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Went looking to see how I'd done something and realized I never made a build thread on this Excursion. I've done a similar thread on all my prior rigs and they've been super helpful to document and remember things. Time to fix that oversite. lol
I'm the 2nd owner. She was clearly loved by someone over the last 18-ish years. Amazing condition interior and exterior. Engine has been studded and EGR deleted. I've owned it for 10 months so far, and have been really happy with it. You'd never know it has 300k miles.
This thread will show things I've done, upgrades, repairs, etc .
2005 Limited, 2wd, 6.0 PSD Excursion. 293,000 miles at time of purchase. Just over 300,000 miles today
To Do List:
Drivetrain:
1. Test pipe
2. Find out if EGR is blocked off. reinstall EGR valve so it's not just sitting on engine
3. Install IH Blue Spring and 6.4 banjo bolts- Done
4. Convert cold side charge pipe to metal - Done
5. Leave alone otherwise
Suspension:
1. Potentially 2" front leveling kit. Front coils are a little tired
2. Modded B/F codes
or
3. 05-10 4x4 conversion? Actively looking for a complete 08+ donor truck
4. Replace brake pads - Done
5. Replace 2wd wheel bearings- Done
Interior:
1. New Rear Hatch Struts - Done
2. Apple Carplay Radio (Bluetooth) - Done
3. 08+ center console/seat - Done
4. Maglite mounted by drivers seat
5. Swap all bulbs to LED lights - Done
6. LED Blinker Relay - Done
7. Integrated USB for radio into dash - Done
8. Hardwire dashcam
9. Replace cracked dash panel - Done
Exterior:
1. 2017 Style Tow Mirrors- Done 2. Upgraded Headlights with projector lowbeams - Done
3. Projector Retrofit for highbeams
4. Shiny tailpipe - Done
5. Backup Camera- Done
6. 2008+ front conversion
7. Tinted Cab lights - Bought, need to install
8. Superduty running boards
9. Marker Lights on running boards - Bought, need to install 10. LED Foglights - Done 11. LED Backup Lights - Done 12. Quad Brakelight mod - Done
13. Brakelight LED mod
14. Block heater bumper mount using male Marinco plug - Bought, need to install
Repairs:
1. Front fan replacement - Done
2. Evap Core cleaning - Done
3. Rear Window reseal - Done
4. Coolant Bypass Filter hoses leaking - Just removed it - Done
5. Idler pulley squeaks and needs new belt - Done
6. Tensioner is squeaking - Done
7. Resolder Trip Computer
8. Figure out why vent windows won't operate
9. Figure out why ABS light comes on/off randomly with no codes
10. Fixed dome light torn ribbon - Replaced with LED assembly - Done
11. Find/Fix minor Oil leak from somewhere on front
12. Driver seat heater doesn't work
13. Fix loose overhead console plastic - Done
Quad Brakelight mod. Same as always. Drilled a 1" hole. Then used a dremel to fine tune the bulb socket. Spliced the 2 new plugs into factory harness and tested. Can't believe this isn't a factory thing.
also fixed the dome light. the ribbon cable had disentigrated. so I just replaced the whole thing with 2 self contained led assemblies. I think they're marker lighs?...had them for 10yrs. they fit in the cavity perfectly.
2017+ Style mirrors. They use 99-16 mount pattern. Per usual, had to snip ~1" off a plastic nipple near the apex of the "V". The 99-07 doors don't have a hole that the 08+ do.
LED foglights with running lights and blinker functions.
Headlights with projector lens. at some point I'm going to retrofit a projector for the highbeams as well.
Fixed the rear window leak. The butyl had totally failed. used Nicmike guide and it was fairly painless. about 2.5hrs of my time and $25. I only needed 1 roll of the new butyl
you can see where the failure point was in upper left. what a mess that stuff makes. residue was not fun to clean off my hands
Thanks for sharing, it’s really looking great and you have taken a big bite out of your to do list. I have been doing a refresh on my 03 which I bought new and also will start a thread myself. I have been waiting for the better weather because I don’t have a garage and do my work in the driveway. I have updated the interior lighting to LED and done a few other interior fixes which I was able to complete with the heater on, now the real fun begins. Please continue to share your journey with us.
I feel you on the space issue. I have a 2 car garage that’s full at the moment. So I try to catch moments of no rain and relative warmth. I have a ton of goodies I’ve bought that need installing. I’m going to try and install my F250 jump seat today. Miss the good cupholders
Skip the 6.4 Banjo bolts, the point of the check valve in the 6.0 Banjo bolts is to keep fuel in the rail so the injectors (especially #7 and #8) don't starve for fuel. I bought into the hype when I first got mine 11 years ago, but knowing what I know now, I'm putting the stock ones back in. The most I'm doing to the fuel system on mine (aside from a new pump) is the Riffraff FRX.
interesting on the banjo’s. It was all the rage when I owned my last 6.0. Oh well, not like they’re expensive. They were included in the IH kit for “free”
interesting on the banjo’s. It was all the rage when I owned my last 6.0. Oh well, not like they’re expensive. They were included in the IH kit for “free”
Nice
Mine is a Job 3 7/2005
If there's anything I've learned, there are a lot of misconceptions in the Diesel world. Everybody thought you needed to have a chip, intake, and 4 inch exhaust on a 7.3 or 6.0. Come to find out, a 4 inch exhaust isn't really required and the exhaust was perfectly engineered to make sure you have the power that you paid for. I don't want to get into the technical weeds, but I can tell you I've gone and undone a lot of the things I thought my 7.3 and 6.0 needed and things got better with it.
On both Rudolph and The Monster, they both now have downpipe much closer to stock. I actually purposely got ahold of a stock downpipe for The Monster. The 4 inch downpipe I had on it caused a low end lag I couldn't resolve with tuning or anything else I did.
So another piece of advice, as I was told by someone who wrote the programming for Navistar and Ford for the 7.3, 6.0, and 6.4: "Unless you plan on racing the truck, leave the exhaust alone" His words proved correct as the more I unmodified exhaust, the power and fuel economy on both my 6.0 and 7.3 Excursions got better.
I got into the weeds a little but you get the idea. Keep in mind, a straight through muffler helps these trucks, but otherwise leave the rest of it alone. Walker BTM was always a popular muffler to use.
If there's anything I've learned, there are a lot of misconceptions in the Diesel world. Everybody thought you needed to have a chip, intake, and 4 inch exhaust on a 7.3 or 6.0. Come to find out, a 4 inch exhaust isn't really required and the exhaust was perfectly engineered to make sure you have the power that you paid for. I don't want to get into the technical weeds, but I can tell you I've gone and undone a lot of the things I thought my 7.3 and 6.0 needed and things got better with it.
On both Rudolph and The Monster, they both now have downpipe much closer to stock. I actually purposely got ahold of a stock downpipe for The Monster. The 4 inch downpipe I had on it caused a low end lag I couldn't resolve with tuning or anything else I did.
So another piece of advice, as I was told by someone who wrote the programming for Navistar and Ford for the 7.3, 6.0, and 6.4: "Unless you plan on racing the truck, leave the exhaust alone" His words proved correct as the more I unmodified exhaust, the power and fuel economy on both my 6.0 and 7.3 Excursions got better.
I got into the weeds a little but you get the idea. Keep in mind, a straight through muffler helps these trucks, but otherwise leave the rest of it alone. Walker BTM was always a popular muffler to use.
I've often wondered if I revert back to a stock exhaust what would happen, aside from eliminating the nominal drone I get now. I bought it with an MBRP exhaust already on it, and haven't given it a second thought.
Installed Apple CarPlay (Bluetooth) radio and integrated USB into cigarette lighter position. Looks slick if I say so myself. Radio is nothing special. It works. Priced good. And the Bluetooth Apple Carplay is so nice
yeah. There was a circa 2010 Sony touchscreen radio in there. It had been wired for Sirius and had all the bells/whistles. The SWC adapter off it plugged right into the new radio
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