I know you said your build thread will move slower than average, but I am anxious to see the finish work.

 

Don't feel like you're the only one here working on a budget I'm 100% disabled from the Army and that's my only source of income. I've tried to work several times and just can't. Before the service I was a chef and made pretty good money. Now my mind can't handle the stress of working in a small kitchen for even 2-3 hours. I feel your pain brother, I'm right here with you if you ever need anything.

 

Looks like fun! We will all likely learn a few pearls on this resurrection. If you go to oemfordpart.com they have everything listed--you just have to sort through to find a name. I told a Ford tech one day I despised looking up Ford parts. It's a major PIA. He said "You'd really think it sucked if you did it every day. It's hard for us too" If you get stuck on finding a part or the name of a part throw it up here-someone will likely know.
Think you already mentioned upgrading the front end--would be a very good time.

Cladding is very individual..some like it and some don't. You could always pull it and hang onto it. Wouldnt be terribly expensive to replace the fender cladding.

As far as the steering column--replace it. Steering on these monsters is a project all by itself. They love to wander. I'd definitely replace the steering gear as well. If your friends have the one off the wrecked X and its not bent up-might be worth considering. Also front suspenson is a booger as well--i'm sure you know to pull and check all of that. I just think in terms of heat conduction around rubber parts even down below. Some of this like number 1042 on a list of 5000 but it would be good to keep in mind as you go from ground up. Sounds like you have a lot of auto/truck experience so that makes your job a lot easier than any of us would experience.

FWIW, I had an 01 and it was not digital so I would imagine most things are identical.

Just picking where to start would be a job for me. Are you planning on rebuilding this from ground up or you planning to get it running and do other things as you go?

Anyway--this will be fun!

 

I used to work for the yard where I get most of my parts. They also sell rebuildables. I started out there as a parts puller, then graduated to driving the loader and getting the new rebuildable arrivals ready for sale. I would usually buy one of the rebuildables to mess with at home in my spare time to sell for extra cash (I usually did the theft recoveries- minimal damage, just replacing radios, wheels, some engine components, etc). After Hurricane Katrina, he bought TONS of flood cars. It was discovered that I had a knack with electrical stuff because everyone was afraid of the flood cars. As long as I had a GOOD set of wiring diagrams, I was golden. From there, I graduated to minor fire vehicles. The key to flood and fire is to REPLACE the harnesses, not repair them! Learned that the hard way!

As far as my Ex, the only reason I'm worried about the steering shaft is it is right under the master cylinder, and I have no way of knowing how hot that location got. I know it DIDN'T get hot enough to melt the aluminum on the master cylinder- didn't even deform it. In fact, the rag joint is perfect, and the plastic cover over the rag joint just has minimal deformation. I was just worried about the heat treating of the shaft. Chances are, the shaft is fine, but my yard is letting me grab one for 5 bucks, so that's really cheap insurance. The steering gear was untouched- doesn't even have smoke damage. I'd like to upgrade it though.

Back when I bought my Super Duty pickup, the entire front end was shot from the previous owner throwing huge tires on it and never maintaining it. I had replaced the tie rods, steering linkage, etc all with new Moog components. I also replaced the hub assemblies and rebuilt the front brakes (I used AC Delco drilled and slotted "police duty" rotors and the extreme duty Motorcraft pads). Three years later I'm still very happy with that setup, so I'll likely duplicate it on the Excursion.

As far as the body goes, I plan to run an aftermarket hood later down the road, but for now, I have a line on a white hood to replace the hood on my truck, so I'll move my slightly-damaged-but-useable hood from the truck to the Ex so I can have a hood that actually latches shut. I'm pretty sure I'm upgrading the front to the 2nd design Super Duty grille (05 I think?).

My plan of attack right now is...
1) Strip out the bad (mostly done)
2) Booster & master cylinder (moving this thing with no brakes is scary!)
3) Wiring & getting the motor to start so I know what I have to work with
4) Chasing electrical gremlins that I just know will be there
5) Rebuilding the front brakes and steering
6) THEN I can play!

 

Wait! That's a thing!?

What, if anything, can be done to prevent it?

 

TSB Go to Ford and see if it was done yet.

 

This should be a great build thread to follow, looking forward to having you walk us through it!

 

According to Alldata the affected vehicles were with the 7.3l only unless there is another TSB I haven't found yet

 

Hey Vwags,

That's worrisome as the OP has an 2001 V10 Limited!

 

I had a brand new f150 in 2001 when I got a recall letter. It had to do with leaky master cylinders on cruise control switches, a very common part in a lot of Fords. I remember being told it was corrected on most 2002 and later F series though. I was ticked because at first all they did was unplug my cruise for a month or so until parts came in.

 

The faulty switches were made by Texas Instruments(?)until late 2002. The fix includes a switch, fuse-able link harness, and a ty-rap strap.

 

Mine was recalled as well. Ford shows my VIN as NOT having the recall done. I'm pretty sure just about ALL 2000-2003 Excursions with cruise control are subject:

Recall #06V-286-- FORD / EXCURSION 2000-2002
Recall #07V-078-- FORD / EXCURSION 2003
Recall #09V-399-- FORD / EXCURSION 2000-2003

Ford Cruise Control Deactivation Switch Recalls and History | The Center for Auto Safety

 

Man, I wish you were closer, i'm sure my old totaled '00 Limited V10 4x4 would have been the perfect harness donor.

Good luck, i can't wait to see the truck back to life and running.

 

By your wording, I take it you no longer have it...

 

Friends of mine bought it front me to repair their 2004 that was also totaled.