2003 Ford Expedition build thread

[grswat]

I got busy this morning and afternoon installing this fan. First I tapped into a wire that was hot with key on.

Then found a nice spot to mount the adjustable fan controller.

The fan mated nicely to the oem shroud. I know its not a perfectly sealed fit but it should work well. It has 3 bolts with double nuts with an old sway bar link bushing sandwiched between the two shrouds to limit vibrations.

And my semi final wiring mess. I will clean things up a bit once I am certain everything works how I want it to.

This fan is an absolute beast. It pulls somewhere between 30 and 40 amps. I know this because it will blow a 30 amp fuse. I matched the wire gauge with what was on the fan already. And I manually ran the fan for about 5 minutes and the wires and relay didn't show any signs of warming up so I feel good about it. I noticed the truck warmed up significantly faster than I recalled before...but it was also almost 60 here today instead of 30s-40s.

[mazdamx640]

What engine does it have 4.6 or 5.4? I'm assuming these are just about the same as a f150 if so 20 mpgs should be easily attainable with a few mods. My 99 f150 gained about 2 mpgs from switching to an electric fan so that's a good start. I also recommend a lawn edging air damn extension, synthetic fluids in diffs and transfercase, upper grill block and 12 hole injectors

[grswat]

Filled up this morning for my first tank with the electric fan conversion. Didn't see any improvement but I know its a step in right direction.

Cut out some coroplast pieces and spray painted them black for my upper grille block. I realize they would be better in front of the grille but I'm opting for the better cosmetic appearance over efficiency on this one. Shoot me.

Planning on picking up a used 3.31 rear end in the next week or so. Then it will be a matter of finding time to install the damn thing. On a related note does anyone have any recommendations for a tuner that can correct the speedometer/odometer once I do the change?

[grswat]

Originally Posted by mazdamx640

What engine does it have 4.6 or 5.4? I'm assuming these are just about the same as a f150 if so 20 mpgs should be easily attainable with a few mods. My 99 f150 gained about 2 mpgs from switching to an electric fan so that's a good start. I also recommend a lawn edging air damn extension, synthetic fluids in diffs and transfercase, upper grill block and 12 hole injectors

5.4 unfortunately. Keep in mind the Expedition is a good 1000+ lbs heavier than an f150. And a lot of f150's have a taller rear end ratio.

[mazdamx640]

Wow had no idea they were so heavy. If you want to have a manual a m5r2 out of a f150 should drop right in and if u can find one that's rwd you could lose the transfercase front diff and axles that should save At least 100lbs and have less drivetrain loss

[grswat]

Originally Posted by mazdamx640

Wow had no idea they were so heavy. If you want to have a manual a m5r2 out of a f150 should drop right in and if u can find one that's rwd you could lose the transfercase front diff and axles that should save At least 100lbs and have less drivetrain loss

According to what I have seen online they are around 5600 lbs. I wouldn't be against a manual swap but everything works fine as it is now so I have no plans to rock that boat. Sounds like a lot of work..cause it is a lot of work.

[mazdamx640]

You have a point some how these Ford's make what should be a small easy job into a grueling task

[grswat]

Originally Posted by mazdamx640

You have a point some how these Ford's make what should be a small easy job into a grueling task

Wouldn't say its a Ford thing just more fabrication that I want to mess with. Driveshaft, mounts, shifter, entire clutch system, linkages, computer issues?, etc etc. With this being more or less a daily driver I can't really have it down for a length of time.

[grswat]

Seems like my grille block is working. I have my 3.31 rear diff ordered, just waiting for it to come in. I also scored some FREE 245 70 17 tires that are nearly new. They are all terrain tires which isn't really what I wanted but free is free. Not sure when I will have time to get everything installed but at least heading in the right direction.

[grswat]

Been lazy about updating on here.

5/12-5/13 I installed the 3.31 rear end. Everything went pretty well. Tore it apart on Saturday late afternoon/evening then finished it up Sunday morning. My scary looking brake lines reared their ugly head when I went to test drive by blowing out the rear line so my hand was forced to replace that. I also removed the front driveshaft since the front diff is still 3.73.

5/17 I got my programmer to correct the speedometer. It is a "power programmer" and it feels like it improved throttle response and transmission shifting immensely. I have a slight concern that has actually hurt mileage but its fine for the time being.

5/18 I installed a manual switch for my electric cooling fan. Mainly did this for A/C performance at low speeds/parked.

5/19 Unfortunately I had to replace one of the axles seals in the rear end. Guess that's what I get for being cheap/lazy and not replacing them while it was on the ground. Other side is not leaking so will leave it alone for now.

5/19-5/20 We took a trip to Michigan. Got about 50 miles from home and the truck totally shut down. Found that the ignition switch fuse had blown. I hastily cut the wires for my manual fan switch. My suspicion is that somehow it back fed through the ignition switch fuse and blew it. Will have to rethink my wiring when I get back to reinstalling.

I feel that the 3.31 rear is probably a little tall. But my plan to go to a smaller tire size will offset that. On the highway it is very sluggish to accelerate without kicking down a gear, which I expected but I feel it is too much.