Cool...I didn’t realize there were cons. I’m starting to source parts to convert my 01 to 05+ mainly for turning radius, the ride quality is a bonus for me.
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Project X - Just another Excursion Project
- Thread starter canyonryder
- Start date
Cool...I didn’t realize there were cons. I’m starting to source parts to convert my 01 to 05+ mainly for turning radius, the ride quality is a bonus for me.
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canyonryder
Member
A bit of progress made. Front axle finally hanging from the springs! Tires mounted on the new wheels! As you can see - it has been wet here. I got the swaybar installed with new poly bushings and endlinks before the rain started up again.
CR
CR
canyonryder
Member
A major milestone! Sitting on 4 tires again!! Woohoo!
And the full-size spare fits - kinda. Haha!
Still more to come! Thanks for following along.
CR
And the full-size spare fits - kinda. Haha!
Still more to come! Thanks for following along.
CR
canyonryder
Member
Here are a couple shots under the truck.
It appears we have a bit of an interference issue between the steering gear and the trackbar. Turns out the 4WD pitman arm is different than the 2WD arm. Back to the donor for more parts!
CR
It appears we have a bit of an interference issue between the steering gear and the trackbar. Turns out the 4WD pitman arm is different than the 2WD arm. Back to the donor for more parts!
CR
canyonryder
Member
Got the new Redhead steering box installed and the steering gear adjusted.
Washed it up and took it for its maiden voyage to the grocery store - no issues.
The required Before & After pics!
I love it!!
CR
Washed it up and took it for its maiden voyage to the grocery store - no issues.
The required Before & After pics!
I love it!!
CR
drumguy_18
New member
Nice work! The Ex turned out great. These are fantastic rigs. I hope it gives you many years of trouble-free adventure.
canyonryder
Member
Another update. Let's start with a picture!
Woohoo!! We have a transfer case!! A major step toward becoming a 4WD!
The fine folks at A1 Performance Transmissions - outside of Atlanta, built me a sweet 4R100 good for 500-600hp. They swapped it into the truck and installed my new NV271F manual transfer case. As suspected the driveshaft from the V10 donor was too long, so they shortened it 2" and re-balanced it. They also replace the cooler with the 31-row 6.0 cooler and flushed the lines. I dropped the truck off at 8am and I was back on the road by 2pm. The 6hr ride home was flawless. Can't say enough good things about this shop!
About all that is left is to pull the seats out, pull the carpet back and install the transfer case shifter!
CR
Woohoo!! We have a transfer case!! A major step toward becoming a 4WD!
The fine folks at A1 Performance Transmissions - outside of Atlanta, built me a sweet 4R100 good for 500-600hp. They swapped it into the truck and installed my new NV271F manual transfer case. As suspected the driveshaft from the V10 donor was too long, so they shortened it 2" and re-balanced it. They also replace the cooler with the 31-row 6.0 cooler and flushed the lines. I dropped the truck off at 8am and I was back on the road by 2pm. The 6hr ride home was flawless. Can't say enough good things about this shop!
About all that is left is to pull the seats out, pull the carpet back and install the transfer case shifter!
CR
canyonryder
Member
As you know the Excursions never came with manual transfer cases. They were all electric shift on the fly. I'm going with a manual - how hard could it be?
After we pull the seat out and pull the carpet back we see there is a cover plate to accommodate the xfr case shifter in the Super Duty trucks. In the Excursion there is a heat duct that blows air from under the driver's seat to the rear passengers.
You're gonna have to tough it out if you sit behind me. No floor heat for you! I cut the duct off to access the cover plate.
Then remove the cover plate and cleanup the body sealer.
I sealed up the duct with aluminum HVAC tape and reinforced it with gorilla tape. Also opened a hole in the under-body insulation.
Next we test fit the shifter. Hmmmmmm Looks to be too far back.
For whatever reason, the transmission and transfer case sits about 2" further back in my 7.3 Excursion than in the V10 gas Donor. I had to shorten the rear driveshaft by 2" because of this. It also appears the shifter sits further back than in the Super Duty trucks. Hmmmmm.
So we'll re-install half the cover plate so the boot will have something to screw into and we'll trim the floor a bit behind the shifter. This pic is with the shifter in 2wd - all the way forward.
Haven't trimmed it yet - lunch break. More to come!
CR
After we pull the seat out and pull the carpet back we see there is a cover plate to accommodate the xfr case shifter in the Super Duty trucks. In the Excursion there is a heat duct that blows air from under the driver's seat to the rear passengers.
You're gonna have to tough it out if you sit behind me. No floor heat for you! I cut the duct off to access the cover plate.
Then remove the cover plate and cleanup the body sealer.
I sealed up the duct with aluminum HVAC tape and reinforced it with gorilla tape. Also opened a hole in the under-body insulation.
Next we test fit the shifter. Hmmmmmm Looks to be too far back.
For whatever reason, the transmission and transfer case sits about 2" further back in my 7.3 Excursion than in the V10 gas Donor. I had to shorten the rear driveshaft by 2" because of this. It also appears the shifter sits further back than in the Super Duty trucks. Hmmmmm.
So we'll re-install half the cover plate so the boot will have something to screw into and we'll trim the floor a bit behind the shifter. This pic is with the shifter in 2wd - all the way forward.
Haven't trimmed it yet - lunch break. More to come!
CR
canyonryder
Member
Well I trimmed the floor a bit - here's a pic of the shifter all the way back in 4wd-low.
After much test fitting, trimming and aggravation - here's the boot installed.
Then I installed the front driveshaft - Yay! And fitted a new factory skidplate.
I think (hopefully) that is a wrap!! We are headed to Moab with the camper in two weeks. Watch for a report!
CR
After much test fitting, trimming and aggravation - here's the boot installed.
Then I installed the front driveshaft - Yay! And fitted a new factory skidplate.
I think (hopefully) that is a wrap!! We are headed to Moab with the camper in two weeks. Watch for a report!
CR
pennsylvaniaboy
New member
man kuddos to you, no offense but having a leaf sprung ex...had i been going thru the work, I would have done and '05+ front suspension setup, and e locker rear diff.....
elpoffroad
Adventurer
Amazing!!! your build inspires me, I been wanting to do the manual transfer case for a while. Looking forward to seeing her at moab.
canyonryder
Member
canyonryder
Member
Moab Report!
Well we towed the camper from NC to Moab and back with no issues! The 4.30 gears were perfect for pulling the long hills of the Appalachians and Rockies. We spent 7 days hiking and off-roading - it was a blast! We did some easy trails with the X - Potash Road, Shafer Switchbacks, Onion Creek - the truck was great. The stiff springs and highway tires forced us to take is very slow, but that was fine because the scenery is so epic. Here's a couple pics at the Thelma & Louise point. The trail had a few steep parts and a couple steps of 12" or so. The X motored right along - no wheel spin no drama. The Detroit TrueTrac worked great in the rear.
We rented a SxS to explore some of the more challenging trails like Chicken Corners and Dome Plateau. THAT was a blast. We'll be back to Moab again!
CR
Well we towed the camper from NC to Moab and back with no issues! The 4.30 gears were perfect for pulling the long hills of the Appalachians and Rockies. We spent 7 days hiking and off-roading - it was a blast! We did some easy trails with the X - Potash Road, Shafer Switchbacks, Onion Creek - the truck was great. The stiff springs and highway tires forced us to take is very slow, but that was fine because the scenery is so epic. Here's a couple pics at the Thelma & Louise point. The trail had a few steep parts and a couple steps of 12" or so. The X motored right along - no wheel spin no drama. The Detroit TrueTrac worked great in the rear.
We rented a SxS to explore some of the more challenging trails like Chicken Corners and Dome Plateau. THAT was a blast. We'll be back to Moab again!
CR