Towing upgrades for NON HD towing pkg Expeds

[andyak]

I have a NO HD tow package 2019 expy 4x4 Titanium 6000lb max tow.

From here: https://www.blueovaltrucks.com/tech-articles/guide-to-ford-truck-suv-axles/
looks like for my expy and many others (NO heavy towing package) we have currently:
(Ford 8.8-Inch Independent Front Suspension)
Specifications:

• 8.8-Inch Ring Gear
• 28 or 31-Spline Axles Using CV Joints

(Ford 8.8-Inch Independent Rear Suspension)
Specifications:

• 8.8-Inch Rear Gear
• 31-spline Axle Shafts Applications: 2003-2019 Expedition

For the heavy duty towing package owners the expys have:
(Ford 9.75-Inch IRS) Rear:

• 9.75-Inch Ring Gear
• 34-Spline Shafts
• 8.8-Inch Independent Front Suspension

It looks like the rear is upgraded to 9.75 IRS front stays 8.8 - but both would could get 3.73 gears.


So it looks like a viable plan to regain max towing capability (aside from extra 4x4 modes and rear antislip):

A: Replace rear 8.8 with 9.75 (3.73) with no ELS
B: Replace rear axels with the beefier 9.75 axles
C: Replace Rear Springs with like to the ones on the oem HD pkg
D: Replace front diff gears to 3.73
E: Replace shocks all around (Bielsteins or?)
F: Install Ford brake controller
G: Place heavy duty radiator
H: Install upgraded radiator cooling fans (how to adapt wiring/ecu to 3 pin variable fans from 2 pin wiring)
I: Possible upgrade to Hellwig anti sway bars

Costs:
Ford brake conrtoller $240
9.75 rear axels: $610
9.75 differential w/3.73 ? $500 ? sources ?
9.75 driveshaft? $402
8.8 front regear to 3.73 ?$500?
Radiator : $266+$12+$14 8005, Seal HL3Z 8348, upper air seal
cooling fans :$360 8C607D

So not sure where to source rear 9.75 non ESL pumpkin and not sure of cost to regear front 8.8 to 3.73

Total ~$3000 + springs/shocks/sway bars

What do you guys think?
Plausible plan for a good expy to tow up to 9000 ?? What am I missing?

 

[Deadman]

ABSOLUTELY NOT. Theres no way it'll all work between the computer BS, ABS sensors, and all kinds of unknown electronic BS.
Just trade it and learn from your mistake and call it a day.

 

[andyak]

Deadman, Not sure why you would say absolutely not...

There should not be any problems with resetting gear ratio. ABS will be fine. Getting the different radiator fans wired in and working may be a pain - BUT one could forego that cooling upgrade until it was deemed necessary.

Just getting the upgraded 9.75 and axels and suspension on the rear with the 3.73 ratio and brake controller would allow towing much closer to 9000lb and open up many more travel trailer options.

 

[andyak]

I just went under the expy and found out I already have 9.75 diff and axles. Maybe this is oem for 4wd setup?

So if I can get by with 3.31 vs 3.73 I should be able to tow more than 6000lb.

Does anyone know about what to buy for upgraded suspension? I have the JL14-5534-CC spring struts.

 

[andyak]

From the 2019 ford towing page info:

Model Expedition Expedition(Option Code)
(Std.) (536)HD tow pkg
7-Wire Harness & 4-/7-Pin Connector X (Std.)
Hitch Receiver X (Std.)
Radiator Upgrade – X
Electronic Traction Assist (eLSD) – X
Upgraded Rear Axle – X
2-Speed Automatic 4WD – X(1)
Trailer Brake Controller – X
Trailer Sway Control X (Std.)
Pro Trailer Backup Assist – X
from here : https://www.ford.com/cmslibs/conten.../guides/19Towing_Ford_Expedition_r1_Dec21.pdf

If I have:
The upgraded rear axle (9.75) (yes truck has it already yay!)
Trailer Brake controller (ordered and will install oem ford)
Same Hitch Receiver
7-Wire Harness & 4-/7-Pin Connector
Trailer Sway Control

The only things I can find preventing towing more than 6000lb would be a need for better suspension (I don't see it in the upgrade list unless the axle upgrade includes it) - and a possible need for radiator upgrade and/or switch up to 3.73 gears...

Any thoughts? help?

 

[JasonH]

Check the springs, I think the HD Tow has a stiffer set.
With the 9.75 even fit in the 8.8 housing? My recollection is that that 3.73 is physically larger.

This seems like a lot of work to get another 3K max, especially when you'll likely hit the payload limit before getting anywhere near the towing maximum.
Let's back up: What are you trying to tow?

 

[andyak]

See above - confusing lol- I do have the 9.75 already

Tryin to have a few more options for travel trailer models in the 5 - 7500 or so weight range

 

[JasonH]

Is your trim an FX4? If you check the brochure for your model year, it is lists the equipment it should have shipped with. The FX4 is the only trim I'm aware of that only had a subset of the HD Tow parts.

 

[andyak]

no FX4 . But I verified it has the 9.75 rear end and axles.

3.31, 9.75, S570B

 

[BMW2FORD]

If you have a Max version and no HD tow, they get the 9.75 rear end gear size but a 3.31 ratio. Only thing I’d think to do is not bother with the Ford HD tow radiator or fans and simply get a Mishimoto radiator and the non HD tow fans will be fine. Plenty of people mainly F150 owners cant keep trucks cool when towing with the Ford HD radiator. The bigger aftermarket radiator which holds about 2 gallons more of coolant. If you’re going to replace the factory unit would the Mishimoto would be a good idea.