7.3 the hard way (Ford Excursion Project)

Brad J

Registered User
Location
Woods Cross, UT
I'll try to shorten this very long story. I have always loved Bronco's and can't afford a new one so I thought why not make one out of an Excursion like this one.
ueLY31W.jpeg
In Oct 2021 I picked up a 2001 V10 4x4 Excursion that was overheating for $1,300. The very nice couple didn't have the title but gave me a Bill of Sale and said that they would get the title for me. I went to the DMV and found out that they didn't own it. I later found out that he left on bad terms from a shop that let him drive it while he worked there. The shops owner wouldn't talk to them so I said that I was bringing it back to them. They said that they would give me 1/2 my money back and then I should part it out to get the rest of my money back. It took a couple weeks but the owner gave me the signed title for $300. I was hoping it was the cooling system but that was not the case. It had bad head gaskets at 262,985 miles. The Body is in good shape except for the front Drivers Fender got a little smashed in an accident.
01 PXL_20211002_200027508.jpg

02 PXL_20211002_200005112.jpg
One month to the day after picking up the Excursion I had the title & ran straight up to Rexburg ID and picked up a Rolled over 2003 7.3L Power Stroke 200,000 mile 4x4 Excursion for $1,500. It was bought on auction 4 years prior and they were unable to get it to start. It had no batteries and AC Compressor and had been the a housing unit for a colony of mice. It looked perfect except it was actually only 2 Wheel Drive.
03 PXL_20211102_221800196.jpg

04 PXL_20211102_221821309.jpg
 

Brad J

Registered User
Location
Woods Cross, UT
I get it home put batteries in and it has 369,574 miles. I couldn't get a response from the seller. I am wondering if my luck with these could get any worse. I talk to an Attorney that we have used and he said I would clearly win and get my money back in Small Claims but I wanted to see if I could get it running before I decided. The thought of taking it back 450 miles (Round trip) and then going to court up there didn't sound fun. It had a bad Starter that I replaced with one from Pull N Save along with an AC Compressor, New Serpentine Belt and it ran and sounded great. I am now planning on keeping it.

05 PXL_20211102_222553660.jpg

06 PXL_20211102_222659657.jpg
One of the many Mouse nests found in the thing
IMG_4692.JPG
Almost double the advertised miles
07 IMG_9934.JPG
 
Last edited:

Brad J

Registered User
Location
Woods Cross, UT
I was able to get a 4WD 4R100 Transmission from a 7.3 for $119 from Pull N Save
IMG_0284 1715 7.3 Transmission from Pull N Save.JPG
Does the writing on the Torque Convertor mean that it has been rebuilt?
IMG_0286 Torque Convertor.JPG
I was unable to find an easy way to get the Electronic Shift on the Fly Transfer Case from the 2001 to work without a Computer that I can't find so I was lucky enough to find a Manual Shift NV 271 Transfer Case from Tear A Part for $83 & $16 for the Shifter.
IMG_4936 They charged 19 for Motor.JPG
The 2001 going into the garage last December to pull the Drivetrain. 5 of my 6 Fords in this pic. My 2006 Mustang is not seen. Yes I know that I have a problem
08 PXL_20211209_222909474.MP_exported_933.jpg
 
Last edited:

Brad J

Registered User
Location
Woods Cross, UT
I was getting a lot done quickly last December due to the warmer weather. I pulled the V10 in Christmas Eve
11 PXL_20211224_222020065.jpg
The wiring changed between 2001 and 2003 so all wiring inside and outside needs to be moved over. All switches on the Doors, everything in the Dash even the Windshield Wiper Motor is different so it all has to be moved over.
14 PXL_20220211_231330085.jpg
The Dash frame on the 03 is rusted so moving everything over to the 01 Dash frame
15 PXL_20220213_013845897.jpg
Steering Columns have different wiring so moving everything over
IMG_6076.JPG
Firewall on the 01
IMG_4899.JPG
Firewall on the 03
IMG_4909.JPG
Now ready for the 03 Wiring on the 01
IMG_5349.JPG
 
Last edited:

Brad J

Registered User
Location
Woods Cross, UT
Why is it always such a mess getting a Transmission out
11 PXL_20220116_010156462.jpg
Got the 7.3 out and on my new $100 KSL 2,000 lb. Stand
12 PXL_20220129_004138352.jpg
Plate on the 7.3
13 PXL_20220130_021944537.MP_exported_1282.jpg
Mostly done with Interior wiring moved over to the 01 20 PXL_20220515_010237955.MP_exported_666.jpg
All wiring and Fuel lines removed from the 01
19 PXL_20220501_002005829.jpg
Swapping places in the Garage to now start working on the Drivetrain install
31 IMG_6287 Explorer dragged 03 then 01 out.JPG
 
Last edited:

Brad J

Registered User
Location
Woods Cross, UT
I should mention that my desire to shorten this Excursion is lessened. I think that it would look awesome but it would no longer be great for towing being a short Wheelbase. Maybe if I find one that has major damage to the center section then I might consider it.
I now was looking at all of the surface rust on the frame and body underneath and figured that now was the time to take care of that.
23 IMG_4736.JPG

24 IMG_5657 One bolt without a head.JPG

27 IMG_5755.JPG
This is where I stopped with it in May
32 IMG_6288 1417 01 back in garage it was in Dec 9th till 25th.JPG
It got placed on hold due to the Vacation Van Project
and now the Ranger Rebuild / Flip Project
I have been too lazy to work outside in the cold so hopefully I can get the Ranger done and get going on cleaning up the Rust. After that then the Drivetrain will go in.
 
Last edited:

Mouse

Trying to wheel
Supporting Member
Location
West Haven, UT
There were quite a bit of electrical changes from the 1999-2001 version to 2002-2007 superduty. The dash from the 7.3l should have a transmission temp gauge versus the older one.

The swap to 4x4 should be pretty easy. Lots of Excursion owners like to add the "X" code front springs to keep from riding on the overloads. I'd assume a lift is in the plans based on your concept pic above however (which will also do the job).
 

Brad J

Registered User
Location
Woods Cross, UT
There were quite a bit of electrical changes from the 1999-2001 version to 2002-2007 superduty. The dash from the 7.3l should have a transmission temp gauge versus the older one.

The swap to 4x4 should be pretty easy. Lots of Excursion owners like to add the "X" code front springs to keep from riding on the overloads. I'd assume a lift is in the plans based on your concept pic above however (which will also do the job).
It's too bad that my Excursions aren't the same year to not have to go through this mess. The front sat a little low with the V10 so I will have to look for some "X" codes since the 7.3 is so heavy. The 01 has new larger than stock tires so I'll run them for now. I don't have immediate plans to lift unless I come across a great deal.

Think this needs to be renamed “7.3 the hard way” 😂
I love that! I added that to the title.
 

Mouse

Trying to wheel
Supporting Member
Location
West Haven, UT
BTW, the "X"-code front springs are supposed to be just a 1" lift. They are factory Ford springs for a snow plow package.
 

johngottfredson

Threat Level Midnight
Location
Alpine
The amount of work and talent that folks around here put into their projects is astounding to me. I don’t buy the “it’s because I can’t afford a new one” line, like at all. You must love pain, and find some satisfaction in the insanity. You put some fraction of this skill and work into the free market and you could buy a new bronco, or a good running 7.3 truck, or whatever.

I am blown away by what you guys tackle. I’m here as a spectator only. Keep up the projects, and thanks for sharing. It’s fun to watch!
 

Brad J

Registered User
Location
Woods Cross, UT
Unfortunately I only spent one day cleaning the dirt and surface rust off of the frame and realized that job sucks especially in the cold. I finally got my 2001 Ford E350 Van to pass Emissions after a new Intake Manifold Gasket and new Exhaust Manifolds and Gaskets. Then moved on onto my 1992 Ford Ranger that is done, running great and for sale. It took a lot more time and money than I had hoped. I picked up a 2011 VW Tiguan that needs a Rear Main Seal and Timing Chain set so I'll focus on that 1st since my wife is bugging me to get it done so she can drive it. I really miss being able to work on stuff in my garage so I have to get going on the Excursion :(
 
Last edited:

Brad J

Registered User
Location
Woods Cross, UT
I got another project that I had to make a priority. I got a 2011 VW Tiguan 2.0T with Bent Valves that is almost wrapped up. I spent a few days last month cleaning up the frame on the Excursion while waiting for parts though. It's been 95 degrees in my Garage so I picked up a Window AC Unit to get installed to make it more comfortable in there before I continue. I don't have a Window in there so that is adding to the challenge. Thanks for the interest/prodding :)
 

Brad J

Registered User
Location
Woods Cross, UT
Always a glutton for punishment I picked up my 3rd Excursion last week for $1,000 that has fairly new BFG All Terrain's. It's a 2001 V10, 4WD that has a bad transmission with 222k miles on it. I have a transmission that seemed fine from my other 2001 V10 that had Bad Head Gaskets so I figured I can swap it out and then sell it. These tires will go on my Truck since those tires were showing their age. This will slow down the project but will hopefully be a way to make a little money, clear out some space and keep another Excursion on the road.
PXL_20240823_165015579.jpg
PXL_20240823_165002142.jpg
 
Last edited:
Top