I'm original owner of a 2003 Expedition with just under 80,000 miles. Excellent mechanical condition but the cancer is setting in. I'd like to get a few more years out of it as new truck prices are heart attack inducing. I must be getting old.

Anyway, the worst place I need to immediately care for is the radiator support. As you can see, the A/C condenser on the drivers side has fallen out the bottom and rests on the support bracket. Plus, as luck would have it, the A/C recently stopped working too so no big loss if I need to disconnect some lines now.

While I have read and seen pictures on it I have not seen an associated good write up with steps and advice. I'd like to take this job on myself. It seems to be mostly labor. Looking for some advice with steps and direction on this. I have already purchased a new third party radiator support (4L1Z16138BA or FO1225133). I see there are spot welds to drill out and such but I am more concerned with what I need to otherwise disassemble.

What are thoughts on using large cherry rivets to put the new support back in along with something like 3M panel bonding adhesive instead of welding?
http://3mcollision.com/products/adhe...ive-08115.html


Here are some pictures:

 

Wow nothing?

 

Yeah sorry but we're not too big on body repair advice around here, it's mostly mechanical advice.

 

I'm going to be taking this same project on soon too. I have aN 04 EB that you can put your finger through the bottom support.
I didn't realize you could use the specialty glue instead of weld.
I'll give that a try. Currently I haven't done NY thing but order the support. I got it through Amazon.com for 120.93. No shipping cost. It will be at my door around Aug 6th. Then the fun begins.
I'll try to post something on what I find.
Thanks.

 

Lots of pictures would be good too.

 

Do you know if this is the same part number for a 2006 expedition. I may have to do this soon as well but I can't seem to find a rad support for a 2006 expedition. I checked several parts sites. Rockauto has them for expies up to 2005 but nothing listed for my 2006. Help!

 

The part number for yours appears to be: 5L1Z-16138-A

RADIATOR SUPPORT for 2006 Ford Expedition|5L1Z-16138-A

 

I found my part # by entering the VIN on fordparts.com. I then bought it through Amazon.com as the price was much better than the OEM. My understanding is that the aftermarket parts are also much better quality than the OEM for this part.

I stiil have yet to start the repare. I just received the part yesterday. I plan to get started next week.
I'll put a post together a s I do the work.

 

Cool I'll look forward to seeing your write up. All I've done is paint the new support so far.

I got side tracked when my rear brake line burst and now changing brake lines is taking priority. Then of course I find my parking brake is seized and I need to replace much of that stuff as well. Brakes come first!

 

I got too busy and had an auto body shop handle the repair for me. It is a costly thing but also a necessary thing. I am quite sure the radiator would have fallen out of the mount this winter if I didn't have it fixed. The radiator support looked even worse after all the body panels were off and it was taken out. I strongly suggest others check this area especially if they live in regions using road salt in winter. It would be especially unfortunate if this were to break on the roadway as it cannot be fixed quickly. Your vehicle would be down for at least a couple days.

 

 

That's all, heck I thought you said the rust was bad.

 

Amazing how bad it was in that one vital area. The rest of the body panels aren't too bad for a near 13 year old truck in the Chicago area. The rocker panels are shot though but they will wait for replacement perhaps next year. I was surprised the inner side panels didn't have hardly any surface rust even though they are barely coated with any paint.

I still think this was a very poor design on Fords part where they know trucks get used in winter regions where there is salt on the roadways. This would never be a problem with a better sloping design for drainage, a simple plastic diverter underneath to prevent salt from getting kicked up in that area, and a thicker radiator support NOT stamped with multiple thin sheets of steel where salt gets in between and rusts it out. I also think the factory steel uncoated brake lines were a joke and cost me a ton of work to fix as well.

That said, it is a nice feeling not to have to worry about it anymore. I have new brake lines all around, new flex lines, new master cylinder, new brakes, new rotors, a nice new radiator support with a new radiator too, and new transmission cooler lines. If this thing gets in a wreck I'm going to be pissed because I just spent a lot of time and money on it. Probably half what it is worth on the market at this point. Still love it though and plan to keep it a long time. I haven't even hit 80,000 miles yet so it should have plenty of life left and with new trucks around $40,000 and up I think it is still wise to keep this thing. Just need to fix up some other rust and paint issues before there is lasting damage and perforation.

 

I ended up purchasing a repacement support. Because I was unable to remove the many spotwelds I opted to cut out the entire bottom half and replace it the the bottom half of the new support. My bro-in-law has a welder that we used to spot weld everything back together. I painted it with rust resistant black then another coat on bottom with undercarriage coating. I got everything back together in time for my inspection appt. They were impressed with the work I did but still wouldn't pass it. They said the passenger side rocker panel was completely rusted into the base of the door pillars causing severe structural compromise. There suggestuin was ti trade it in.
Long story short I got 2000.00 for it towards a '13 f150 sepercrew 3.5 ecoboost. Do I miss the EB Expy? Not one bit.

 

That's too bad about the inspection. They should know better about the rocker panels and structural implications on a body on frame vehicle vs unibody construction. Though the body may be rusting on my Expedition the frame is very sound and it is very safe to drive still. No inspections in IL for 8,000lb and under trucks surprisingly.

For anyone else concerned about spot welds, Harbor Freight sells surprisingly decent spot weld drill bits for about $5. You might go through 2 bits to drill out this support and it isn't that hard. I'd think it easier to replace the whole thing than trying to match up and weld cut pieces. At least that was my plan before I paid to have it done.

Congrats on your new truck and nice choice! My Expedition was giving me such fits I lost some confidence in it for a bit and bought a new vehicle too. 2015 Mustang Ecoboost is surprisingly affordable and fun to scoot around in. Glad to have the Expedition for the winter and Home Depot runs.