Gen 2 Body Mounts and info

[whtbronco]

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 replacement upper bushing now. I'm also wondering if I pull the others apart to replace this one will I find more of the same thing. It certainly appears that the passenger side radiator support body mount and the driver side #3 body mount of

The part number molded into the lower #2 and #3 bushing is 2L74-7800193. I ordered a replacement from eBay . Supposedly it's the same as 2L7Z-100015-KA.

I found the Ford part numbers using a link to Ford Parts Giant that Hamfisted and others provided in a another body mount related thread.

Body mounts verified via the local Ford dealer:
Ford 6L1Z-1000155-BA - supposedly does not fit 2004 (5/2005 +)

Ford 6L1Z-1000155-FA / 7800193 - lower radiator support 2 required. $14FPG
Ford 2L1Z-1000155-FA replaced by 6L1Z-1000155-FA. Base # 00154C
Ford 2L1Z-1000154-FA / 7800192 - upper radiator support 2 required.
$14eBay $21FPG $30.37msrp, Base # 00154E
Ford 2L1Z-1000154-AA - position #1 w/2 mounting flanges 2 required. $45eBay
(there's only 1 mount/bushing for #1), Base # 00154A
Ford 2L1Z-1000154-BA - upper position #2, 2 required eBay $65, Base # 00154B
Ford 2L1Z-1000155-BA - lower position #2, 2 required. Base # 00155A
Ford 2L1Z-1000154-CA - upper position #3, 2 required, Base # 00154C
Ford 2L1Z-1000155-CA - lower position #3, 2 required, Base # 00155B
Ford 6L7Z-1000154-LA - position #4, 2 required, Base # 00154D

I'm still trying to find the exact body mount location for most of the above part numbers.

I found these part numbers on AllData, and I started adding some measurements:
Radiator support body mount:
8052 - (RH) bracket assembly
8053 - (LH) bracket assembly
7800192 - upper body mount 1.38" tall, 2.79" bushing/washer diameter
7800193 - lower body mount 1.40" tall, 2.52" bushing/washer diameter, 2.79"
78001B39 - radiator support body mount bolt

#1 body mount:
W506433 - bolts (2 of them)
7800192 - upper body mount with bracket (no lower bushing)
W708210 - lower washer
W708330 - body mount bolt

#2 body mount:
7800192 - upper body mount 1.37" tall, 2.85" bushing diameter, 2.97" washer diameter
7800193 - lower body mount 1.19" tall, 2.54" washer, bushing 2.54-2.75" @ top
W708330 - body mount bolt

#3 body mount: same as #2
7800192 - upper body mount
7800193 - lower body mount
W708330 - body mount bolt

#4 body mount: basically under the tailgate though I have yet to lay eyes on this one
W708109 - body mount nut and washer
W506433 - body mount bolts (2 of them)
7800192 - upper body mount with bracket and a stud on top (no lower bushing)

I have been scouring everything I can find to come up with part numbers, sizes, available body mounts etc. Thus far this is what I have found. I found multiple threads about this so hopefully I will be able to continue to compile some more info and put it here.

It kinda looks like I may be heading down the custom path, but we'll see.

 

[whtbronco]

I updated the Ford part numbers listed in the original post using the info I got from the local Ford dealer. I have also attached the documents I got from the local dealer.

I needed a new COP boot and asked the gentlemen in the parts department if he could help me identify the body mount part numbers and associated location. Talk about helpful, though he as expected said he can't get me any of the body mounts.

Now back to trying to find body mounts. It's tough to find them and gonna be costly.

 

[whtbronco]

I have thus far located just 6 of the 16 bushings I need to replace all the body mounts, more info below.

My current thought/plan is to buy the radiator support bushings, buy the single #1 I found. I will begin trying salvage yards for used #1 and #4 mounts, the closest "you pull it" type salvage yard is 45 minutes away now and they have no idea what they have, you can come look. I will find some poly bushings I can buy that will either fit or can be modified to fit to replace mounts 2 and 3.

That said I am a bit concerned about mixing rubber and poly bushings since rubber crushes much more easily.

Ford 2L1Z-1000155-FA / 6L1Z-1000155-FA - lower radiator support. Found 2
Ford 2L1Z-1000154-FA - upper radiator. Found 2.

Ford 2L1Z-1000154-AA position #1. Found 1, need 2.

I believe based on the measurements and numbers molded into the factory bushings that that the lower bushing for positions 2 and 3 are identical despite the different Ford part number.

Ford 2L1Z-1000155-BA - lower position #2. Found and installed 1, need 1 more

I can't find any of these that are available:
Ford 2L1Z-1000154-BA - upper position #2

Ford 2L1Z-1000154-CA - upper position #3
Ford 2L1Z-1000155-CA - lower position #3

Ford 6L7Z-1000154-LA - position #4.

 

[whtbronco]

Thus far out of the 16 bushings I am trying to acquire I have 3. I have another enroute that I believe will be correct.

The upper radiator support bushing that I ordered is not right and the others I can find that have pictures also show the same thing I received. The part number needed is 2L1Z-1000154-FA. The part number received is AL34-7800192-FA. So back to the drawing board on this one. The bushing on the truck is old, installed and thus compressed, but it measures 1-3/8". The replacement I received measures 1-3/4". I don't think the new bushing will crush 3/8" it's awfully hard, maybe 1/8".

I don't recall ever installing rubber body mounts though, I always replace with poly so this is sorta new ground for me. Poly bushings don't compress. I'd get poly bushings for the Expedition, but there are none made for it and finding ones that will work will take some serious time assuming it's possible. The #1 and 4 position bushings being the real issue with poly bushings.

#1 and #4 are 1 piece bushings like the picture, the other 3 positions are all 2 piece more traditional.

 

[whtbronco]

My quest continues. I've still had no luck finding replacements for positions 2, 3 or 4.

My plan for the #2 and #3 position mounts is to stop by the local dealer to see if they have any for of them in stock for 2007-2017 Expeditions. They look similar so I want to compare and measure them to see if they can be used as a replacement. If not I'll order some universal poly mounts from Energy Suspension and see if I can modify them to fit.

There's not much I can do about the #4 position body mount. Being a 1 piece pushing molded into a metal housing I'm not sure I could make anything work. Maybe the body mount for the 2007-2017 is an option. For now I'm just hoping they remain in usable condition.

If you have any suggestions or information to lend I'd like to hear it.

Here's a cross reference of Ford part numbers and what's actually molded into them. I plan to keep this list updated as I find more info. The molded in part numbers can be helpful for finding bushings on eBay since they are often used or NOS not in the original package so seller only has the molded in part numbers to list.

Upper Radiator Support (Official part number 2L1Z-1000154-FA)
Molded in: JL34-2500192-FA and JL14-2500192-FB and AL34-7800192-FA and FL34-2500192-FC. I bought 2 new ones. 1 came from eBay and had just AL34-7800192-FA molded into it, so I didn't trust it. I bought the other from a Ford dealer and it had all 4 part numbers molded in. Otherwise they are identical.

Lower Radiator Support (Official part number 2L1Z-1000155-FA replaced with 6L1Z-1000155-FA)
Molded in: 6L14-7800193-FB

Position #1 (single piece bushing) (Official part number 2L1Z-1000154-AA)
Molded in: 2L14-7800192-AB

Lower position #2 and #3 (Official part number 2L1Z-1000155-BA/CA)
Molded in: 2L14-7800193-CB and 6L14-7800193-BA and 2L74-7800193-KA

Upper position #2 and #3 (Official part number 2L1Z-1000154-BA/CA)
Molded in: 2L14-7800192-GA and 2L14-7800192-HA

Position #4 (Official part number 6L7Z-1000154-LA)
Molded in: 2L74-7800192-LA and 2L14-7800192-JA

 

[whtbronco]

I have new OEM bushings for the radiator support and the #1 position. I have 1 new OEM bushing for the lower #2 position and 1 used upper bushing for the #2 position. The used bushing is not in real good shape, but better than mine. The real issue with mine is the metal interior support has completely rusted away.

I have pretty much given up on obtaining the rest. I've found no OEM, aftermarket or used for positions 3 and 4.

I need 1 more lower bushing for #2, 2 upper bushings for #2, 2 upper and lower bushings for #3 and both bushings for #4(1 piece bushing). I might be able to get away without replacing the #4 bushings, they appear to be in usable condition. I'd just prefer to go ahead and replace them all.

I stopped by the local dealer to look at the #2 and 3 position bushings for the 2007-2017 Expeditions. They didn't have any of the 4 in stock. Wanted $200 to order them and $40 re-stocking fee if I don't want them.

Has anyone else dealt with this, if so how?

I have also considered buying the Dorman 924-064 which is a replacement for #2 and 3 positions on the 2007-2017's. I'm not sure if they will fit or if I can make them fit and I'm not keen on Dorman for the most part. However, the OEM bushings for the 2007-2017's clearly are not very good based on all the total bushing disintegration I have seen on them. At least if buy 1 of the Dorman bushing sets and decide it's not usable for mine I can give it to someone and at least do a bit of good for less than the restocking fee at the dealer.

 

[whtbronco]

I received the Dorman 924-064 which is intended for 2007-2017 Expedition body mount positions 2 and 3. It might work for 2003-2006 positions 2 and 3, it certainly would work as a replacement for the radiator support body mount though. It, as you can see, is almost identical to the OEM radiator support body mount I picked up. Dorman 924-064 on the left and Ford 2L1Z-1000155-FA(lower) / 2L1Z-1000154-FA(upper) on the right in all 4 pics. The larger of the pair of bushings is the upper portion, in pic 1 the top bushing is what you see.

I am concerned that I'd need to crush the upper bushing by 7/16" to match the height of my current body mounts. I know it's tough to cut rubber so trimming is not a good option for 4 sets of bushings. I've never installed rubber body mounts so I don't know how much they typically crush, maybe up to 7/16" is normal. Anyone know?

My primary concern with this project is what I will find when I take all 10 body mounts loose to inspect and replace some of them. Which is why I am trying to find a suitable replacement for all 10 before I start. The thought of trying to replace the original body mount that I found totally rusted out inside and not being prepared to replace them all really irks me. Power tools are not appropriate for this task so it will be a long day and several days of recovery for me, I don't want to do it twice.

 

[whtbronco]

Well the Dorman 924-064 that is for the 2007-17 Gen 3 doesn't fit for the #2 and #3 body positions on our Gen 2's. It would replace the radiator support mount on Gen 2's though.

I mocked up how it would be mounted on the truck so I could measure the amount it compressed. The lower bushing compressed about 1/2", the upper by 1/8". I needed the upper bushing to compress about 7/16". I could try cutting the bushing and the sleeve in the center, but cutting rubber with any accuracy isn't easy at all. Maybe a hot knife would work. However, I think I am at the point where I am going to just go with Energy Suspension 9.4102G universal polyurethane bushings. I think they will be much easier to cut and the sleeve is separate so I don't have to cut around it like the Dorman bushing. I can also calculate the compression of the 70a durometer poly used so I will know how much to cut it ahead of time.

However, this project will slow down some. It's time do a timing job on it.