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2000 7.3 4x4 Excursion. Completely stock. Flipped over 170,000 miles on the drive home from Texas.
I'm going to list things changed/fixed/upgraded and cost of parts/service. I won't include shipping or taxes. I'm also not including tools purchased to do the fixes.
18 Apr 17
-Tires (Yokohama Geolandar A/T G015, 10 ply, Tire Rack $662.16 including shipping)
-Alignment, Pitman Arm Tie Rod End, Rear Brake Rotors+Calipers+Pads, Turn Front Rotors, Flush Brake Fluid, Install and Balance Tires (Fowler's in Phenix City, AL $1128.00)
19 Apr 17
-Put in Front Windshield Sunshade (WeatherTech TS0046, $59.95 WeatherTech)
25 Apr 17
-Install Rear Bump Stops and Snubbers (Energy Suspension 9.9155 and 9.9156, $51.70 Suspension.com)
-Rust Conversion and Paint Sway Bar Bushing Bracket (Loctite Extend Rust Neutralizer, $8.99 Amazon) + (Eastwood Extreme Chassis Black, $14.97 Eastwood)
30 Apr 17
-Paint Front Sway Bar and Brackets (Eastwood Extreme Chassis Black Primer, $11.97 Eastwood) + (Eastwood Extreme Chassis Black, already counted)
-Install Front Bump Stops (Energy Suspension 4.9103, $80.17 Suspension.com)
-Install Headlights (99-04 F250 F350 Excursion Chrome w/ Xenon 4pc set, $89.95 eBay) + (2x BWD PT326 Turn Signal Socket, $17.98 O'Reilly) + (Dorman Headlight Socket, 2 pack, $11.99 AutoZone) + (Side Marker Light Bulbs SYL194, Turn Signal Bulbs SYL3157, $11.95 O'Reilly)
1 May 17
-Install Front Sway Bar (Moog K80203 Sway Bar Bushing Kit, $9.27 Amazon) + (Moog K80273 Stabilizer Bar Link Kit, $47.46 Amazon) + (Moog K80274 Stabilizer Bar Link Kit, $49.78 Amazon) + (Mobil 1 Syn Grease, $8.99 Auto Zone)
-Install Water Pump, Flush, Fill With ELC (OEM Water Pump, Lower Elbow, Degas Bottle and Cap, Billet Thermostat Housing, Thermostat, $367.82 Riffraff) + (Gates 22433 Upper Radiator Hose, Gates 22434 Lower Radiator Hose, Gates 19812 Heater Hose, Motorcraft JK81223AA V-Ribbed Belt, Motorcraft YS238 Idler Pulley, Motorcraft BT-50 Belt Tensioner, $181.64 Amazon) + (28 Gallons Distilled Water, $22.96 Walmart) + (4 Gallons Rotella ELC, $59.96 Tractor Supply)
13 May 17
-Install 6.0 Transmission Cooler (5C3Z-7A095-CA, $293.84 MBAutoParts.com) + (1/2" Cooler Line Derale 15700 10', 3/8" Cooler Line Derale 13016 5', 10x Precision Brand Hose Clamps M10S, $53.11 Amazon) + (3/8"-1/2" hose barbs 2x, UPE Group, $11.90 eBay)
14 May 17
-Install Transmission Filter and Fluid Flush (Motorcraft FT-114, $26.87 Amazon) + (Mobil 1 ATF, 4 cases of 6, $196.64 The Lubricant Store) + (4x Magnefine Inline ATF Filters, $64 Magnefine)
15 May 17
-7.3 Power Stroke Excursion badges ($55.95, Truck Emblem Warehouse)
18 May 17
-Change Rear Differential Fluid and Diff Cover (Ford 8C3Z-4033-A Differential Cover, Lube Locker Ford Sterling 10.25 & 10.5 Differential Gasket, 5/16" Flat SS Washers Hillman Group 830504 x100, 5/16"-18 X 1-1/4" FT SHCS x25, Mobil 1 102490 75W-140 Synthetic Gear Lube x4 quarts, $175.04 Amazon)
21 May 17
-Changed Transfer Case Fluid (originally used Mobil 1 ATF, but on 1 Sep 18 changed to Ford Transfer Case Fluid XL-12)
-Changed Front Differential Lube (Lube Locker Dana 60 Differential Gasket, $21.95 Amazon) + (Mobil 1 104361 75W-90 Synthetic Gear Oil x3 quarts, $39.50 Amazon)
28 May 17
-Install Rear Sway Bar (Hellwig 7643 Rear Sway Bar, $237.59 AutoAnything)
31 May 17
-Touch Up Paint (Dupli-Color AFM0359 Deep Wedgewood Blue Ford, $12.66 Amazon)
7 Jun 17
-Installed V and C code springs and caster shims (V and C spring kit for Excursion, ATS $971.76 including shipping) + (2* caster shims, WFO $35) + (installation and alignment , $475 Fowler's in Phenix City, AL)
18 Jun 17
-Installed back up camera and mirror (Gentex Rearview Camera Display Mirror 50-GENK332s, Autoanything $297.14) + (BOYO License Plate Camera VTL300CL, Amazon $83.49)
21 Jun 17
-Installed mirror wire cover (Gentex 50-9010227001M Long Black Wire Cover, $14.99 Amazon)
22 Jun 17
-Installed Tablet and OBD Reader (8" Samsung Galaxy Tab A, $129.00 AAFES) + (ScanTool 426101 OBDLink MX Bluetooth, Arkon Car Seat Rail Phone or Tablet Mount for iPhone 7..., Anker Quick Charge 3.0 39W Dual USB Car Charger, $141.53 Amazon) + (Torque Pro, $4.95 Google Play)
23 Jun 17
-Installed A Pillar Grab Handle Bolt Cover (Ford YC3Z-2531458-AAA, eBay/Tasca $15.82)
25 Jul 17
-Resealed Rear Window (Stephen's Auto Glass, Columbus, GA $100)
27 Jul 17
-Flushed Power Steering/Brake Booster System (Mobil 1 Synthetic ATF, 3x quarts, $24.58 thelubricantstore.com)+(Magnefine 3/8" Magnetic Inline Power Steering Filter, $19.95 magnefinefilters.com)+(Constant-Tension Spring-Band Clamps for 5/8" OD Hose and Tube, pack of 10, $4.13 McMaster Carr)
29 Jul 17
-Replaced Passenger Window Switch (Motorcraft 7123, Rock Auto $38.79)
-Rear Window Washer Relay (Ford F57B-14B192-AA, eBay $15.99 for 6 used ones)
-Replace Front HVAC Blower and Resistor (Blower Motor Four Seasons 76900, Dorman Blower Resistor 973013, Rock Auto $43.18)
1 Aug 17
-Install Tekonsha Prodigy P3 Brake Controller (Tekonsha Prodigy P3 Trailer Brake Controller, Tekonsha Plug-In Wiring Adapter for Electric Brake Controllers - Ford, Lincoln, Mercury $133.96, eTrailer.com)
9 Oct 17
-Install Stereo (Sony XAV-AX100, $417.99 Crutchfield. BATIGE USB 3.0 Male to USB 3.0 Female AUX Flush Mount, $9.90 Amazon)
23 Oct 17
-New Spare Tire and Rim (Yokohama Geolandar A/T G015, $153.13 Tire Rack, Rim, $75 Craig’s List, Mount & Balance, $24.50 Ft Benning Auto Skills)
28 Oct 17
-Engine Bay upkeep and mods (Complete CAC Intercooler Boot Kit $128.13, Plenum Reinforcing Inserts $35.86, AIH Delete Plug $12.99, Intercooler Boot Complete Clamp Kit $47.99, AIH Plug Code Eliminator $14.99, Turbo Wastegate Actuator Vacuum Lines $15.96, Heater Core Inlet Hose $45.23, HPOP Quick Disconnect Hose Removal Tool $12.88, HPOP Line Drivers Side Head $89.33, HPOP Line Passenger Side Head $89.91, Passenger Side Fuel Line $45.66, Pressure Power Steering Hose $79.81, HPX $49.88, FRx $188.81, All from Riffraff)
30 Oct 17
-Transmission Thermostat (Derale 15719 Fluid Control Thermostat Kit, $53.92 Amazon)
7 Nov 17
-EBP Sensor and Tube (Exhaust Back Pressure Sensor 97-04 4C3Z9J460A1 $81.28, Exhaust Back Pressure Tube 99-03 1C3Z9D477AA1 $42.24, Exhaust Back Pressure Tube Manifold Fitting 3C3Z9F485BA $6.90, all Riffraff)
19 Feb 18
-Hutch & Harpoon (Filler & Vent Hoses + New Hose Clamps, $56.95 Filler Neck Supply Co) + (Racor PS120-02, $56.95 Racor Store) + (Permatex 85420, $11.26, Gasoila, $10.79, Dorman 800-157 Repair Line, $15.90, Dorman 800-156 Repair Line, $13.25, Ford Pickup Foot E5TZ-9J306-BA, $33.47, AAS 3/8" Fuel Injection Clamps, $4.79, All Amazon) + (Stainless 3/8 NPTx5/16 Hose Barb, $3.98, Stainless 3/8 NPTx3/8 Hose Barb $4.97, 5' of 5/16" 30R9 Fuel Injector Line, $33.75, 5' (needed 10') of 3/8 30R9 Fuel Injector line $33.95, All eBay) + (~$8.00 Mounting Hardware, Home Depot) + (Replacement 30R7 3/8" Fuel Line and Hose Clamps, ~$20 O'Reilly's) + (Replacement 3/8" Compression Union, $4, local hardware store)
12 Mar 18
-Gauges (Glowshift MaxTow 100psi Fuel Pressure Gauge, 1500F Pyro Gauge, 260F Trans Gauge, 35psi Boost, MaxTow 4-Gauge Power Wire Harness, 7.3 Fuel Pressure adapter, Glowshift Direct $363.44) + (F650 Dash 4C4Z-7004302-HA, $32.61 OEMFordPartsDirect.com) + (Dark Tan Parchment Paint, AIH Delete Plug with Boost, $31.16 Riffraff) + (2x add-a-circuit (small fuse), Dupli-color Adhesion Promoter, Dupli-color Matte Clear Coat, shrink fit butt connectors and spade terminal connectors, wire, ~$75 various auto parts stores) + (Rocker Switches: Fog Lights, Rear Lights, USB, and 2xUSB Charger with Voltmeter, $63.92 Amazon)
24-25 Mar 18
-Install Fog Lights (Rigid SAE D-Series Fog Lights 504813, Rigid '99-'16 Superduty Mounting Brackets 46503, Hebron Auto Parts $254.98) + (fog light brackets from salvage yard, $20)
7 Apr 18
-Installed HPOP Line Fittings (High Flow for HPOP and OEM for the heads, dieselorings.com $60.20)
2 Jun 18
-Steering Gear and AIS (Blue Top 2765BS 1999-2004 Ford Super Duty Steering Gear w/36 Spline Sector, Blue Top Steering Gears $260 (plus $150 core)) + (Gates 365436, 365437, 352899 power steering return lines, Motorcraft AIS (FA1759), Rock Auto $299.33) + (Mobil 1 ATF, Amazon, 6-pack, $64.99) + (Magnefine PS 3/8” Inline Filter, $19.95 magnefinefilters.com)
20 Jun 18
-08 Tow Mirrors (Mirrors TRMRP00019, 1AAuto $246.95) + (Ford Wedgelock Pin Type Terminals 20-18 Gauge .060" Pin Diameter, clipsandfasteners.com $7.69)
23 Jun 18
-Backup lights (Rigid Industries Ignite Pair Backup Lights #20641, Hebron Auto Parts $97.99) + (303 Stainless Bar, McMaster Carr $12.99) + (relay and in-line fuse, eBay $12.35)
1 Sep 18
-Changed Transfer Case Fluid (Ford Transfer Case Fluid XL-12, Amazon $27.98)
12 Oct 18
-Replaced Front Hood Seal (Ford F81Z-16A238-AA, Amazon $34.09)
2-8 Jun 19
-Turbo Rebuild, Blank Pedestal, Up Pipes (7.3 360 Turbo Rebuild Kit, SP Turboost $69.99)+(Additional 4 12-pt bolts, EPV Fooler Resister and Turbo Outlet O-ring, Diesel O-Rings $12.66)+(Riffraff 4x4 Billet Wheel, Riffraff Blank Pedestal, Riffraff High Flow Outlet, Riffraff $328.39)+ICP Sensor and Pigtail (Motorcraft F6TZ9F838A and 5C3Z12224A, Riffraff $212.38)+Bellowed Up Pipes (Dorman 679005, Rock Auto $153.79)
11-16 May 20
- Replaced Radiator, re-plumbed for OTW trans cooler in radiator (Spectra Premium CU2171 radiator, $221.73, AutoZone) + (Dorman Oil Cooler Lines 624-276 & 624-035, $26.47, Rock Auto) + (2x 1/2”x3/8” Barb fittings, $17.26, Amazon)
25 May 20
- Dash LED bulb replacement (6x 194-CWHP5 (1 spare): Cool White, 2x 74-CWHP3 (1 spare): Cool White, 5x 74-WHP: Cool White (in case any warning lights need replacing), $46.36, SuperbrightLEDs.com)
21 June 20
-Brake Soft Lines (0"-3" Lift Brake Line Kit for Excursion + Rear Line Kit (different lengths), $208.98, Crown Performance) + (3 Quarts Lucas DOT3 Brake Fluid, $26.97, The Zone) + (2x Dorman 13906 Bleeders, $5.99, O'Reilly's)
27 June 20
-Rear Brake Calipers and Pads (2x Duralast 18-B4752 passenger rear bracketed calipers, DG 757 Duralast Gold brake pads, 2x quarts of Lucas DOT3 brake fluid, $194.85, AutoZone)
12 July 20
-Driver's seat cushion (OEM foam cushion C-EXC-01-FOAM-D, $131.99, The Seat Shop)
1 Oct 20
-Re-wire trailer plug socket (Pollak 11-998 Pigtail Wiring Harness, $19.55 + Pollak 11-893P RV 7-Way Socket (New Part number, old one is PA66-GF30), $12.25, Amazon)
3 Oct 20
-Brake peddle cover (Dorman 20753, $5.02, Amazon)
17 Oct 20
-Hydra Install (PHP Hydra Tuner and Riffraff Flush Mount Bezel, $324.67, Riffraff Diesel)
1 Nov 20
-New IPR and Pigtail (Motorcraft F81Z 9C986 AB and 6E7Z 12A690 DA , $216.03, Diesel o-Rings)
21 Feb 21
-New batteries (Odyssey Extreme AGM group 65, $599, Auto Zone)
8 May 21
-Front brake calipers and pads (Duralast bracketed caliper, 18 B4790 and 18 B4791, Lucas DOT3 brake fluid, $133.58, AutoZone), and (Hawk SD brake pads, $90.57, Amazon)
9 May 21
-Drivers side grab handle (used, $50, private sale)
16 Aug 21
-Alternator (Bosch AL7555N, $179.79, Rock Auto)
10 Nov 22
-Rebuilt transmission (American Transmission, 36mo/100k, $2452.17, installed by Brocks Tri-County Transmission in Mineral Bluff, GA, $840)
20 Oct 23 -Install 6.0 Transmission Cooler (5C3Z-7A095-CA, $225.30 FordPartsGiant.com)
8 Mar 24
-Sous Be Positive mod: Alternator Terminal Extension (96505623, $17.69, Maniac Electric Motors), Blue Sea Systems Dual MRBF Terminal Fuse Block and two 150A Blue Sea Systems Terminal Fuses (Amazon, $64.79), and wiring, crimping lugs, and battery clamps I had for my future new battery cable project.
11 Nov 24
-Alternator swap: Bosch Alternator (AL7526N, Rock Auto, $156.99), 6G to 3G Alternator Conversion Wire Harness (eBay, $16.28), Shim Gaskets, Stainless (17mmx24mmx1mm, Amazon, $8.85)
28 Apr 25
-PowerSteering Pump (Duralast 7107N, $226.79, Auto Zone). Power Steering Pump to Hydraboost Pressure Line (Duralast 80245, $34.99, Autozone)
21 May 25
-Bed slide (5-1/2’ bed stock slide, $2000+, Slidemaster). Hardware ($200+, various)
25 Mar 26
-Hood and Lift Gate struts (Generic, Rock Auto, $38.58)
Total (so far) $21,443.66
Last edited by ArmyLifer; Mar 30, 2026 at 03:56 PM.
I've had a rear tire go flat at highway speeds, not sure it's safer than a front tire going, barely kept my Tahoe from rolling - as the rear started to slide sideways.
Congratulations on the new Ex, find a GOOD alignment shop that does a lot of pickups, consider adjustable caster/camber bushings (especially if you are doing new Upper ball joints) to address the wander, before you consider a Red-Head steering box.
I'm reading through all the 203 vs. 195 stuff on the thermostat right now. So many decisions. I just don't want to potentially do anything to damage my "new" truck.
Ok, I ordered a stock thermostat and a "billet" thermostat housing from Riffraff. That, in addition to a pile of other small stuff should give me lots to do in the near future.
As a side note, I frequent a machinist forum where they regularly ridicule anyone using the term "billet" in describing auto parts. What most auto parts makers mean by billet is "machined from solid". Not the same thing, at least from a strict definition standpoint. This may be the first "billet" part I've bought. I have made a ton of "machined from solid" parts in my time though.
From his list in the first post it's obvious he has a diesel, and since he would already have a 6.0 cooler if he had a 6.0, I figured I was safe this time if I assumed. Plus, he mentioned the spare CPS he was bringing that was lost with his luggage in another thread.
Stewart
Last edited by Stewart_H; Apr 9, 2017 at 05:53 PM.
From Wikipedia: "A billet is a length of metal that has a round or square cross-section, with an area less than 36 in2 (230 cm2). Billets are created directly via continuous casting or extrusion or indirectly via hot rolling an ingot or bloom. Billets are further processed via profile rolling and drawing."
Typically a billet is an intermediate step in the foundry process before the metal is formed into the solid shape (flats, rounds, tube, sheet, etc) that a machinist uses to make our parts. The only one making anything from billet is the foundry, extruder, or casting house.
I'm not sure why the machinists on that site get up in arms about it. Maybe it's like me with the modern use of your and you're? Makes me crazy.
Sorry, I did start this thread off without any pictures. I'll go back and fix that.
Ok, what flush kit is in use now? Prestone has the "Flush and Fill", but Napa doesn't sell the kit in Gooch's picture. Just curious what will work for this application?
I guess I'll pick the low hanging fruit first.
Air filter swapped out. New Motorcraft installed.
Also replaced the cracked and weathered hood shield with this AVS one. Going to fill out the $10 rebate for it this evening.
I was going to take this fix it up slowly, but I've already ordered about $1200 worth of parts. I haven't even got to the high dollar things like tires. Too many of these threads giving me ideas...
