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Old 03-31-2018, 06:31 PM   #11 (permalink)
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Join Date: Jun 2008
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Workstar - '01 Ford Windstar SEL
90 day: 20.12 mpg (US)

2003 Expedition - '03 Ford Expedition
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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.

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Old 04-07-2018, 05:57 AM   #12 (permalink)
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Join Date: Feb 2010
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Supra - '88 Toyota Supra

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superhawk - '98 Honda superhawk
Last 3: 27.62 mpg (US)

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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
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Old 04-08-2018, 12:11 PM   #13 (permalink)
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Join Date: Jun 2008
Location: Ohio
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Workstar - '01 Ford Windstar SEL
90 day: 20.12 mpg (US)

2003 Expedition - '03 Ford Expedition
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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?
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Old 04-08-2018, 12:18 PM   #14 (permalink)
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Quote:
Originally Posted by mazdamx640 View Post
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.
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Old 04-08-2018, 04:56 PM   #15 (permalink)
EcoModding Apprentice
 
Join Date: Feb 2010
Location: Howells Ne
Posts: 124

Supra - '88 Toyota Supra

Truk - '99 Ford F150
Team Ford
Pickups
90 day: 18.75 mpg (US)

superhawk - '98 Honda superhawk
Last 3: 27.62 mpg (US)

Lesabre - '96 buick lesabre
3800
90 day: 25.85 mpg (US)

Saturn - '97 Saturn Sc2
Team Saturn
Sports Cars
90 day: 39.12 mpg (US)
Thanks: 15
Thanked 7 Times in 6 Posts
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
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Old 04-09-2018, 06:36 AM   #16 (permalink)
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Join Date: Jun 2008
Location: Ohio
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Workstar - '01 Ford Windstar SEL
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2003 Expedition - '03 Ford Expedition
90 day: 14.54 mpg (US)
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Quote:
Originally Posted by mazdamx640 View Post
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.
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Old 04-09-2018, 12:34 PM   #17 (permalink)
EcoModding Apprentice
 
Join Date: Feb 2010
Location: Howells Ne
Posts: 124

Supra - '88 Toyota Supra

Truk - '99 Ford F150
Team Ford
Pickups
90 day: 18.75 mpg (US)

superhawk - '98 Honda superhawk
Last 3: 27.62 mpg (US)

Lesabre - '96 buick lesabre
3800
90 day: 25.85 mpg (US)

Saturn - '97 Saturn Sc2
Team Saturn
Sports Cars
90 day: 39.12 mpg (US)
Thanks: 15
Thanked 7 Times in 6 Posts
You have a point some how these Ford's make what should be a small easy job into a grueling task
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Old 04-11-2018, 09:27 AM   #18 (permalink)
EcoModding Lurker
 
Join Date: Jun 2008
Location: Ohio
Posts: 23

Workstar - '01 Ford Windstar SEL
90 day: 20.12 mpg (US)

2003 Expedition - '03 Ford Expedition
90 day: 14.54 mpg (US)
Thanks: 0
Thanked 0 Times in 0 Posts
Quote:
Originally Posted by mazdamx640 View Post
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.

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