My wife drives a 2000 Expy with 188600 mi and in a few months were gonna trade.. Can you guys give me some advice on the yrs that you like or to stay away from..Im not fond of the air bag suspension so I need reccomendations on years there, are there any years to stay away from...2003-2007 or so is what Im looking at.. I really like the 4.6 but Id be willing for a 5.4 on the best year..Thanks for your help!!

 

If you like the '03 body style, then that ended in 2006. The 2007 gen Expy's came with the new 6 speed tranny and some other goodies such as the extended length version, roll stability control / traction control and a heftier price tag partially due to production cutbacks. The rear axle components are no longer solid aluminum but rather stamped steel and seem to be more difficult or more expensive to align.

I still think the 2003-2006 are best looking and best built Expy's. The 4.6L is not available after 2004. I have the 4.6L and love it but it's not powerful enough to tow much. It seems the rear blend doors are the weakest part of the truck in these years, but it's an easy fix if / when it fails.

These are just my opinions and may be contrary to many others.

 

Our 5.4 03 has been very reliable but we've only managed 80K since buying it (new). Changed the plugs and COP's at about 70k (cheap COP's from Ebay). Synthetic oil and filter every 5k. tseekins is bang-on about the blend doors, I've had to replace them every 3 years, it's like they've got little timers in 'em. Replaced both front door window regulators, they went bad within 3 months of each others. I suspect they have timers too. The down-side is yesterday I put $95 in the gas tank but you already know about that problem. The 03 change in the rear axle made a huge difference in the ride quality and the fold-flat rear seat is great.
The bride would like a new ride but I tell her that at 80K it's just barely broke in. There is a growl or howl that I think is coming from one of the front hubs but I haven't spent enough time chasing the noise to be certain. That'll need some attention this fall I expect.

 

My '03 is rock solid at 110K, but I did fight the blend door and clutch pack issues while under warranty. Now that the bugs have been worked out for awhile, the routine maintenance is paying off. I have the 5.4, and have not heard of any real fuel mileage benefits of the smaller 4.6.

I'd shoot for an '05 or '06 to get the 3V motor which provides 300 from the 5.4L 3-valve, versus the 232 you are getting from the 4.6L 2-valve, with essentially the same fuel economy. You will love the IRS, and with a good set of shocks and tires the ride is great around town and on the open road...

 

The 04 has been very good, currently at 120K miles (as of Monday this week). 2004 is the last year for the "2V" 5.4, so far not a single issue there. Had 1 bad ball joint at 80K, the power driver's seat has had a recurring issue. Otherwise all good.

 

Thanks for the info guys, I appreciate it!! Will keep an eye on those yrs suggested!!

 

... just make an "informed decision" regarding an early 5.4- 3V. There can be major issues with changing the plugs - should be easy to find a couple of threads about that. Good Luck.

 

What ABolt1 says about the IRS is more than true. I owned an 02 and then an 03 and the ride difference is night and day. While we haven't logged that many miles we have managed several long road trips (Houston to Monument Valley, Durango CO, Silver City NM and we are planning a trip to Orlando to pick up a travel trailer soon) and it's been nothing but reliable. Not cheap but reliable.