I'm not sure where to start this one, current issue or from the start?? Current issue Fords infamous loose steering column lower shaft. The joints are fine, it is lose in the center where the collapse point is. From the start , well go get a beer or take potty break, Cuz this will be book :-).
I got thi9s truck on a take it or forever shut your pie hole! He owed me money, and was headed to club Fed, and I needed a truck. It ran and was spoused to pass smog (that's what they all say). While driving it home I changed course to the alignment shop (very scary) to see if it could be aligned. NOT! Lose idler arm appeared to be the issue. No Problem, changed it and then was called to jury duty and was picked. When I had a day off I took Her in for an align an smog, well Fail Fail, now the upper control arm was lose and had stored codes w/no cel. Thats good and bad, The bad WTF is up with the steering. The good with a failed smog I can get a EOP emergency operating permit (up to 90 days) not just 1-day passes. Back to Jury duty I go and the wife goes to the DMV (gotta get tags it is on the street) an texts me Life Is Good. I get home I'm ambushed by the wife with my mother in tow. They wana know why I would bring such a roached vehicle (how it got the name Roach Coach) home and then pay $975.00 in DMV fees for a 2001. Who Paid What, nothing had been done since 2016 this is 2022. I won't go thru the math, but the state charged 9x the yearly fees and the wife just paid it. Non Refundable so no I'm on the hook. Tyrin to smooth this out I tell the budget committee My Wife & Mama that we are stuck and do need a truck I will only fix what is needed instead of jus droppin from the frame down and replace (the only way right way IMHO). The good the decision of the committee was the budget would remain the same, but whatever I save will be rolled in to the next budget (I always go over :-).) The bad now I'm starting with multiple drivability issues and failed smog w/no cel om the cheap RIGHT. At the end of the day I got a car an I got a budget, so Life Is Good. With 204K on the clock I went with drop an replace and just told the women I was Savin Money. Now let's fast forward to 208K and almost half of the budget spent everything has been replaced from the pitman arm out to the wheels. While making the appointment for alignment the service writer asks Me am I sure it will be able to be aligned this time I said it better. The tech tells me of the shaft, and I tell him align it anyway cuz it is tearing up tires. He says he can't Cuz the idler arm is still lose. So, I remove the idler and take it back, Guess What?? The counter person tells me that it is not the idler I paid for WTF??? How did it escape and leave a clone in it place LOL Sounds like this belongs on the SYFY channel or call Scully and Mulder . I'm jus being an A$$. I have my suspicions who... Without a smokin gun I can't say nonthin bout her son so ill close that book and put it back on the shelf.
All this leads up to Cuz the shaft is lose in the middle not the joints it can go on for long time GI. Or bite the bullet and replace both now idler so it can be aligned and the shaft so I'm not sailing a boat down the road/// My crystal ball says go all in or it will bite me in the A$$. My wallet says save a buck now inflating my next budget. Choose between More Money and the right thing the age old dilemma. It is hard enough doing this kind of work in the street but then have to re-do work due to another's selfish actions really sucks. I want My shop back.
I told you it would be a long one
AMF for now Mike/EZ

 

I've searched the world over, and thought I found true love. I clicked on another and poof you were gone. That is what is feels like searching price and availability of a lower steering shaft and of course it is the to 4/01/ 36.5" length. I found a low of 100$ used to just under 500$ new if the place had the early model. Rock auto was 187$, NAPA 425$ {both Dorman}, and almost 300$ for motorcraft.
It is close in cost between making a shaft and buying one. My Question: is the shaft collapsible just for accidents or does the shaft expand and contract. While rolling down the road?
Option1 buy new
Option2 buy used
Option 3 make one
Option 4 just keep sailing a boat till i run up on one on the cheap., cuz it is loose in the middle not the joints and does not feel dangerously loose> each has pro and con so I would think option 4 would seem the most likely way ahead. This truck seems every time I turn around it is another 200.00 bill for somthing LOL Mike/EZ.

 

Lower steering shaft ordered, and it should be the last component needed for the steering, Heck only 2 items left the steering column and the steering box. This job is AWAP
Information that might help someone in the future:
1) Before 4/20/2001 takes a 36.5" shaft only!! Dorman # 425-379 is the only OTS direct replacement.
2) Several vendors and fitment guides indicate the 425-354 will fit but it is only 31" in length, and everyone and his brother makes this one also it is way cheap.
3) a 36" collapsible shaft is available if you want to make a shaft, but they do not make a direct replacement for the Expedition
4) RockAuto was the least expensive at 188$ + shipping & tax Amazon was 237$ w/tax and no shipping only a couple bucks difference, but Amazon is supposed to be 5 days faster to the doorstep.
If this helps anyone it will have been worth the trouble Mike/EZ

 

Amazon had the shaft and sprig isolators on my porch before dinner time yesterday (Tuesday) .The shaft appears to be or normal Dorman quality or lack or quality however you feel.
I measured and tested the shaft, and coleslaw up the data.
collapsed the shaft is lose and measured 24”
fully extended the shaft was tight and measured 36 1/4
jooking at the shipping container size most being so close most shafts collapsed probably are 24-25 “ and the way it was lose then tightened up as it was extended is the critical measurement. I think the only way to find my answer is to get my hands on some shafts because the data isn’t readily available mike ez

 

What is up with this truck? My 10/00 mfg. date Expedition has been a nightmare as far as parts. now it the steering shat; the book calls for 2 shafts 1 before 4/21 dorman # 425-379 36" in length and the other is after 4/21 dorman # 425-354 31" in length. The 425-379 is to short by apx. 1.5 ". that makes the 425-354 way short. WTF I guess I will have to make temporary repairs on the shaft that came out of the truck, keeping it in service until the correct replacement or custom-made shaft can be procured. Mike/EZ

 

??? Nobody, somebody has to have run into this issue before, and I can't accept not knowing.
I have the feeling this might have to do with year model production issues. with the before and after call out in the book, something changed. What and when, only father ford knows??? Whatever it was it was it changed the shaft length and a 39" shaft was used as a substitute until corrected by the 4/21 date. Thats my best guess, and at the end of the day only thing that matters is: "What Freakin Shaft Is 39" In length".
If I have learned anything by working on discontinued vehicles is people will sell you anything, then tell you but the book says. Yes the part probably will fit and most people will never notice the difference, but that doesn't make the right part! On my crown Vic they kept sending me an aluminum LLCA with a steel RLCA, and nobody could find a match for either. One person told me to just install what I was sent and move on, nobody will know the difference. RIGHT, not on my watch. So, I ended up rebuilding what was on the car.
I'm not just crying in my beer, there is some bitchin in there too. I know somebody has or had this issue, so when and if I find an answer I will let you all in on it ... Mike/Ez
PS: The joints were good, but lose where the shaft slides, Abracadabra an a little Mikie Magic the Expedition is back in service :-).

 

Not to squash your pursuit of knowledge but the absence of other contributors suggests this is a non-issue for most Expedition owners? As much as I regret saying this site and/or sub-forum might not be very helpful.

Good luck though!

 

Thank You for the response, JWA. On the other hand, members are stopping bye for a look so there must be interest in the subject. I don't mind talking to myself, because I hear the echo off the walls, and that echo helps me make sure I have it correct.
The only reason I'm pursuing this issue is because, I am not finding any information on this subject, to help My Son understand what goes along with a build, and finally with the shaft at full extension when i install the body lift, I'm quite sure I will need more length in the steering shaft. That translates to either a longer shaft or a shaft extension. It's the same over in suspension a simple spring lift can and did snowball creating new issues, also finding corrective components (off the shelf) for the Expedition is difficult to say the least. on that note I have My parts guy at napa looking into a direct replacement shaft over 39" in length.
The Good News Is: I have crossed the part numbers and physically tested the Steering and front Suspension from a 99 F-150 2wd on My 01 Expedition 2wd, all components interchange.
The OCD in Me will not allow me to half A$$ a job, I'm all in or nothing. "Root Cause analyses" is one of the tools I use to help keep order in all the clutter around Me. You Guy's will warm up to Me I'm not worried, I'm just an acquired taste. Mike/EZ

 

Steering is awap. Go figure a drag link damaged in shipping. This will give me time to re-evaluate the way ahead. I have the same picture in my mind, it is going to take a bit more engineering with a lack of OTS corrective components other than custom fabrication. Mike/EZ.