tow hitch cover modification

[hoopty114]

Posting this in case anyone might find it useful.

We bought our 2023 Expo XLT Max last month and has been fantastic.
Constantly using it to tow, so decided to just keep the tow hitch attached and not take it off.
Keeping the tow hitch cover off leaves a huge gaping hole in the bumper, you can see the spare tire, muffler, etc.
I thought it might look a little nicer to at least partially cover up the hole, so this is what I came up with.
- bought a replacement tow hitch cover
- cut out a hole in the middle to allow access to the tow hitch, electrical connectors, and safety chain loops
- paint to match

The Ford OEM replacement tow hitch cover P/N is NL1Z17F000BAPTM. ~$100

To allow the access needed, I measured 2" from left edge, 7 1/4" from right edge, and 3/4" in from top and bottom edges. I probably could have made it smaller but I wanted to have zero problems hooking up the electrical and chains. I used a cutoff wheel for major cuts and cleaned up with box cutter and sander.

I used Automotive Touch Up online to get a paint-to-match aerosol can for my vehicle, Iconic Silver Metallic, paint code JS / 7432. ~$45 for both base and clear.
The replacement cover is already primed so I just sprayed 4 coats of basecoat and 6 coats of clearcoat.

Not perfect by any means, but it turned out way better than I expected and definitely better than without any cover at all.

 

[mbrown1]

Nice! I may do the same on our new to us Silver '23 Limited. It is more of less a tow vehicle and that gaping hole... ick

 

[LanceExp2025]

Very NICE job there hoopty114!

If you don't mind, I may copy your idea and do the same for our 2024 Expy MAX Limited soon. I took off the cover and was thinking about just leaving it off, but that opening is Super UGLY! Also, with your cut-out in the cover, it's much less likely that it will be possibly STOLEN, it seems to me. Don't know though?

Once the hole is cut out in the hitch cover, is the bottom edge still pretty strong (at least enough) to be snapped back into the bottom 2 center clips? Or, do you have to be real careful with that? When the whole hitch cover is in-tact, it's awfully difficult to remove but NOT so difficult to be re-installed, for us. Thanks for the info, description and great photo's, Lance

 

[hoopty114]

Thanks mbrown1 and Lance!

the modified cover is pretty stiff, I had no problems snapping it in place at the bottom 2 clips. I have not yet removed it, but I would imagine it would not be a problem, since you are pushing the clips themselves up, with minimal tension on the cover itself.

if you're not sure, you can make the bottom lip 1-1.5" thick (from bottom edge) rather than the 3/4" that I did, and I'm pretty sure there will still be enough space for the chain stays and definitely enough room for the electrical.

with the cutout size that I have, it can be finagled over our tow hitch and taken on and off without having to remove the hitch. If the bottom lip is longer / cutout is smaller, that may or may not be the case (then you'd have to remove the tow hitch first before installing/removing the cover, which may be what you want).

very happy if you would like to copy it, that's why I shared. If you make it even better please share back, would love to see improvements.

 

[LanceExp2025]

With the cutout size that I have, it can be finagled over our tow hitch and taken on and off without having to remove the hitch. If the bottom lip is longer / cutout is smaller, that may or may not be the case (then you'd have to remove the tow hitch first before installing/removing the cover, which may be what you want).

very happy if you would like to copy it, that's why I shared. If you make it even better, please share back, would love to see improvements.

Thanks again hoopy114; I will then copy your modified cover design & maybe w/ a slightly larger bottom rail, as you suggested.

One more question, with your opening cut-out size, is it possible to get the hitch pin and clip in and out without removing this modified cover? The reason I ask is, that our Expedition MAX is always garaged and, if the hitch is left in place, the garage door will hit it while going down. So, we must remove it after each use. My wife uses the Expedition every 6-8 weeks to tow our cube (horse feed) trailer to the feed store and back w/ 2000# of hay cubes loaded up. If your modified style hitch cover is left in place (which would be easiest for my wife) I just wanted to make sure the hitch pin and clip can be installed & removed without this modified covers removal??

Thanks again for your time and knowledge here, Lance

 

[tominwi]

Took my cover off for the first time today. Had to find something to push-in the two underside clips with and a plastic j-shaped pipe hanger laying-around did the trick. First time putting it back I didn't align tabs correctly, and it went flying when I tried to pull it back a bit. Thankfully I didn't scratch it doing this!

I think Ford needs to make a part akin to what the OP has done. I'm new to Expys--has this cover arrangement been around for a while? Or just this gen?

 

[Fastcar]

AARRRRRGGGGGG...... I have towed for years and always remove it. Leaving those thing on are a real ***** when at night walling behind your truck in a parking lot and you whack your shin on it. It takes a couple of seconds to pull the pin or unlock it so nobody gets hurt.

 

[LanceExp2025]

Yep, tominwi. Those things can be a bear to get off, at times. When we bought our new 2024 Expy MAX Limited 2 weeks ago, neither me nor the Ford salesman were able to get that thing off. The next day, after we brought it home, I still couldn't get it off because it seemed like the bottom of the whole bumper flexed out so much that I thought it was going to break the whole thing off. Not until I did what you did and pushed up on the 2 bottom, center tabs, then it came off.

Yep, Fastcar, I think we have all whacked our shins on those hitches, more than once! We never left the hitch in our 2012 Expy EL Limited either and won't do so in this new one either. We also don't want anyone hurt nor do we want someone to walk off with our hitch either. It is good to hear others on this forum have or have had similar experiences with these wonderful cars. Just in the 2-3 weeks since I joined the forum, I have learned so much and it also helped to learn that we actually made the best decisions on what to look for when buying one of these 2024 Expy's. We both love this car!

Be well guys, Lance

 

[Fastcar]

Yep, tominwi. Those things can be a bear to get off, at times. When we bought our new 2024 Expy MAX Limited 2 weeks ago, neither me nor the Ford salesman were able to get that thing off. The next day, after we brought it home, I still couldn't get it off because it seemed like the bottom of the whole bumper flexed out so much that I thought it was going to break the whole thing off. Not until I did what you did and pushed up on the 2 bottom, center tabs, then it came off.

Yep, Fastcar, I think we have all whacked our shins on those hitches, more than once! We never left the hitch in our 2012 Expy EL Limited either and won't do so in this new one either. We also don't want anyone hurt nor do we want someone to walk off with our hitch either. It is good to hear others on this forum have or have had similar experiences with these wonderful cars. Just in the 2-3 weeks since I joined the forum, I have learned so much and it also helped to learn that we actually made the best decisions on what to look for when buying one of these 2024 Expy's. We both love this car!

Be well guys, Lance

My wife and I were leaving a movie theater late one rainy night and was walking through the parking lot when she hit her leg on one of them. The hit peeled about 2" of skin of skin and flesh about down to the bone. Long story short. 3 hours in the ER to get 14 stitches doc's thought she might be looking at a skin graft. All because somebody was to busy or lazy to remove it.

 

[LanceExp2025]

Ouch!! Fastcar. Sorry to hear about that. That's a painfull story. Hope she's OK now with not too bad of a scar, to live with. Lance

 

[tominwi]

Yep I parked our other truck in the garage and Wife walked-into the hitch ball. I'd left it on cuz was about to leave and needed it.

I've learned to remove it, or otherwise to put a bucket or something over the top of it so as not to harm Wife or myself!!!!

 

[Fastcar]

Ouch!! Fastcar. Sorry to hear about that. That's a painfull story. Hope she's OK now with not too bad of a scar, to live with. Lance

Thanks for that Lance. She was really pissed off cause she couldn't go to the beach for a few weeks. As far as a scar she's usually tanned most of the year.

 

[LanceExp2025]

Yes tominwe, that's a GREAT IDEA to put a bucket, or maybe even a towel, over the hitch to bring it to your/someone's attention!

On my work 2023 Transit T350 Cargo Van, I leave the hitch in 'permanently' because I use it so often. But, when I had it made really heavy duty, I had them totally radius the plate end where the ball bolts through (no sharp 90 degree corners), it's tucked right up next to the bumper and I had them put a heavy steel wheel on the bottom w/ a 5/8" Grade 8 axle bolt so that it would roll instead of the ball threads dragging on the pavement approaches. I also have a hardened 1/4" bolt and nylon locking-nut bolted through the hitch pin (instead of the clip) to deter someone from stealing it. It works great and even though I am aware of it, I still have clunked my shin into it a few times but, while slightly painful, it doesn't tear my hide off. I also always carry a couple of small orange cones in my van to put behind it a couple of feet to maintain rear door opening radius clearance, which also protects walker-byes from walking right up next to the van where the hitch sticks out. So far, so good? Here's a picture of my Transit Hitch. That's my 2 cents worth on these hitches, for what it's worth, Lance

 

[tominwi]

Yes tominwe, that's a GREAT IDEA to put a bucket, or maybe even a towel, over the hitch to bring it to your/someone's attention!

On my work 2023 Transit T350 Cargo Van, I leave the hitch in 'permanently' because I use it so often. But, when I had it made really heavy duty, I had them totally radius the plate end where the ball bolts through (no sharp 90 degree corners), it's tucked right up next to the bumper and I had them put a heavy steel wheel on the bottom w/ a 5/8" Grade 8 axle bolt so that it would roll instead of the ball threads dragging on the pavement approaches. I also have a hardened 1/4" bolt and nylon locking-nut bolted through the hitch pin (instead of the clip) to deter someone from stealing it. It works great and even though I am aware of it, I still have clunked my shin into it a few times but, while slightly painful, it doesn't tear my hide off. I also always carry a couple of small orange cones in my van to put behind it a couple of feet to maintain rear door opening radius clearance, which also protects walker-byes from walking right up next to the van where the hitch sticks out. So far, so good? Here's a picture of my Transit Hitch. That's my 2 cents worth on these hitches, for what it's worth, Lance

The radius edge is a great idea, but you've inspired me to wonder if any wheel at Harbor Freight might have an "axle hole" big enough that one could just put it thru the ball extension underneath. Bump into rubber instead of metal.

I don't know if you can buy a ball with a long throw that would be required.

 

[hoopty114]

Thanks again hoopy114; I will then copy your modified cover design & maybe w/ a slightly larger bottom rail, as you suggested.

One more question, with your opening cut-out size, is it possible to get the hitch pin and clip in and out without removing this modified cover? The reason I ask is, that our Expedition MAX is always garaged and, if the hitch is left in place, the garage door will hit it while going down. So, we must remove it after each use. My wife uses the Expedition every 6-8 weeks to tow our cube (horse feed) trailer to the feed store and back w/ 2000# of hay cubes loaded up. If your modified style hitch cover is left in place (which would be easiest for my wife) I just wanted to make sure the hitch pin and clip can be installed & removed without this modified covers removal??

Thanks again for your time and knowledge here, Lance

I tried to make it big enough to be able to take the hitch pin on and off without removing the cover.

with a simple hitch pin it is not a problem, slip it in and out on the left side over the electrical.

we use a locking hitch pin since we have a pricey B&W hitch. at first I had the lock on the right and it is a pain to get the key into the lock side (but possible). not really possible leaving the key on my key fob with the bunch of other keys. I swapped sides and slid the pin into the right, which is easily doable, and now locking and unlocking on the left, in front of the electrical, is a piece of cake, and I can leave the key on my key fob without problems.

the B&W stowage feature has been very nice and makes avoiding banging your shins on the hitch a no-brainer. no painful tik tok videos

 

[LanceExp2025]

Thanks hoopty114 for the great pictures! That makes it perfectly clear and it will definitely work for us too! No locking pin for us because we put the hitch in to tow the trailer to the feed store then, back to the barn, un-hitch and the hitch comes out when we put the Expy back into the garage. Much appreciated, Lance

 

[LanceExp2025]

Hey tominwe, I don't know if "long shank" balls are available in 2" diameter sizes (never looked for nor bought one in 2") but on the 2-5/16" balls (that I use on my Transit, for both our trailers) they are available w/ long shanks but mostly I've seen them in the heavy duty (7000, 8000 & 10,000 #) balls w/ 1-1/4" & 1-1/2" dia. shanks.

As far as putting a wheel/tire from Harbor Freight on the shank, I guess that would work but you would definitely want to put it below the clamping nut holding the ball to the hitch, by using a second nut jamb-nut. You don't want anything to cause loosening of the ball to your hitch. In our case, it would have to be a very small diameter tire so that it wouldn't hit the drop-downs of the larger couplers.

If you ever end up making one, please post a picture of what you came up with! Thanks, Lance

​

 

[lyanheart]

I came here looking for information on this very subject for the 2023 I recently picked up (prior to this, I had a 2006 and 2016 expeditions). Instead of cutting a hole in the cover, I am going to try "replacing" the PITA lock tabs with some dual-lock velcro on the edges of the panels and see how that goes to make removing it easier. At least a replacement panel is easy to get and inexpensive if it flies off someplace. But I have had good luck with the dual-lock stuff keeping things secure riding on my boat and trailers. It has a very positive snap together action, much stronger than traditional velcro.

 

[Craig Hall]

Bought a Weathertech 18” step to fit in the receiver and it completely covers the tow hitch hole on my ‘24 Expedition.

 

[rovertrader]

Would you mind posting a pic? Thx!