What repairs do you still need?

[Habbibie]

Majority of members here have a fairly used expedition and with age comes problems, what issues do you have with yours? List the year, engine size & mileage.

My 05 5.4 w/ 139K needs

New brake lines
Exhaust manifolds
Power steering pump
A.C. recharged
Oil pan gasket
Rear wiper motor
Shocks/struts
And a good wash...

I just started it up, been 21 days according to my calender since I last drove it

 

[ChrisOIFdoc]

Mine needs a 351c, edelbrock intake and carb, manual transmission and transfer case, straight front axle and lower gears

 

[JExpedition07]

Mine was shaking on the front end when hitting the brakes and passing fast and the rear wiper stopped working. I believe it's not always the motor there is a thread here somewhere. I "traded mine in" in my mind but I really gave it to a family member to see if they like it to buy it... an extended test drive since I got the pickup. They think it's too big so it might not be gone, which is fine I'll keep it as a secondary vehicle if they pull back on it. If that's the case I'll have to tear the front end apart to see what's making it shake. Kinda thought this was coming but it's ok the expy is way more comfortable for when I'm driving two hours down to the cabin on dirt roads. This 350 isn't the best for long drives ride wise. Everyone tried to tell me to keep it anyway as a backup and a ol' workhorse secondary. If I end up getting it tossed back at me my profile pic will be changed to it that's how you'll know lol.

 

[ExpeditionAndy]

On the rear wiper. The wiper transmission binds where it goes through the glass. I had to replace mine last year on the 05. The transmission was $35 from Rock Auto, I think it was a Dorman. I replaced ti because the end sheared off when I tried to remove the nut. I think I posted a thread in the 2nd gen when I replaced it. It was a pretty easy fix but a small puller comes in hand to get the arm off the shaft.

 

[08T1]

08 needs timing parts replaced. Not much more. I only have 110 miles on it.

CJ

 

[USMCBuckWild]

Starting to get the “cold start rattle” of the timing components so need to do a timing chain set/adjusters.

Got a weird “CLUNK” when I shift from drive into reverse that comes from what sounds like the front end. I have gone through the entire driveline and can’t find anything loose or worn. Took the wheels and brakes off to turn everything with no resistance to see if I could isolate the noise.

 

[Habbibie]

Starting to get the “cold start rattle” of the timing components so need to do a timing chain set/adjusters.

Got a weird “CLUNK” when I shift from drive into reverse that comes from what sounds like the front end. I have gone through the entire driveline and can’t find anything loose or worn. Took the wheels and brakes off to turn everything with no resistance to see if I could isolate the noise.

Is that clunk with the truck on leveled ground or an incline?

 

[USMCBuckWild]

Is that clunk with the truck on leveled ground or an incline?

Both.

It sounds like a bad u-joint clunk or loose lug nut/rotor slap. The diffs are tight and consistent (tested by hand free-spinning and under load, did not dissasemble to check lash) and all u-joints and cv shafts are in excellent working condition with no slop or other indicators of wear.

 

[SnuffThePunkz]

I don't want to play this game...

1997 5.4L, 180ish k

Upper ball joints
Replace lower ball joints with oversized Moog's
Lower front of truck 1" (level truck driver/passenger)
Replace torque converter
Rebuild transmission pump
Replace transmission filter
If metal/plastic/carbon in transmission pan, rebuild transmission.
Install transgo shift kit
Remove Fram filter from engine (I know, I was dumb)
Flush oil
Replace damaged valve cover
Replace damaged intake manifold
Replace rear shocks with extended length shocks.

Edit:1

Exhaust manifolds
Cat delete (likely clogged)
New muffler
New exhaust everything
Rebuild LS
Gear swap for 37's that are coming
20's for 37's
God...

 

[USMCBuckWild]

Figured out my “clunk”.......

Bad t-case shift motor. I am going to attempt to pop the cover off with the 3 torx screws and clean it up underneath. If that fails then a new one will be ordered.

 

[Plati]

2003 Expy XLT 5.4L
this is the list of repair work I've needed in 180K miles

- some kind of warranty drive train work not sure what soon after I bought it
- that suspension link that always breaks and makes a clunk
- tranny flush
- alignments, oil & air filer changes etc
- brakes & tires obviously
- check engine & airbag light on ... wiring harness frayed & repaired
- cooling system flush
- spark plugs & coils at 100K
- pcv valve
- window regulators twice
- both rear wheel hub assemblies
- clean tighten battery terminals
- window master switch driver side
- vacuum hose to front wheel
- rear window hinges
- vacuum hose junction behind battery (air was only blowing out defrost, youtube video)
- new battery (once!)
- damn rear heat a/c clunking noise common problem both disabled
- multiple rear window wiper frozen , take apart & clean lube
- rebuild emergency brakes several times
- lube ignition key & door locks
- dielectric grease on trailer plug
- fuel filter several times (replacement rusts out) & connectors
- rear differential fluid change
- alternator (3 times)
- serpentine belt idler (bearing noise)
- wiper blades obviously
- lower sheering shaft (rusted, binding)
- multiple brake lines both rubber & metal
- gorilla tape to repair rusted out areas
- serpentine belt

The weirdest problems I've had:
- interior lights stay on ... usually after car wash ... no more drive through car wash!
- driver side door doesn't latch in cold weather, have to cycle electronic door locks!
- E brake design is ridiculous, just barely works when fully serviced
- try to avoid using electric windows in cold weather since that's when the regulator breaks
- weak alternator, worked fine unless headlights on then battery drains
- stupid design for rear windshield wiper requires disassembly & lube every 3 years
- rear heat a/c ALWAYS breaks on these clunking noise
- rear liftgate latch stopped working then started again months later
- doubt I could get my spare tire off after all these years (RUST) if needed
- absolutely LOVE having to bang & destroy rear rotor with sledgehammer to remove

 

[ExpeditionAndy]

2003 Expy XLT 5.4L
this is the list of repair work I've needed in 180K miles


- E brake design is ridiculous, just barely works when fully serviced

The e brake uses a couple of levers that actuate the parking brake - these become encrusted with rust and fail to move after time. Take them off and put them on a wire wheel and remove the rust. Make sure the pivot axle is clean and that the other arm moves freely. The levers are the same on both sides but their orientation is side specific so make sure you don't put them in backwards. I had this problem on my 05 and after spending a lot of money to get the parking brake to work we discovered the solution. I think you can also buy new ones if you don't want to mess with them. Make sure you use anti-seize or a good high temp grease. After you service the levers then make sure you adjust the parking brake shoes according to Fords specs.

This video will show you how to do it.

 

[CrackedCubes]

2000 Expy XLT 5.4L
155K

Need replacement for Rear Wiper Motor Seal. Mine was stolen. Dealers no longer stock. Do not want to go to junkyard. Part #F75Z-17C412-AA.

Any recommendations on sourcing?

 

[ExpeditionAndy]

2000 Expy XLT 5.4L
155K

Need replacement for Rear Wiper Motor Seal. Mine was stolen. Dealers no longer stock. Do not want to go to junkyard. Part #F75Z-17C412-AA.

Any recommendations on sourcing?

Are you talking about the rubber washer that goes between the glass and the handle on the glass?

 

[Plati]

Wow this is weird. Just got in 03 Expy to drive to store and the steering wheel wrap was super tacky and left dark goo on my hands. Figured it was incredibly dirty (this is my utility Expy) so I came home and cleaned it with simple green and then window cleaner. Kind of cleaned up but kept oozing. I googled it and a common problem I guess at a certain advanced age & temp/humidity. Seems like nothing you can do just buy a wrap and cover it. May have to do that. Next morning its back to normal (lot cooler) but for how long?

2000 Expy XLT 5.4L
155K

Need replacement for Rear Wiper Motor Seal. Mine was stolen. Dealers no longer stock. Do not want to go to junkyard. Part #F75Z-17C412-AA.

Any recommendations on sourcing?

Did you GOOGLE it? (FORD rear wiper motor seal F75Z-17C412-AA)
I did and looks like you can buy them from internet, did not try though so not sure.

When you grease that , make sure you use non water soluble grease.

My favorite part of that wiper locking up? If it locks up and not in the HOME position, the battery will run down and unable to start vehicle. That's usually how I know that its happened. Love it when you park your EXPY at a snowmobile access point, go on a 3 day trip and return to dead battery! I pack a JumpnCarry JNC770R now! It fits perfectly under the back of the front passenger seat.

 

[SnuffThePunkz]

That sounds horrible...

I would not like that.

 

[CrackedCubes]

Are you talking about the rubber washer that goes between the glass and the handle on the glass?

View attachment 21962

Nope the plastic cover that covers the hole in rear gate where the motor spindle mates to the rear wiper blade. Can't remember if its plastic or rubber. probably plastic. Ford OEM Part #F75Z-17C412-AA. Ford OEM Parts Breakdown above-Part #1 17C412 in section D. Just a cap really to keep the water from entering the tailgate.



Thanks for trying!

 

[ExpeditionAndy]

View attachment 21971

Nope the plastic cover that covers the hole in rear gate where the motor spindle mates to the rear wiper blade. Can't remember if its plastic or rubber. probably plastic. Ford OEM Part #F75Z-17C412-AA. Ford OEM Parts Breakdown above-Part #1 17C412 in section D. Just a cap really to keep the water from entering the tailgate.



Thanks for trying!

Okay, if it was the rubber piece, I would have mailed it to you.

I guess you'll have to go to a junk yard for one of those.

 

[Plati]

View attachment 21971

Nope the plastic cover that covers the hole in rear gate where the motor spindle mates to the rear wiper blade. Can't remember if its plastic or rubber. probably plastic. Ford OEM Part #F75Z-17C412-AA. Ford OEM Parts Breakdown above-Part #1 17C412 in section D. Just a cap really to keep the water from entering the tailgate.



Thanks for trying!

Is it this part ... also ... 2L1Z-17C526AA ??

mainly just a cosmetic part, I think you could make one out of Gorilla Tape?

or they have that on ebay, probably other places
http://www.ebay.ca/itm/New-Genuine-...ash=item51b43deb55:g:WqgAAMXQfvlSc-e7&vxp=mtr

I fixed the one on my 2003 Expy with Gorilla tape last time cause I broke it with pliers.
It also looks VERY similar to the one on my 2014 Expy, but I don't think (not sure) if you can buy it individually - must be part of an assembly (kit) although it might be available as a 9L1Z-17C526A
https://www.ebay.com/p/Ford-OEM-Wiper-Washer-lift-Gate-wiper-Arm-Cap-9L1Z17C526A/1522238216

can get that part from here
https://www.parts.com/index.cfm?fuseaction=store.PartInfo&PartNumber=9L1Z17C526A&VehicleID=377612&diagram=MC07955&Title=-WIPER-ARM-CAP

https://www.ebay.com/itm/NEW-OEM-RE...ash=item35f01a12d9:g:5woAAOSwZVlXitMl&vxp=mtr

You could make one out of the tapered top part of a Clorox bottle or the right plastic bottle cap also. I make a lot of stuff like that because I'm too cheap to pay money sometimes

... I just realized I have way too much free time since I retired !!!

 

[CrackedCubes]

Is it this part ... also ... 2L1Z-17C526AA ??

mainly just a cosmetic part, I think you could make one out of Gorilla Tape?

or they have that on ebay, probably other places
http://www.ebay.ca/itm/New-Genuine-...ash=item51b43deb55:g:WqgAAMXQfvlSc-e7&vxp=mtr

I fixed the one on my 2003 Expy with Gorilla tape last time cause I broke it with pliers.
It also looks VERY similar to the one on my 2014 Expy, but I don't think (not sure) if you can buy it individually - must be part of an assembly (kit) although it might be available as a 9L1Z-17C526A
https://www.ebay.com/p/Ford-OEM-Wiper-Washer-lift-Gate-wiper-Arm-Cap-9L1Z17C526A/1522238216

can get that part from here
https://www.parts.com/index.cfm?fuseaction=store.PartInfo&PartNumber=9L1Z17C526A&VehicleID=377612&diagram=MC07955&Title=-WIPER-ARM-CAP

https://www.ebay.com/itm/NEW-OEM-REAR-BACK-WINDOW-CAP-2003-2014-LINCOLN-NAVIGATOR-FORD-EXPEDITION-/231661507289?fits=Make:Ford&epid=1522238216&hash=item35f01a12d9:g:5woAAOSwZVlXitMl&vxp=mtr

You could make one out of the tapered top part of a Clorox bottle or the right plastic bottle cap also. I make a lot of stuff like that because I'm too cheap to pay money sometimes

... I just realized I have way too much free time since I retired !!!

Thanks Polarizer....your part referenced is for 2nd Gen i believe which is shaped differently than the 1st gen part. It actually does function as a seal keeping water out of the interior part of the rear liftgate as it seals the hole where the wiper arm spindle exists the liftgate. I'll keep looking around. If I can find one. I can mold it and reproduce it for personal use obviously...wink wink...