7.3 the hard way (Ford Excursion Project)

[Brad J]

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.

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.



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.

 

[Brad J]

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.




One of the many Mouse nests found in the thing

Almost double the advertised miles

 

[Brad J]

I was able to get a 4WD 4R100 Transmission from a 7.3 for $119 from Pull N Save

Does the writing on the Torque Convertor mean that it has been rebuilt?

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.

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

 

[Brad J]

I was getting a lot done quickly last December due to the warmer weather. I pulled the V10 in Christmas Eve

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.

The Dash frame on the 03 is rusted so moving everything over to the 01 Dash frame

Steering Columns have different wiring so moving everything over

Firewall on the 01

Firewall on the 03

Now ready for the 03 Wiring on the 01

 

[Brad J]

Why is it always such a mess getting a Transmission out

Got the 7.3 out and on my new $100 KSL 2,000 lb. Stand

Plate on the 7.3

Mostly done with Interior wiring moved over to the 01
All wiring and Fuel lines removed from the 01

Swapping places in the Garage to now start working on the Drivetrain install

 

[Brad J]

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.





This is where I stopped with it in May

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.

 

[Mouse]

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).

 

[I Lean]

That looks like a ton of work!

 

[Stephen]

I'm intrigued by this. Looking forward to the progress.

 

[TRD270]

Think this needs to be renamed “7.3 the hard way” 😂

 

[Brad J]

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]

BTW, the "X"-code front springs are supposed to be just a 1" lift. They are factory Ford springs for a snow plow package.

 

[Bart]

Intrigued and subscribed. Have to agree that this looks like a LOT of work.

 

[johngottfredson]

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!

 

[Gravy]

How's it coming on this?

 

[glockman]

Better yet, what ever happened to that Ranger?

 

[Brad J]

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

 

[Die Blaue Ziege]

any update on this project? looks fun

 

[Brad J]

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]

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.