First Gen Ford Expedition

TheViking

Adventurer
I’m looking to build a full size expedition vehicle. I looked at Suburban and Tahoe but went back to my roots Ford. Being cheap and a in a career field with a down season I want to keep it older, used, but still dependable and serviceable.

My target has become the 99 to 02 Ford Expedition In Eddie Bauer trim with a 5.4 and 4.10’s if I can find one geared so.

Now my goal is 33’s, CB, 10K winch, additional lighting, dual battery, high output alternator, roof top tent, and fridge, snorkel as well. Added drawer system for tools, cooking and eating utensils, and recovery gear.

My desire is the ability to go out for a week at a time with myself or up to three plus my dog. I also want this to be serviceable as a daily driver , able to pick my kids up from school, and take me to church.

I’m sure there are some things I have overlooked and forgotten. Please let me know about your experience with this platform and if I’m totally wrong. Thank you.




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Mickey Bitsko

Adventurer
I had a 2v 5.4 never had a problem.
Don't quote me, I believe the 01' 5.4 3v was introduced little more power etc.
I wouldn't be concerned. You're looking at buying a 20 yo vehicle and it WILL be a project, but, you can make it as good as you can afford.
 

ExplorerTom

Explorer
The 3v motors started in 2004. The early 2nd gens still had the 2v motor.

I don’t think any 1st gens came with 4.10 gears. Best you can do is 3.73 from the factory. I have 3.55 in mine. With my 33s..... I wish I had 4.10. But that may happen some day.

I have 255k miles on my 2000 Expedition (see link below). Wouldn’t hesitate to jump in it now and either drive it across country or drive it deep into the back country. It’s a great platform- it’s essentially an F-150.

What to look out for:
The rear trailing arms are known to rust. There are some good aftermarket arms from Supreme Suspension as well as another but the name is escaping me right now. Even on mine, that I believe spent its life out West, the arms were a little rusty.

In late 1999 they switched the heads over to “PI” heads. Performance Improved. More desirable. Frankly, I’d look at 2000+.

Spark plugs. Everyone will say how the spark plugs shoot out because of the heads aren’t threaded enough. But it seems that it you torque them properly, it’s not an issue.

Intake manifold. The intake manifold has a coolant crossover tube that will eventually crack and leak coolant everywhere. Easy fix if you are comfortable spinning wrenches. My advice: stay away from the Dorman brand replacement. Go OEM.

I love mine. It’s 19 years old with over 1/4 million miles and I have zero plans to replace it.
 

Mickey Bitsko

Adventurer
The only issue with the 2v 5.4 was spitting plugs, I didn't mess with them I had a reputable mechanic change them as recommended by Ford then if there was an issue it was on the mechanic. Been Ford my entire life , your starting with a good platform.
Good luck, have fun.
 

TheViking

Adventurer
The 3v motors started in 2004. The early 2nd gens still had the 2v motor.

I don’t think any 1st gens came with 4.10 gears. Best you can do is 3.73 from the factory. I have 3.55 in mine. With my 33s..... I wish I had 4.10. But that may happen some day.

I have 255k miles on my 2000 Expedition (see link below). Wouldn’t hesitate to jump in it now and either drive it across country or drive it deep into the back country. It’s a great platform- it’s essentially an F-150.

What to look out for:
The rear trailing arms are known to rust. There are some good aftermarket arms from Supreme Suspension as well as another but the name is escaping me right now. Even on mine, that I believe spent its life out West, the arms were a little rusty.

In late 1999 they switched the heads over to “PI” heads. Performance Improved. More desirable. Frankly, I’d look at 2000+.

Spark plugs. Everyone will say how the spark plugs shoot out because of the heads aren’t threaded enough. But it seems that it you torque them properly, it’s not an issue.

Intake manifold. The intake manifold has a coolant crossover tube that will eventually crack and leak coolant everywhere. Easy fix if you are comfortable spinning wrenches. My advice: stay away from the Dorman brand replacement. Go OEM.

I love mine. It’s 19 years old with over 1/4 million miles and I have zero plans to replace it.

I don’t know if it was due to Tapatalk or what but the link never posted could you please post that and thank you for the input!


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ExplorerTom

Explorer
 

TheViking

Adventurer

Thank you for the link awesome build!


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Kmrtnsn

Explorer
We ran the 1st Gen Ford Expeditions back in the day when I was a Border Patrol Agent. They're a poor platform for off-roading. Eventually it will develop cracks in the firewall that will extend to the floorpan in the driver's footwell. This a torque/twisting issue between the monocoque body and the frame. It is not repairable. It is documented with a Ford. We had two dozen deadlined and undrivable when I left the station, which was too bad because I liked the way they handled. I liked the electric four wheel drive engagement and the all-around good visibility from the driver's seat. Two other off-road issues I personally experienced was the lift cable for the spare tire failing, making me backtrack several miles to recover my spare and a tie-rod breaking.
 

ExplorerTom

Explorer
I wonder if Border Patrol uses their vehicles like most other police agencies. Which is to say: aggresively. The cops that I know drive with the gas in one of 2 positions: off and on. Add in the extra element of offroad and you’ve got yourself an extreme torture test. Sure it may be documented, but there is a massive difference in stress between high speed bumps and abuse (Border Patrol) and slow twisting and flexing (regular driver).

But then you use the word “monocoque” and I start to think that either you are just misusing the word, or these failures were on an entirely different platform. A monocoque, by definition, is one where the body and chassis are the integral to each other. Like a Jeep Cherokee. The Expedition is a body on frame. The frame could still twist enough to cause damage to the body, but it’s not a monocoque.

I should probably crawl under there and look for cracks, but I’m guessing even at 255k miles, mine has lived a pampered life compared to one that is used exclusively offroad by a bunch of guys who aren’t financially liable for the vehicle and generally need to use speed offroad instead of caution on a daily basis.
 

85_Ranger4x4

Well-known member
But then you use the word “monocoque” and I start to think that either you are just misusing the word, or these failures were on an entirely different platform. A monocoque, by definition, is one where the body and chassis are the integral to each other. Like a Jeep Cherokee. The Expedition is a body on frame. The frame could still twist enough to cause damage to the body, but it’s not a monocoque.

It kinda sorta is. The body is all one piece as opposed to a pickup that is broke in the middle with the cab and bed being separate. That would put more twist on the body.

I don't know much about Expedition specific stuff like the firewall cracking but I have had a similar F-150 for 14 years/160k miles (truck is 17 years old and sitting at 180k)

Spark plugs are a mild PITA to get at and are very picky on being torqued. I let my brother who is a Ford tech change them every 75k miles and haven't had an issue. Coil packs can be flaky, best to carry a spare or two with boots if going offroad for several days at a time. A darn near impossible to find locally when you need it 7mm wobble socket (NOT a 7mm socket with a wobble) makes it easier to change the coils. I keep one in a quarter inch drive set under my seat to ensure I never need it. I have a little wireless OBDII broadcaster thing and can pull codes with dashcommand on my phone.

Front wheel bearings, be careful, they are not cheap to replace and a really hard hit will ruin them. For sure get the name brand ones with the better warranty.

For the intake crossover tube, if you stay up on coolant changes/flushes it isn't as big of a deal. Of course now you are exactly buying them new either...

4wd, make sure it is fully engaged before you get after it. There is a sacrificial aluminum shift fork in the front diff that will break off if you get too rammy with it while it is trying to engage. It is designed that way so the front diff doesn't grenade. T-case motor appreciates being cleaned/lubed, there are write ups out there on how to do it. My '150 has a manual t-case which I love, I pull the lever something in the dash clicks three times and everything is engaged.

If yours doesn't have it some Expeditions and OR/FX4 F-150's have a nice skidplate that fills in the gap across the front of the engine.

For ease of working on, they kinda started the trend of going downhill with this vintage. I haven't worked on newer, maybe not (not counting IRS Expeditions, they have more of what I hate rather than less) but compared the OBS trucks they went way backwards. Heater core and evaporator are buried in the dash, unit wheel bearings vs component wheel bearings that last forever because you can grease them (and cost $20/side to replace) it is easier to change spark plugs on a 460 big block than a 4.6 etc. I pulled the manual trans out of a 04 F-150 heritage for my Ranger, the crossmemeber that holds the back of the torsion bars (and thus holds the front suspension together) had to come out before the trans/t-case could come out. Stuff like that just kinda makes me go eek.

Ford really missed the boat by not offering a 4dr Bronco, it would have been awesome. And yes I know about the goofy 50' long Centurion thing...
 

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