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2002 7.3 2wd build thread. 4x4 conversion, 2005 axles, etc

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Old Apr 20, 2026 | 10:48 AM
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2002 7.3 2wd build thread. 4x4 conversion, 2005 axles, etc

Hey guys, I'm slowly making progress on my conversion, this forum has been a great help. I've been reading old posts on here about other similar conversions people have done.
I recently picked up this 2002 Excursion with a 7.3 and 2 wheel drive. It has zero rust, came from somewhere in the southern US like Arizona/Utah. It has 200k miles and is in pretty good shape. My goal is to build a nice cruiser I can take on trips and pull my boat with it.
I picked up a set of 2017 Platinum wheels with 35" tires and a front end from a 2007 F350 King Ranch. Hoping to give it an updated "facelift" look.
Here are some photos of my progress so far.
I've also trying to film everything and will post some videos to YouTube when it's all done and I have time to edit them

On the day I picked it up
On the day I picked it up

On the day I picked it up
On the day I picked it up

Interior in the Ex is pretty nice. Only thing wrong is the seat switches dont work on either seat
Interior in the Ex is pretty nice. Only thing wrong is the seat switches don't work on either seat

Interior in the Ex is pretty nice. Only thing wrong is the seat switches dont work on either seat
Interior in the Ex is pretty nice. Only thing wrong is the seat switches don't work on either seat

Picking up the parts truck
Picking up the parts truck

Getting ready for surgery
Getting ready for surgery


Lifted the cab off the parts truck
Lifted the cab off the parts truck

Front end components off the parts truck all painted up.
Front end components off the parts truck all painted up.

Lifted body off the Ex
Lifted body off the Ex

Wire harness was squished on the frame by the body. Not sure if thats how they are from the factory?
Wire harness was squished on the frame by the body. Not sure if that's how they are from the factory?

Wire harness was squished on the frame by the body. Not sure if thats how they are from the factory?
Wire harness was squished on the frame by the body. Not sure if that's how they are from the factory?

Brought the engine over to my friend for him to go over and replace all the seals and injector cups, o rings, water pump (was original 2002 pump), power steering pump, etc.
Brought the engine over to my friend for him to go over and replace all the seals and injector cups, o rings, water pump (was original 2002 pump), power steering pump, etc.

Installing KC Balanced assembly and new KC pedestal
Installing KC Balanced assembly and new KC pedestal

Front part of the frame all painted
Front part of the frame all painted

Coil buckets and radius arm brackets installed
Coil buckets and radius arm brackets installed

Front coil buckets installed
Front coil buckets installed

Got longer bolts for the steering box. Original 2005 bolts were too short
Got longer bolts for the steering box. Original 2005 bolts were too short

Was hoping to re-use the wheel speed sensors on the front, quickly found out that the 2 wheel drive wheel speed sensors are much different
Was hoping to re-use the wheel speed sensors on the front, quickly found out that the 2 wheel drive wheel speed sensors are much different

Front end coming together
Front end coming together

Brake lines re-bent and plumbed
Brake lines re-bent and plumbed

Brake lines re-bent and plumbed
Brake lines re-bent and plumbed

Front end all put together
Front end all put together

2017 Platinum wheels with Goodyear Wrangler 35
2017 Platinum wheels with Goodyear Wrangler 35" tires fitted

Mocking up a bumper from a 2007 King Ranch F350
Mocking up a bumper from a 2007 King Ranch F350

Comparing the color of the 2007 King Ranch upper trim to the fender flares. Sadly the color is off
Comparing the color of the 2007 King Ranch upper trim to the fender flares. Sadly the color is off

Getting ready to remove the rear end
Getting ready to remove the rear end

Rear frame portion stripped ready for paint
Rear frame portion stripped ready for paint

Old rear end out of the truck
Old rear end out of the truck

Rear frame all painted
Rear frame all painted

Rear frame portion all done with PMF hangers
Rear frame portion all done with PMF hangers

Rear end from the parts truck all put together with all new parts. Forgive my mess
Rear end from the parts truck all put together with all new parts. Forgive my mess

Rear end all together
Rear end all together
 
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Old Apr 20, 2026 | 10:49 AM
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xpl0sive's Avatar
xpl0sive
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Old Apr 20, 2026 | 10:49 AM
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xpl0sive
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Old Apr 20, 2026 | 02:17 PM
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Vinny G-the EX man
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Looking great, following the thread.
 
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Old Apr 22, 2026 | 12:14 PM
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Awesome, You doing any gears/ lockers or lift?
 
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Old Apr 22, 2026 | 12:16 PM
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Nah, just building it as a road trip/tow my boat type truck.
 
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