My Stock EB Expy to Overlanding 4X4 Build

[OverlandExpy]

Hey everyone, been lurking these forums for awhile, but now that I finally was able to purchase a family members 04 Eddie bauer I figured I'd make an account.

It has 155k miles on it, was primarily used for towing, and in excellent condition. Except for the air suspension which has a leak, but is going to be replaced anyway. Which brings me to the purpose of my post; I am looking to turn this into a 100% purpose built over lander. I have a 9000lb car lift, a well stocked shop, tube benders, and welding equipment. What I don't have is tons of experience/knowledge about fords, other than the routine maintenance I have performed on the truck for my family over the years.

From what I've read here it seems that there really aren't any purpose built suspension lift kits for us. Ideally a 4" front, 3" lift is what I'm looking for. No matter what I do, the air suspension is going to be the first thing to go. 35" tires with no rubbing is the goal, and I do not want to do a body lift or spacers. Maybe a 1inch spacer in the front if needed to level it out. Swapping control arms or any other parts needed for a true 3-4 inch lift wouldn't be a problem, has anyone here done anything similar to this?

Once suspension is figured out I plan to weld up some bumpers and skid plates, and I definitely need to make some armor for the gas tank. Had it up on the lift the other day and noticed how exposed it was.

I'll make more posts and add some pictures once I get started on working on it, but any advice or recommendations, or links to posts that you think would be helpful would be greatly appreciated!

Cheers

 

[ExplorerTom]

Sounds good! Keep us in the loop on your progress.

 

[Jb14]

Years ago Rize use to make a dedicated suspension kit for our model years expy (6 or 8 inch lift dont remember) maybe that can give you a design starting point

 

[David E]

I'd start at the link attached. This guy did a really good job it seems. It does take quite some work to do a lift as such and properly have a 35" with clean clearance. If you are good with a welder then nothing is really beyond the starts...

Good luck...

https://offroadium.com/ford-expedition-33-inch-tires-vs-35-pictures-lift-and-wheel-specs.html

 

[OverlandExpy]

Thanks David that's just what I was looking for! Also thanks Jb14, I knew I saw people talking about that big lift kit on this forum somewhere. I will definitely look into it!

 

[Vancouver Bob]

Here's a link to an album someone here created showing their install of a Rize lift...

https://www.expeditionforum.com/media/albums/installation-of-rize-suspension-lift.192/

The key to a "true" lift and maintaining existing suspension geometry is to lower the lower control arm along with the differential while keeping the upper control arm in place which requires a taller spindle or a way to lower the spindle while maintaining structural integrity.

Most of us with lifts/levels are running spacers which, as you probably know, essentially just pushes the spring and strut down to push the vehicle up. This does change the suspension geometry of course. I've been running with mine for over two years and am very pleased with how little, if any, impact it's had on ride quality. It does eat into the down travel a bit. I'm running 35's which did require some trimming. I changed gearing from 3.73 to 4.56 and added front and rear ARB lockers at the same time. Here's what mine ended up looking like along with a link to the build if you're interested to see how it went together.



https://www.expeditionforum.com/threads/2003-expedition-face-lift-begins.31657/

Others here run coil overs which either lift the bottom of the spring or include integrated spacers from Rancho or Icon Vehicle Dynamics. The Icon's are much more specialized but aren't offered for our older gen Expeditions (you may be able to get others to fit though). All of which change suspension geometry a bit.

Hope that helps.

 

[OverlandExpy]

Here's a link to an album someone here created showing their install of a Rize lift...

https://www.expeditionforum.com/media/albums/installation-of-rize-suspension-lift.192/

The key to a "true" lift and maintaining existing suspension geometry is to lower the lower control arm along with the differential while keeping the upper control arm in place which requires a taller spindle or a way to lower the spindle while maintaining structural integrity.

Most of us with lifts/levels are running spacers which, as you probably know, essentially just pushes the spring and strut down to push the vehicle up. This does change the suspension geometry of course. I've been running with mine for over two years and am very pleased with how little, if any, impact it's had on ride quality. It does eat into the down travel a bit. I'm running 35's which did require some trimming. I changed gearing from 3.73 to 4.56 and added front and rear ARB lockers at the same time. Here's what mine ended up looking like along with a link to the build if you're interested to see how it went together.

View attachment 39557

https://www.expeditionforum.com/threads/2003-expedition-face-lift-begins.31657/

Others here run coil overs which either lift the bottom of the spring or include integrated spacers from Rancho or Icon Vehicle Dynamics. The Icon's are much more specialized but aren't offered for our older gen Expeditions (you may be able to get others to fit though). All of which change suspension geometry a bit.

Hope that helps.

Thank you so much for your post! I am starting to lose my mind trying to find a good lift for my expy. I've been calling and emailing all of the major lift companies, and everyone has discontinued their 2nd gen expy products. Rize appears to have vanished off the face of the earth, every single link on these forums on where to purchase the kit (and there are a lot of them for the rize kit, seems to be a popular topic) is dead.

So far I have spoken to a rep at Rancho who said they only have a 1" lift for the front and nothing for the back, even though I have seen sites that say they will fit on my model/year. Monroe and strutmasters just replace the air suspension and keep it at stock height, so I'd have to add spacers, which due to some of the reasons you mentioned above I am not too interested in. I may add some spacers to level it out after (if) I find and install new coilovers.

I've also emailed Fox and Icon, and struck out there as well. At this point I don't even care about price, I just want coilovers that will give me 2-4inches above stock. Anything to fit 37" tires.

Sidenote: looks like mindgame who has the rize kit installed in the post you linked above has not been active for a few years. I sent him a PM but haven't heard anything back yet. Looks like he got rid of the independent rear suspension and added a live axle? Would be nice to keep the independent suspension so I dont have to worry about scraping my diff everywhere. Still planning out exactly what I'm going to do, and haven't taken my rig on so much as a dirt road yet. I wonder if the controltrac would function well enough as a locker or if I should just replace the whole driveline more or less to add lockers and a solid axle.

Sorry for rambling here, just been browsing the forums and random websites for a few days trying to find answers but all I keep coming up with are more questions ¯\_(ツ)_/¯

 

[joethefordguy]

I'm in the same boat you're in. I've been able to fit 33.8" tires on the stock suspension, which alone provided 1.1" of lift over factory ground clearance.
I'm holding off on suspension work until it's time to buy new tires again. I've got a tuner, which was less than a value add, and I'm planning duals with shorty headers, armor underneath the chassis, and bumpers.
FWIW, as a police package, it already has "duals" from the manifolds all the way back to the muffler; so two cats on each side already. I have not bought custom tunes; that's waiting for all the upgrades so I don't have to keep getting new tunes. I'm hoping a custom tune will make the high cost of the tuner worth it. we'll see.
I've considered and rejected electric fans, under pulleys, catch cans, and CAI. I did install a high flow air filter, and eventually I'll install a better intake.

 

[OverlandExpy]

Sounds cool joe, keep us posted on your progress! For now my plan is to hold off and start saving up for some long travel fox or icon bypass shocks, and then just start cutting and welding to put em on my rig. I've got all the tools I'll need to do it just lacking a bit in the expertise department. While I'm saving up I'm planning on practicing welding a little bit everyday before I start taking the torch to my rig lol

 

[BrandonZ55]

I have a set of coilovers I would get rid of. They gave me about an inch or so over my 2 inch lift spacers. I'm looking to go back to more stock. Gonna find something a little newer soon. If interested let me know.

 

[OverlandExpy]

After dealing with a bit of an issue for over a month with the Rancho suspension, lift is complete. Rancho quick lift struts combined with a supreme suspension 2" lift kit for a total of 3" front and rear. Also took off the runner boards. Next on the list is good offroading rims and bigger tires. Anyone have any recommendations for 17" 6x135mm 8 or 9 inch wide beadlock rims? The more reasonably priced the better lol.

 

[Vancouver Bob]

Sorry to hear about the issues you encountered but glad you persevered. Looks great so far!

 

[OverlandExpy]

Sorry to hear about the issues you encountered but glad you persevered. Looks great so far!

Thanks! It's definitely going to be a long and slow process, mainly due to budget lol, but I'm looking forward to modding the hell out of this thing! May try to fab up some rock sliders one of these days since it would be pretty straight forward and I already have the metal tubing and all the tools I need.. Number 1 priority right now is some rock/offroad rims and bigger tires! I can probably fit 35s in there now no problem, and was planning on trimming the body anyway so the end goal is 37s!

 

[Vancouver Bob]

I knew someone here that ran 37" tires.

https://www.expeditionforum.com/posts/318261/

 

[OverlandExpy]

Oh man that thing looks awesome, thanks for linking it @Vancouver Bob ! Definitely looks doable. About to pull the trigger on some used rims/35" tires I found online. If it looks like I'll have enough clearance I'm definitely buying 37's! Need to look into doing a body lift, dont really know many pros/cons to it or how long it would take, but anything for more clearance would be helpful!

 

[Vincent Vega]

OVerlandExpy what issues did you have with the Ranchos? And now that they are installed, would you recommend them? I have seen mixed reviews on them, but never been able to get feedback from someone who actually uses them offroad, as I would. I am considering them because they should bolt right in, and will provide the exact (mild) amount of lift I want, so it still fits in my garage and won't make my 33s look too small.

 

[OverlandExpy]

@Vincent Vega check out my profile, I made a post in the suspension forum detailing my issues. If you know anyone who can do a quick weld for you, and you want a mild lift that will bolt in with ease, I'd recommend them so far. But I've only put about 30 miles on it since I put them in, I still need to get an alignment. Haven't taken it off road yet but I just ordered some bead locks and am looking at some good AT tires, I'll do a write up after I take it offroading the first time. Unfortunately for 2nd gen expys we don't have many options for lifts besides Rancho or leveling kits. I went with both as you can see above and am super stoked how much lift I got out of it.

I'll definitely keep this thread updated with any issues I have and all my future mods as well

 

[OverlandExpy]

Just placed an order for a set of 5 Method 105 beadlocks. If anyone in norcal has some good 35 inch 17r tires hit me up! Will post pictures as soon as they arrive!

 

[MrBlargMan]

Following this post.
@OverlandExpy - Looks like good progress so far!
I have the 3.5" / 2.5" spacer lift on mine and have had zero issues with my 35" mud terrains on or off road.
I have dreams of lockers and 4.11 gear sets, but she gets around alright for now.
Excited to see this build progress!

Cheers!

 

[OverlandExpy]

@MrBlargMan thanks!! Can't wait to really get working on this thing but the big thing holding me back is my budget at the moment lol. Also trying to renovate the place I just bought so I'm a bit pressed for cash right now. Bought the bead lock rims but they didn't include the hardware to actually mount the tires haha so waiting for them to send me those, then getting some decent tires, and then I'll finally be ready to test this thing out!

Rock sliders are coming soon, trying to design them in solid works now, I have all the metal I need to fabricate them, just need to find the time to make em!