Hi folks, I have a 2004 Expedition XLT 4WD 5.4L, and I'm starting to get vacuum leaks. I have a leak in what Ford calls a Vacuum Hose Harness, part #2L1Z9E498AA, which is obsolete, like half the stuff on this vehicle. I have googled the part number and found some hits but none of them panned out. I have a couple of questions for you. First, does anyone know of this part being available? I don't mean for you to do my research for me, I'm just asking if you've already located this part for yourself, etc. Second, what are you guys doing to either locate, repair, or make your own when it comes to all of the obsolete parts for this model/year? I would try to make my own vacuum hoses and assemblies, but I've heard that pretty much everything has to be exactly the same as on the original part. If it's not, the vacuum won't work right and I'll have more problems than I do now. Has anyone had luck in making your own? Any sources for the raw materials? Thanks for reading!

 

Just get some vacuum hose and couplings for it and then run the lines yourself. Save the original end fittings and use the couplings to attach them to the new lines you ran.

 

Did you call these guys : New Old Stock Parts - Ford They "say" it's in stock, but who knows. Most of that line is plastic tubing, with just ends being rubber elbows or connectors. You can find new elbows in the HELP display at any Advance Auto parts store.

However, the PCV vacuum tree is still available through eBay or Amazon if you need that.

2000-2004 Ford 5.4L PCV Vacuum Tree

You might consider smoke testing the intake system to make sure exactly where the leaks are.

Mechanics Smoke Testing Machine

 

Alloro, thanks for the suggestion and I may try this. It sounds like you've had success with it.

Hamfisted, thanks also for your help. The vacuum tree shown on Ebay is not the one that I need, but it's good to know that there are some vacuum parts that are still available. I have a smoke detector and that's how I located the leak in the vacuum tree that connects to the left fuel rail. It also smoked at the EGR valve so I'm replacing that. Fortunately the Motorcraft EGR valve is still available, just got one from Amazon.

I appreciate the help folks!

 

Yes I've done this many times when original vacuum lines are not available. Probably the most difficult part of it is routing the new lines neatly.

 

Hamfisted, I emailed NOS and am waiting for a reply. I'll let you guys know what I find out, and thanks for the good lead!

 

Have not had a problem making my own vacuum hose assemblies for our Exped or Excur.
The problems I've had with vacuum hoses is the non-reinforced hose used in the PCV line, plastic tubing/fittings and anywhere a neoprene hose connects to the engine.
The PCV non-reinforced hose elbow gets soft, the plastic tubing can break and neoprene hose within 1-2 in of the connection to the engine will degrade from heat.
When rebuilding the vacuum hose lines I use reinforced hoses, brass fitting/tees/reducers and silicone hose.
Don't see any reason the hoses can't be whatever length works to route them to allow easier access to the plugs, particularly on the passenger side.
Ford routes the hoses tight around the engine to make it easier to install the engine.
The pic is a rebuild of the PCV line for our Excur.

 

Thanks R&T Babich! The photo helps a lot. I would like to use silicone and brass fittings to make the vacuum system as bulletproof as possible. May I ask your sources for the materials you used?

 

I got the parts on ebay and Amazon.
It can take a couple of weeks for stuff from ebay.
I used a reinforced fuel tank vent hose to get the PCV elbow, but next time I would use a brass elbow. (3/8" 10mm elbow brass barb - $2)
The silicone hoses are sometimes listed in mm - 3/8" = 10mm, 5/16" = 8mm, 1/4" - 6mm, etc.
I rerouted the heater hose lines to make it easier to get to the plugs on the passenger side, used a couple of 3 layer reinforced silicone turbocharger hose elbows which work well.

 

Very helpful! Thank you!