I have a 2003 Expy EB 5.4L 2wd that I purchased not to long ago for the wife to replace our stolen Explorer. It currently has 35K miles on it and this weekend will be the first time I have had time to do some maintenance. I have some questions.

1. I looked for the fuel filter along the driver's side frame rail and can't find it. All I see is the 2 fuel lines coming from the top of the tank and they run all the way up front to the engine. No fuel filter seen. Is it hiding somewhere?

2. I am going to drop the tranny pan, but when looking at it, the 2 most forward bolts are directly behind the crossmember and I don't think that I'll be able to slip a socket in there. Any secrets to getting at them? Also, does the filter just pop off/on?

3. What is the specified fluid change for the rear diff. And how do I know what size it is? I have the H6 rear. It seems I am one of the lucky few that haven't had problems with Ford's IRS set up and would liek to keep it that way. Our Explorer's rear end was completely replaced twice, not to mention a whole other host of problems, but I'm not gonna start on that heap. Very satisfied with the Expedition so far.

Thanks guys for the help. I've only posted here a few times and find that most are respectful and knowledgable here, more than I can say for some of the other sites.

 

well the fuel filter is under a black plastic cover molded in the bottom of the tank. just pop it off and there it is. waring the fuel filter is fg1063 ford is the only brand sold but runs about 25.00 this fuel filter has 3 ports compared to the old 2 prong style. the tranny pan is easy. the filter does nto need replacement nor does hte gasket. but you should clean the magnet in the pan. the pan holds 4 quarts of mercon v. the rear gets 75w140 synthetic gear oil and 4 oz friction modifier.

 

I found the fuel filter. Imazing how well the search function works! I am going to do the tranny and the fuel filter this weekend. The fluid is dark red, but doesn't smell burnt. Should I remove all of it using the return line trick or just pull the pan and replace the amount of fluid that is in the pan? I do not want to burn up the tranny and since it was a Ford CPO, it has the extended drivetrain warranty.

Also, what is the time interval on the rear?

What do you guys think?

 

One man job.
The bell housing has a rubber plug. Remove the plug and turn the engine over with a ratchet and socket. Watch through the hole in the bell housing for a small pipe plug. Removal of this plug will drain the torque converter. Remove the pan and clean the magnet. Disconnect one of the lines going to the radiator. Loosely replace the pan and blow into the disconnect line. This will remove the fluid in the trany cooler in the radiator. Now you can put it all back together and add fluid. Add 4 quarts and start the engine to fill the TC. Continue adding fluid until you have the proper amount installed.

 

the tranny does not have a drain plug on the t/c it has the hole but no plug. ford did away with that. and the the lines to the cooler are non removable unless you use a special release tool which even the guys at my foird dealer don't have because it is almost 90.00.

 

SORRY. This worked on my 99 Exp and my 02 Grand Marquis.

 

So regarding the tranny, basically all I can do is drop the pan, clean it, and replace the fluid that was in the pan with new fluid?

Hey Gashog, why don't I need to change out the filter? When do I?

I guess my last question is more rhetorical, but if we are supposed to maintain our vehicles, why do all the manufactures make it so hard for us (and thier techs)?

 

the filter under normal service does very little. it only has the ability to catch very large particles so unless those are present the filter is good for the life of the trans. the gasket is also reuseable.

 

I agree the gasket is reuseable, but why not just go ahead and replace the filter while you are there. They dont cost that much, and it would give you a peace in mind. On a side note be sure not to over fill the trany. Get it to the min line and go drive it to warm it up good. Then come back and check it again. Then add as needed. GL

 

Serviced the tranny in my 03 Expedition at 36K last weekend and there was no drain plug for the tourque converter. My dad was quite surprised, he suggested we could drill and plug the converter ourselves next time we drop the pan. Has anyone else done this?

 

that is overall bad idea. you will get metal inside the the fins and you will have to drill and braze a bung on there. so it will be way out of balance.

 

Well, didn't quite get around to it guys.

I did get a Purolator fuel filter for $20. What does the tool look like to disconnect it as they had a couple and how does it work? Is it really necessary at 30K, I normally do them at 50K?

Should I just drain and fill the trans pan or let the dealer do a flush with the machine?

Do I just use some RTV on the rear, or is there a gasket?

I just didn't have the time this weekend with school and all. It was also rainy and I wasn't about to crawl around on some wet ground.

 

The rear Diff cover gasket is Peramatex Black 500 degree RTV. Put enough on it to get a "squeeze out" on the outside of the cover. I found the easiest way to refill the DIFF housing is to:
1. remove the spare tire,
2. Jack up the vehicle to get room between the rearl axel and the body
3. Take the ABS sensor out,
4. Remove the side plug and clean the magnet, leave it out for now.
5. Put a funnel in the ABS sensor hole and add DIFF oil until it is at the side plug hole. 6. Reinstall the side plug and the ABS sensor.
NOTE: It is easier if you loosen the sway bar from the frame on each side to get room to remove and reinstall the DIFF cover.

 

Thanks for the tip on the rear. How bout the tranny fluid and fuel filter?

 

Fuel Filter:
Release tools are used to disengage the fuel filter from the fuel line. Find the tool that just fits the diameter of the filter. Try this on the new filter first to get the right sized one.
Release the pressure from the fuel system by depressing the schrader valve on the fuel rail (chrome tubing ontop of the intake manifold). Put the release tool over the fuel filter tube on the fank side of the filter and push it toward the fuel tubing, it will go in about a 1/4 to 3/8 inch, twist the filter to break the seal with the "O" ring and pull the tube off of the filter. Have a can ready to catch the gas from the filter. When the filter is drained then disconnect the other end of the filter. Install the new filter by pushing the lines on to the filter.

Tranny: Drop the pan, clean it and the magnet, install a new filter and bolt it back in place. Add about 4 quarts through the dip stick tube.