Expedition Squared build

[ExplorerTom]

Ive done a lot of cosmetic "upgrades" along the way as well. Every 1st gen I see has a rusty receiver hanging down and is quite the eye sore. So I painted mine.



I "muted" the tail lights:



Painted the grey grille black:



Painted the stuff on the back glass black:



Painted the side window attachments black:



Painted the endow trim black:



I know I said I don't like the "murdered out" look. I'm keeping the gold trim. I'm just trying to consolidate colors to as close to 2 as possible.

 

[justcuz]

How were the Rancho's priced compared to stock replacement KYB or Bilsteins? What is your plan to repair the 4wd and do you have any LSD in the rear axle. Yours has the 9.75 Sterling semi-float correct? Does the front have an axle disconnect like Chevys or is it a solid axle out to the end of the housing?

 

[ExplorerTom]

I mentioned before I had an issue with the AWD system. I was getting driveline binding on dry pavement when turning tight- like into a parking spot. I could also detect a faint grinding noise when accelerating in a straight line. I pulled the fuse that controls the transfercase and it seemed solve those problems. My 4wd selector switch only has AWD, 4hi and 4lo. 4hi and 4lo worked like they should- AWD just seemed to be "always" engaged instead of only during times of rear wheel slippage like it was designed.

It appeared that I needed a way to turn the transfer case on and off easier than pulling and replacing the fuse. A common mod is "the brown wire mod" where you cut the brown wire that tells the transfercase shift motor to energize and install a switch. I did this and it appears to work great.

The switch was placed just below the instrument cluster:


I can turn the switch on to get AWD- useful when the roads are slippery but full time 4hi isn't needed. But for the most part, even when the streets are covered in snow, I keep the switch off and use RWD. It's more fun and the truck behaves normally if I behave normally.

 

[ExplorerTom]

How were the Rancho's priced compared to stock replacement KYB or Bilsteins?

The Ranchos are like $50/shock. I don't remember the exact price and to be honest, I didn't shop other brands. When I did shocks, my plan for this truck was for daily driver/road trip. The Ranchos are great for that.

and do you have any LSD in the rear axle.

Yes it does. Trac-loc is the technical term for Ford's take on this version of LSD. It seems to work. I can drift like a champ in the snow. I haven't had an opportunity to test it off-road yet. If I get larger tires (I'd like to get 35s- current tires are 32), I would probably regear. And while the carrier is out, a Truetrac might find its way back in. I have Truetracs front and rear in my Explorer and they are great.

Yours has the 9.75 Sterling semi-float correct? Does the front have an axle disconnect like Chevys or is it a solid axle out to the end of the housing?

I think it's solid. But I don't know for sure. I assumed all rear axles were solid- if that's what you're talking about. The front is an 8.8 that uses some kind of vacuum system to disconnect. I believe part of the Brown Wire Mod also effects the vacuum solenoids keeps them from engaging the axle. To fix it properly I would have to replace these- or possibly a broken vacuum line. The Brown Wire Mod seems to do the same thing.

 

[ExplorerTom]

The day after Christmas 2015, we headed down to Destin, FL for a week. We left at 2am to get the jump on a snow storm threatening CO. We did the drive down all in one shot. 1500 miles in 24 hours.

We rented a $1.5 million house for the week with my wife's family that was basically right across the street from the beach.


I didn't really take any pictures of this trip. It was gas, eat and go. On the way back we did stop for the night. 3100 miles total. We have thoroughly vetted the Expedition's comfort on long trips. The rear HVAC system is great for the kids to control the temp back there. They also have reading lights in the ceiling so they can read at night.

 

[Ivan]

From my research, the 7700 GVW torsion bars from the pickup (not sure if F-150 or 250) are the desired torsion bar, BUT I've heard they are too long to be used on the Expedition.

Some did come with air suspension instead of torsion bars though. As these vehicles get older and the air suspension wears out, people would rather not repair the air suspension and get a coilover instead. I think Monroe makes it. I don't know much about that, but it would be interesting to explore that route and play with different coil springs and better shocks.

7700's fit, they're just unobtainium now.

Air suspension still comes with bars, but those have the lowest "spring rate" out of all the torsion bars.

I'm going to buy some torsion bars from an FX4 and give it a go, see if those help with lift/support after a winch is added.

 

[ExplorerTom]

^^good to know. Thanks.

Let me know how the FX4 bars work. Do you have a build thread?

 

[ukrboy]

The 2V Modular motors don't have the problem with the spark plugs breaking off like the 3V motors. I believe the 3V motor started in 2003 or 2004, but I'm not sure. The only problem I had was access. Those near the firewall, especially on the driver side, are very tight. You just need to properly tighten them so they vibrate loose and get spit out.

If your intake manifold ever cracks (common problem that I'll address in a future post), that would be a GREAT time to replace spark plugs. The access problem is solved. And getting the manifold out really isn't that complicated.

Check out youtube for a channel called FordTechMakuloco (LINK). He provides fantastic videos on hundreds of different Ford related tech issues. His video on spark plug replacement says to tighten it down and then to go a little more to get it so it's good and tight. He details everything very well. Plus he's Canadian, so he does it all in a super friendly way.

Thanks for the link.
I had to replace the ignition coil on the driver side by the firewall. Took me three days.
Your expy looks amazing btw. Ours is not nearly as clean. Love the look with those wheels.
Not sure you know, but that third row seat belt comes off with a push of a button.
It's a great idea though with the osb in the back. Makes it much easier to load stuff in.


Sent from my iPhone using Tapatalk

 

[kojackJKU]

I have it's cousin the screw 150. I see a lot of things IM going to be doing with mine!

 

[ExplorerTom]

I have it's cousin the screw 150. I see a lot of things IM going to be doing with mine!

You should check out this build:
http://www.expeditionportal.com/forum/threads/145917-10th-Gen-F150-Build

 

[Ivan]

^^good to know. Thanks.

Let me know how the FX4 bars work. Do you have a build thread?

Not yet. I haven't done enough to mine to really start a thread. I might after the next few mods (storage drawers, extended diff breathers, etc). I'm just in the same boat, trying to find out as much as possible about these trucks: for as much info as there is out there, there seems to be a dearth of info on the suspension and the different 4wd systems used on the first gen.

Which reminds me: If I recall, the 1997 - 1999.5 (the ones equipped with the 2hi-A4wd-4hi-4lo switch) use the vacuum actuator just like the 10th gen F150's. The late 1999.5 - 2002 first gen do not. Those are a live axle set up (like a jeep or dodge) with the magnetic (electronic?) clutch inside the BW 4404 acting as an on/off switch during auto 4wd, but locks in place in 4hi or 4lo.

That's why if you do the brown wire mod, regardless of what they say at f150forums, you will not get power transfered to the front axle at all with the swith on "off", even if you move the knob to the 4hi or 4lo position.

Though you will get 2wd low, which is kind of cool.

 

[kojackJKU]

already have. I am doing things a little different than wolvee. suspension is going to be different. I think I don't need any higher, maybe a 1" lift in rear and a little crank on the bars...but that's about it. I am adding air bags for trailering.

 

[secondechomatt]

Good stuff! I love my 98. Daily driver, weekend warrior, camping machine!

 

[justcuz]

So Ivan the later front axles are solid with no disconnect? Like you said, I know Jeep and Dodge did this later to simplify their 4wd systems. Id like to see more technical info on this platform, not a lot out there.

Tom saw your Florida picture and was surprised how large the Traverse is parked next to the Expedition. I guess I never realized how big those crossovers really are.
Looking forward to more improvements on your Expedition!

 

[Ivan]

So Ivan the later front axles are solid with no disconnect? Like you said, I know Jeep and Dodge did this later to simplify their 4wd systems. Id like to see more technical info on this platform, not a lot out there.

Tom saw your Florida picture and was surprised how large the Traverse is parked next to the Expedition. I guess I never realized how big those crossovers really are.
Looking forward to more improvements on your Expedition!

Yeah, from all the research that I've done, the 2nd half of the first gens differ in the live axle vs. vacuum disconnect.

Personally, if I was going to do more with the truck, I would rather have an F150 front end with a cable actuated disconnect/engagement, and a manual transfercase. Less of a chance of the internal clutch set up in the 4404 from failing when you need it (that and less electronics to mess up).