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    Ignition Coil Pack Bolts - WTH SIZE ARE THEY?

    Thanks, @Hamfisted! When I put things back together, I was thinking about finding Grade 8 bolts to reinstall. Those two back ones are too hard to reach to be f-ing around with them!
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    Ignition Coil Pack Bolts - WTH SIZE ARE THEY?

    Thanks for the input, gentlemen. I feel kinda' stupid that I simply didn't notice I had a couple of fairly rounded bolts on the front two packs of Bank One. Took some persuading with a ball peen to loosen them, but we're good now.
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    Ignition Coil Pack Bolts - WTH SIZE ARE THEY?

    Can someone tell me what size wrench I need to remove the coil packs from my 4.6L 2003? These things are starting to piss me off. The bolt head is bigger than 6mm, way smaller than 8mm, and 1/4" is just a hair too small as well. Is there a special tool? I actually put a caliper on the one that I...
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    Probable Vacuum Leak on A/C Recirc Door?

    Ham: Thanks for the vac system diagram! Allow me to walk through what I think I'm looking at, just for clarity. - Recirc Door actuator is @9, the door itself @8 - Floor/Defrost actuator is @1, with dual vac inputs - Panel Vents actuator is @14, with dual vac inputs Question: On the diagram...
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    Probable Vacuum Leak on A/C Recirc Door?

    Happy Friday! My wife's 2003 Expy has a small problem in the a/c that I need a little help with. When you set the a/c control to MAX, the air flow through the dash vents works just fine at idle, but as soon as you hit the throttle, the blend door eases closed and the air diverts to the defrost...
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    Lower Control Arm Bushing Replacement ?

    Ham: Dang, I was afraid you'd say that. I have two problems with that. 1.) Just on principle, if you have a part that you sell a replacement for, you should be able to install said part. Simple. 2.) On a 17 year-old car, I don't want to invest in the cost of dealership parts, and getting them...
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    Lower Control Arm Bushing Replacement ?

    So I took both LCAs off of the wife's '03 2WD XLT yesterday to replace all four of the bushings. Found out that no rental / loaner ball joint / bushing press is big enough to reach around all the pieces and press them out. Took the arms and my new bushings to a local shop (highly recommended by...
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    Need Some P0405 EGR Halp, STAT!

    UPDATE - This dang thing is driving me crazy! Here is the latest: Took the valve itself off a few days ago and gave it an inspection and cleaning. Didn't have any noticeable carbon build-up in the valve body but gave it some carb cleaner anyway. Verified valve opening and closing fully by...
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    Need Some P0405 EGR Halp, STAT!

    For whatever dumb reason, that's pretty much the only thing I haven't done. Let me pull it and do a thorough cleaning. Thanks for the input.
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    Need Some P0405 EGR Halp, STAT!

    Morning, folks! I seriously need some advice on my wife's '03 XLT 4.6L. I have a recurring (off and on for the last year) P0405 code for "EGR Sensor A Circuit Low" and now, new just this morning I have P0403 "EGR A Control Circuit". MUST get these corrected for state inspection here in Texas...
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    How many miles on your 2nd Gen Ford Expedition?

    2003 2wd 4.6L: 415,000 without any really major issues. I just put a new timing set on it two months ago, which was a chore, but manageable.
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    Timing set install done. Trouble Codes Abound!

    Thanks, Stamp. I don't know why I didn't think of RTV. Job is done for now (#1 - #4 are good to go).
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    Timing set install done. Trouble Codes Abound!

    USPS: I was thinking about small zip ties, but didn't get out in the rain today to investigate. Stamp: Do you mean a ring of RTV around the "male" connector on the injector/coil, then slide the plug down over it?
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    Timing set install done. Trouble Codes Abound!

    New update: Need some suggestions. Car is running fine, most of the time. As I mentioned above, the engine wiring harness (particularly on the passenger side) has at least a couple of plugs (injector and coil) with the locks/latches broken. They are just loose enough to slip off far enough to...
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    Timing set install done. Trouble Codes Abound!

    Bump/Update: I went through the injectors one by one and figured out the loose plugs from the wiring harness to the injectors (20 years of repairs have broken the little latches on too many of the plugs all the way around that harness. But I digress.) Today's status: Got all of the injectors...
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    2003 Expy Timing Chain Done

    P0203, 0204, 0205. Cylinder x Injector Circuit / Open
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    Timing set install done. Trouble Codes Abound!

    I just finished the install of a timing set on my wife's '03 4.6L 2V, and I am having issues. Everything is back together, I replaced the crank and cam position sensors and plugged everything back up. Idles with just a hint of a stumble or a miss somewhere. I put the code reader on it and was...
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    2003 Expy Timing Chain Done

    Glad to see yours went smoothly. I just finished the install of a timing set on my wife's '03 4.6L 2V, and I am having issues. Everything is back together, I replaced the crank and cam position sensors and plugged everything back up. Idles with just a hint of a stumble or a miss somewhere. I put...
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    Troubleshooting An A/C Recirc Door Vacuum Problem

    Update to the update: Progress made, although not 100%. I did a thorough visual on that vac line and snugged up all the fittings. Pulled the small canister from the fender behind the battery and the connection to that canister may have been a bit loose. I put it all back together and gave it a...
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    Troubleshooting An A/C Recirc Door Vacuum Problem

    Damn, Ham, that is what I call a full-service reply! Not just anyone goes ahead and looks up the parts I might need. Thanks! Now, a clarifying question. I have good vent selection function at the dash controller (REG a/c, heat, defrost, etc. and temp/blend door), with the MAX a/c recirc door...
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    Troubleshooting An A/C Recirc Door Vacuum Problem

    Update: Believe I've found the vac line running across the top of the firewall with a tee fitting feeding a very small diameter vac line that goes through the firewall high on the passenger side.That line goes around the back of the battery to the small vac reservoir canister? I'll give that...
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    Troubleshooting An A/C Recirc Door Vacuum Problem

    Need some guidance on where to start looking for a vacuum problem. This is my starting point: 2003 Expy, standard climate system (NO EATC) A/C will work fine in "Regular" a/c mode (at least getting as cool as it can in town with outside air in 103 Texas heat). "MAX (recirc) mode works only at...
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    '03 4.6L - Battery Warning Light

    I've got the "battery warning light" issue, but I believe perhaps not quite the same symptoms I see in other posts, So, excuse the repetition if this has been addressed. At cold startup, the warning light will take several minutes to come on, and will occasionally cycle on and off...
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    A/C Recirc Door Vacuum Problem?

    Thanks for the input while I've been away! :) Looking at the climate control diagram (and thanks for that, @BRIANGEE), in my case it looks like everything is working OK except for the recirc door. Heater control valve is on the same line (other side of a tee) and is functional. So I need to...
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    A/C Recirc Door Vacuum Problem?

    Thanks for the input. No, we are not EATC, so I'm looking for a vac leak. @Bain64, man would a map of the vac system be wonderful to have! So, with the problem only in recirc mode, is there a vac line that branches off of the line to the reservoir bottle that comes through the firewall to the...

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