Ford Excursion and $5k To Spend: What Would You Do?

IPA

Observer
Last April I bought a 2002 Excursion with the V10 and 103k on it. It's very clean inside and out (with the exception of a fair amount of surface rust on the undercarriage, and a few small dings here and there), and it runs and drives well. Only problems are typical, minor annoyances like the CC not working and some of the power windows moving slow. It recently had the front springs replaced with new OEM leafs and has a cheap head unit in place of the factory radio. It is otherwise completely original and stock. I don't know any details of the maintenance history other than it was apparently pretty well taken care of.

I bought it to be a daily driver / beach trip / camping trip / ski trip / road trip / family vehicle, as well for for some treks out west to explore some backcountry in AZ and CO and UT for a week or so at a time about once a year. No heavy towing planned. I put a lot of miles on a vehicle, probably 25k a year or a little more, and I want to have this thing last me for at least 5 or 6 years before it reaches that point where the repair costs make it not worth keeping.

I'm new to Fords and haven't driven this truck a ton or really gotten to know it well yet. I don't have any elaborate "build" plans but I'm thinking about stuff like quality floor liners, towing mirrors and putting a 2005 grill on it (both just for aesthetics), maybe some bumpers and a small lift with some good AT tires. I'd like to clean up the surface rust underneath to some extent as well; it's not a big issue at all but it just bugs me knowing it's there on this otherwise clean truck. Maybe some sort of fridge. No sleeping platform or anything; I do plan to sleep in it occasionally, but I can just put my air mattress and sleeping bag down in the back of it. Maybe a new in-dash nav / backup camera and a CB. The biggest goal is just keeping it reliable and durable and versatile, that's all.

So, let me pick the brains of those of you who know these trucks well: if this truck was yours and you had, say, about $5-$6k to put into it over the next 6-12 months, and you planned to use it the way I've described, what would you do with it? What are the first items you'd inspect and perhaps expect to need to fix or replace in the near future? What sort of tires and lift and bumpers and other mods would you consider?
 

oldestof11

Observer
I'd save that money for a Cummins swap. :D

For the 05 grille, you'll need the head lights and I think front fenders. I know you need the lights. My brother looked at doing the same to his old F250.

At that point, you can pick out the 08-10 front end too.

Since you drive a lot, I'm serious about the Cummins swap. For reliability, you can't beat a good 12v. Total cost around $10k including rebuilding the 12v and some small parts to help it get up and go.
 

Rovertrader

Supporting Sponsor
Check front axle hubs and ball joints, flush cooling and Trans, change diff oils, sway bar bushings, etc- likely $1-1.5k, but now base lined and ready for weeks away from pavement.
Just change shackle on front to level, add seperately fuse block and second batt for fridge and such.
Get essentials for you, not others- i.e.:fridge, etc
Then get out and enjoy!
 

IPA

Observer
Thanks for the maintenance advice. Exactly the type of info I was looking for.

A 12v would be awesome, but a big custom project like that isn't something I'm interested in tackling. I have often wondered if I wouldn't be better off with a PSD than with the V10, but around here guys want $15k and up for ones with way over 200,000 miles and if you can find a nice clean one with low miles they are often asking $20k - $25k. I just can't justify that when the V10 I already own is a solid motor to begin with.
 

justcuz

Explorer
For suspension just install Superduty truck springs. There is an Excursion website that tells you the part numbers. Good for a couple inches of lift. Next would be traction adders for the diffs. Locker out back and an LSD front. The Excursion will have a Dana 50 front, its up to you wether an upgrade to a front Dana 60 is worth it. Finally some quality shocks. You'll be able to run 35's with this setup, no problem.
Navigation can be anything from phone/laptop down loads to a vehicle in dash system. Maps and a compass still work good for me!
If it's clean, just keep it that way, most folks won't know if you swapped the grille.
Focus on the stuff that will get you out there using it.
 

damon1272

Observer
One weak point with the V10 is that they like to spit spark plugs. Very common. May want to have held-coils installed now so as not to strand you. Otherwise it is a very good engine.
 

XJSuperman

OhIOWAn
Pics?

Do the maintenance first, then see whats left of the budget.

With that remainder, I would look at skipping the grill swap, but mirrors are doable, and I even have a set I need to sell. How about that? Lol. I agree on the SuperDuty springs as well.

I always liked a nice Excursion. Maybe a nice set of fog lights, and a good set of tires. I'd look at Cooper ST Maxx, MasterCraft MT, Firestones, or Cooper AT3s. I know people who like Falken Wildpeaks, but Im not sold yet.

Maintenance: Check the axle seals and ujoints. Fuel rail, oil filter housing, and spark plugs. My dad had an 01 F250 with the v10 and those went on out on it first.
 

82fb

Adventurer
I would not drop a cent into that thing. Save the money for the fuel you are about to use. 25,000 miles at 10 mpg or so, 2500 gallons at 2.50/gallon is a lot of money.
 

Ozymandias

Observer
I second this, this V10 sucks fuel like camel sucks water. Not the best for a travel car.
So if you stick with it, spend the money for a spare fuel tank that raises the range to go.
 

IPA

Observer
Here is how she sits this morning:
Excursion Jan2016.jpg


Do the maintenance first, then see whats left of the budget.

This week I'm going to crawl up under it and inspect everything closely. Next oil change I think I'll spring to have them replace all the fluids, and I should probably have the spark plugs done, because I don't know if they've ever been done.

With that remainder, I would look at skipping the grill swap, but mirrors are doable, and I even have a set I need to sell. How about that? Lol. I agree on the SuperDuty springs as well.

I always liked a nice Excursion. Maybe a nice set of fog lights, and a good set of tires. I'd look at Cooper ST Maxx, MasterCraft MT, Firestones, or Cooper AT3s. I know people who like Falken Wildpeaks, but Im not sold yet.

Maintenance: Check the axle seals and ujoints. Fuel rail, oil filter housing, and spark plugs. My dad had an 01 F250 with the v10 and those went on out on it first.

The grille swap is a cheap, simple job. $200 for a new one (much less for used, of course) and about 15 minutes of work. Admittedly it is purely about appearances (so are the towing mirrors, in my case), but IMO the two together completely transforms and updates the overall appearance of the truck.

Fog lights are a good idea. The tires are in good shape but I'm going to try to get them replaced before my two weeks at the beach this summer. I'll consider the ones you mentioned, but I'm pretty partial to BFG's and I'm eyeing a set of KO2's.


I would not drop a cent into that thing. Save the money for the fuel you are about to use. 25,000 miles at 10 mpg or so, 2500 gallons at 2.50/gallon is a lot of money.

I second this, this V10 sucks fuel like camel sucks water. Not the best for a travel car.
So if you stick with it, spend the money for a spare fuel tank that raises the range to go.

Really guys? :rolleyes:
 

mtm_motors

Observer
For the 05 grille, you'll need the head lights and I think front fenders. I know you need the lights.

Excursions are great trucks, I drove a 7.3 Limited for a while. I did an 05 front end on it, you only need the grille, lights, and bumper, which if you do a custom front bumper just make sure it is for 05 and up. The grille drops lower on 05 up, I know some bumpers are universal for 99-07 but they likely don't fit as well. Some folks do the front bulkhead, but I think you can trim in a few spots if there are interference issues (it is NOT necessary to swap the bulkhead). The mirrors are super easy... I did manual ones, but I think the power plugs interchange as well. I believe the 08 and up mirrors that are more squared off fit as well.

Certainly a diesel swap would be a good long term investment, but it will be pricey. Folks want a mint for diesel Excursions in my area as well, or I would have another one! It is one of the most enjoyable trucks I've driven and an excellent trip vehicle. We used it to haul four wheelers to the dunes and multiple trips with 4 plus passengers and it never failed to be comfortable.
 

SDDiver5

Expedition Leader
Definitely get the spark plugs checked. My fam used to have an X and we blew a spark plug while towing our boat home from summer vaca. No fun. Bring it to a Ford mechanic to change it and also be prepared for helio coil replacement if any of them do break.

I grew up driving my family's X. So much fun and its pretty incredible how capable they are as is.

Don't bother with the people telling you about gas. If your X has the top tow package it should have a 40 Gal tank. That will get you 400-500 miles depending on your foot.
 

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