Install F150 Bilstein 5100 or 6112 products on my 2004 Expedition?

[Vincent Vega]

I have a 2004 Exp and am considering installing the Bilstein 5100 or 6112 adjustable-height shocks (made for the F150) on the front of my Exp to improve the suspension off road, and to get about 1 inch lift without using spacers. The Bilstein 5100 does not include new coils, the 6100 does.
The 5100 and 6100 products are not offered for the Exp, but are for the F150. The front suspension for the Exp and F150 is very similar. One diff appears to be the spring rates. I don't know how diff they are, but it doesn't seem like a big deal because the weights of the two vehicles are similar.
Bilstein does offer the 4600 shocks for the Exp and the F150, so comparing the lengths of the 4600 shocks for the two vehicles seems helpful. Bilstein's 4600 info indicates that the compressed and extended lengths of the F150 4x4 shocks are about 1 inch longer than for my Exp. However, the Bilstein 4600 and 5100 products for the F150 2WD are almost exactly the same lengths as the 4600 for the Exp. Based on this, looks like the F150 products will my Exp because they are similar in length, esp the 2WD product.
I have seen a few threads about this, but nothing conclusive. I called Bilstein, but they were not helpful. I considered the Rancho 9000 Quicklift, but have read mixed reviews about them.
So even if it Bilstein's F150 parts bolt onto the Exp no problem, does it improve the off road performance? Or does it just not work well because it is designed for the F150 for some reason? Has anyone done this or know of a forum thread about it? Thanks

 

[OverlandExpy]

I've done hours of research online about this exact issue, but have not found anything conclusive either. There is basically no aftermarket true lift kits (not spacers) for 03-05 expys. There are TONS of lift kits for 150s, and I've been eyeing a few different 5"+ kits, but haven't pulled the trigger because I am not sure if the kits would fit.

It would definitely improve offroad performance if it fits. I've seen around these forums that the front end of the expy and 150 are very similar, but again have not found anything conclusive. I've been on the lookout for someone with a 150 in my area that I know so I can put it up on my lift and take some measurements, but haven't found anyone yet. The big issue I think would be finding a lift for the rear suspension as we have IRS and the 150 has a solid axle.

Good luck though and keep us posted if you end up buying the 150 suspension and let us know if it fits!

 

[Vincent Vega]

Thanks OverlandExpy. I am going to buy a set of F150 5100s from Bilstein and try them. I also found a 2004 F150 and (awkwardly) got underneath and took measurements when nobody was looking. I measured the spring height, distance between shock mount and spring perch, and overall strut height. All measurements were similar or the same as the Exp. I will let you know if it works.
And yeah, for the rear we will probably be stuck with spacers.

 

[Jb14]

Disclaimer please verify yourself:: I have done quite a bit of research on this my self and it appears the 5100 for the F150 will work on the front (in fact aftermarket A-arms and such will work as well) For the rear Bilstein makes a 5100 for 2018 expedition that may work.

***Again please verify I have only done a cursory but looks good***

 

[UpRiver88]

Just a quick question along the same lines, if I have a 2003 expy, for the front pair would I be wanting to get 5100's meant for a 2004-2008 4x4 F150? And I looked at the 2018 expy rear 5100's as a possibility but the collapsed and extended lengths (15/20.95) is pretty close to the 2003-2006 4600's (14.09/21.2). Does the adjustability of the 5100 allow it to sit higher than the 4600, in other words, actually give it a lift?

 

[BrandonZ55]

Front suspension is basically the same on the f150 and expys 03-06. They basically have the same front half of frame. My lift spacers are from an f150 front. Obviously rear is different. Spring rates very because of different options and snow plow prep packages and tow packages.

 

[medrano]

Just wondering if anyone went through with the parts spoken of. I went with the rancho quick lifts on my 05 expy. The only problem I am running into is my A Arms are maxed out. Full extension with tons of stress on the ball joint lol. Does run a little rough. And I have put it through some trails so the only way to correct that is by getting lift spindles but guess what! They don’t make them for expeditions. So I would have to get F150 spindles BUT they are different. So I’m now thinking of doing a full swap, lower arms, upper, spindle and obviously brakes. Anyone on here done this?

 

[Vincent Vega]

@medrano How much increase in ride height did you get from the Ranchos? Are they any better offroad vs. Motorcraft struts?
I have not had time to upgrade my suspension. I have been busy replacing my intake manifold, front brakes, and timing chains, tensioners, etc. Just trying to keep it up and running. I will update this thread when I make a move on the suspension.

 

[Vincent Vega]

Took a while for me to get to this because last year I had to install a new intake manifold, front brakes (w rotors), master cylinder, and new timing and hoses. Also I checked around with offroad parts and custom fab places to try to figure out some outside the box options because there is not much out there available for Gen 2 Exps, but that went mostly nowhere (All they wanted to talk about was Jeeps and Toyotas).
For the front, I installed the Bilstein 5100s advertised for the F150, with AC Delco F150 standard duty coil springs. I wanted 6112s but they were not available ("supply chain"). I set the 5100s at the stock ride height circlip, which based on all the math and stuff I did should have meant 1.75-2 inches of lift on my Exp, but ended up 2.5 inches. Going into this, I didn't want that much because it needs to fit in my garage and I didn't want CV joint, balljoint or UCA problems. But it ended up great.
For the rear, I was going to install Rancho Quicklifts (0.75 inch lift), but after the front went up 2.5, that would not have been enough to level the truck. So I installed Ebay lift spacers for 1.5 inches of lift, and new Bilstein 4600s.
The truck doesn't look that much different. It would need new wheels to make it pop, but that is out of my budget for now. But it rides way better. Night and day. Way better offroad, which was the whole reason for doing this.

 

[Jb14]

Thanks for posting this write up. I am in the process of changing out my fronts 4600 with the 5100 as you did. You stated that at the stock setting on the 5100 it lifted the truck 2.5 inches I thought that getting the 2.5 inches of lift was placing the circlip at the max lift (top ring) If at the stock setting does that mean at max setting you get 3.5 inches of lift?