replaced(long story with tech info)

    I did a fair amount of research, but was not as prepared as I thought I was. So I typed up my 3 day fuel pump replacement experience. This is long, but does include a little bit of useful info in the midst of my rambling. Just thought I'd share the fiasco(err I mean story), since I always...
  12. whtbronco

    No longer available: 2004 rear seat DVD player, screen and headphones

    Not sure if anyone has any interest, but I thought I'd see, maybe this stuff can help someone with young kids. I have no interest in making any money, parts are available for the cost of shipping. I removed the rear seat DVD player from my 2004 Expedition. The electronics worked fine, but the...
  13. whtbronco

    NOS vs Aftermarket wheel bearing hubs

    I'm chasing a speed related vibration that begins about 35mph and increases. I have been searching for it and replaced the rear driveshaft slip yoke which eliminated the coasting vibration I had, of course the u-joints as well. The only other thing I have found is that when spinning the front...
  14. whtbronco

    Various module communication issues and J2534 adapter suggestion

    BLUF: looking for a J2534 pass through adapter verified to work with the Gen 2 Expeditions for Forscan troubleshooting Long version/story: My wife called to say that Message Center showed Tire Pressure Monitor Fault on our 2004 EB. BTW, I think EB stands for too much crap. She was 400 miles...
  15. whtbronco

    Rear brake/hub issue

    I went to adjust the parking brake on my 04, the parking brake on these is as many have found the most frustrating and challenging brake assembly I have ever deal with. Drum brakes are no problem for me, these are special. I found that my rear rotors were not running true, like they had warped...
  16. whtbronco

    Head unit display too bright

    So I installed a Kenwood DPX794BH head unit(non-touchscreen) in my 2004 EB and I really like the sound quality. I sure thought that with a display brightness range of 00-31 it would dim a decent amount. Nope that range is really more like 15-31. I'm using the 00 setting for day and at night...
  17. whtbronco

    04 EB factory 4ohm sub amp with 2ohm load?

    I have been pondering this, and yes I know it's questionable, but I like thinking through things and tinkering. My 04 Exp came with a 4ohm amp for the sub, which differs from the 2ohm amp in every other 2nd gen I have seen. Any idea if the 4ohm amp can handle a 2ohm load? Obviously I'm...
  18. whtbronco

    Introduction from the top of Virginia

    I'm clearly new to the forum. I've owned my 2004 EB 5.4L since new, it's now got 260k miles. This is the first truck I have ever owned that remained mostly stock. All others were lifted typically with 38" tires or bigger and all Fords. Generally speaking no one touches my vehicles. I do all...

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