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I have done a search and read dozens of posts, but would like to throw out some symptoms and see if anyone can help.
I have a 2000 Ford Expedition 4x4 with 91,000 miles. Recent work includes:
12000 miles ago - Engine rebuild
4500 miles ago - most of the front end was rebuilt
4500 miles ago - front and rear brakes done
3500 miles ago - transfer casing repaired (not sure the exact issue)
150 miles ago - speed sensors replaced
50 miles ago - tires replaced
Current symptoms - Vibration is coming from the front end. I can feel it both in the steering wheel and the gas pedal. It usually occurs at higher speeds (55+mph) but also can be felt "occasionally" at speeds as low as 25mph.
The tires that were just replaced had no odd wear pattern to them, suggesting an alignment was necessary but I am not discounting a needed alignment. The new addition of tires did seem to help a small bit (15% or so improvement)
The sound cannot really be heard, just felt. Steering does not seem any different that before the vibration occured. I'd say it has really been evident only for the last 1000 miles, around the same time the speed sensors failed.
I would check the tierods I have a 99 Expedition and I have a similar experience and I found my inner tierods to be bad. I have not changed them yet so I can not sa whether or not this is th eproblem but I would bet it is...
What was rebuilt on your front end? Ball joints? Upper control arm? Bushings? Tie rods? Recently, I had the same thing going on and replaced the lower ball joints and the outer tie rods and problem was solved. The factory non-greasable parts are not stout enough for the weight of the engine and truck body in the front of the truck, the parts are just too poorly made. Replace the parts with Moog greasable units and you won't have any problems.
Is the EXPY automatic 4wd or true 2 that shifts into 4hi/4low? and did you change all four tires or just two? The reason I ask is that on the A4WD if you only change two tires the difference in diameter between the semi worn tires and the new ones will cause front end diff noise and vibration. Could this be the case with your EXPY?
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