2003 ford excursion front suspension diagram

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• 2003 Expedition
• Workshop manual

Ford Expedition 2003 Workshop Manual

• Quick reference manual (2 pages)
• Owner's manual (346 pages)
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Summary of Contents for Ford Expedition 2003

• Page 1 2003 Expedition/Navigator Workshop Manual Page 1 of 18 SECTION 308-07A: Four Wheel Drive (4WD) Systems 2003 Expedition/Navigator Workshop Manual DIAGNOSIS AND TESTING Procedure revision date: 04/13/2006 Four Wheel Drive (4WD) Systems Printable View (375 KB) Refer to Wiring Diagrams Cell 24, Engine Controls for schematic and connector information. Refer to Wiring Diagrams Cell 23, Engine Controls for schematic and connector information.
• Page 2 2003 Expedition/Navigator Workshop Manual Page 2 of 18 The 4WD shift motor is controlled by the 4WD control module which shifts the transfer case shift motor between HIGH range (A4WD, 4WD HIGH), and 4WD LOW modes. The solid-state clutch is duty-cycled by the 4WD control module to activate the 4WD clutch within the transfer case. In the A4WD system, the 4WD control module varies the torque sent to the front driveline by controlling the transfer case clutch.
• Page 3 2003 Expedition/Navigator Workshop Manual Page 3 of 18 4WD control module Wiring harness Gearmotor encoder assembly Connector(s) Circuitry 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4.
• Page 4 2003 Expedition/Navigator Workshop Manual Page 4 of 18 U1950 UBP Communication BUS Fault 4WD control Section 418-00. module U2023 External Node Fault 4WD control Section 418-00. module U2306 Invalid UBP Data From Instrument 4WD control Section 418-00. Cluster (Node 60) module U2226 Invalid UBP Data From PCM (Node...
• Page 5 2003 Expedition/Navigator Workshop Manual Page 5 of 18 GO to Pinpoint Test front axle shaft and universal joint. Rotate the right front tire one revolution forward and one revolution backward while observing the right front axle shaft and universal joint. Did both front axle shafts rotate? A8 CHECK FOR FRONT AXLE/DIFFERENTIAL ENGAGEMENT...
• Page 6 2003 Expedition/Navigator Workshop Manual Page 6 of 18 NEUTRAL. Listen for relay clicks and gearmotor operation. Hold the shift conditions for 20 seconds. (The GO to A17. system will use up to five cycles of shift attempts trying to engage 4X4.) Is the 4X4 LOW indicator OFF? A17 ATTEMPT MECHANICAL ASSIST OF 4X4 LOW DISENGAGEMENT...
• Page 7 2003 Expedition/Navigator Workshop Manual Page 7 of 18 one revolution backward while observing the right front axle shaft and universal joint. Does either axle rotate? Symptom Chart Symptom Chart Condition Possible Sources Action The vehicle does not Central junction GO to Pinpoint Test operate correctly in A4WD box (CJB) fuses: and 4WD HIGH modes...
• Page 8 2003 Expedition/Navigator Workshop Manual Page 8 of 18 PINPOINT TEST B: THE VEHICLE DOES NOT OPERATE CORRECTLY IN A4WD AND 4WD HIGH MODES Test Step Result / Action to Take B1 CHECK INDICATOR PROVE-OUT Ignition OFF. GO to B3. Start the vehicle while observing the 4WD indicators for prove out.
• Page 9 2003 Expedition/Navigator Workshop Manual Page 9 of 18 4WD HIGH 128.7 - 131.3 4WD LOW 61.38 - 62.62 2WD HIGH 616.9 - 623.1 Are the resistances within specification? B11 CHECK CIRCUIT 682 (DB) FOR AN OPEN Ignition OFF. GO to B12. Disconnect: Mode Select Switch C284.
• Page 10 2003 Expedition/Navigator Workshop Manual Page 10 of 18 Does the front driveshaft lock to the rear? B15 CHECK THE ELECTRIC CLUTCH—NOT ENERGIZED Connect the scan tool. GO to B17. Trigger the electric clutch control output command (CLUTCHSOL). Set the command to zero percent. Rotate the front driveshaft.
• Page 11 2003 Expedition/Navigator Workshop Manual Page 11 of 18 Is the resistance less than 5 ohms? B20 CHECK THE THROTTLE POSITION INPUT—MONITOR THE 4WD PID TPI Ignition ON. DISCONNECT 4WD control module connector C3184b and the PCM connector Monitor the PID: TPI while pressing and releasing the accelerator pedal.
• Page 12 2003 Expedition/Navigator Workshop Manual Page 12 of 18 Is the resistance less than 5 ohms? B25 CHECK IWE SOLENOID Carry out the IWE solenoid component test. GO to B26. Refer to Wiring Diagrams Cell for component testing. INSTALL a new IWE solenoid. CLEAR the DTCs. TEST the system for normal Did the IWE solenoid pass the component tests? operation.
• Page 13 2003 Expedition/Navigator Workshop Manual Page 13 of 18 INSTALL a new 4WD control module. CLEAR the connector (C350). DTCs. REPEAT the self-test. Check for: corrosion pushed-out pins The system is operating correctly at this time. Concern Connect all 4WD control module connectors and the transfer case connector and make sure they seat correctly.
• Page 14 2003 Expedition/Navigator Workshop Manual Page 14 of 18 Measure the voltage between 4WD control module connector C3184b pin 16, circuit 780 GO to D8. (DB) and ground. Is voltage present on either pin? D8 CHECK CIRCUITS 682 (DB) AND 780 (DB) FOR AN OPEN Ignition OFF.
• Page 15 2003 Expedition/Navigator Workshop Manual Page 15 of 18 Is any voltage present? D12 CHECK CIRCUIT 762 (YE/WH), CIRCUIT 763 (OG/WH), CIRCUIT 764 (BN/WH), CIRCUIT 770 (WH), AND CIRCUIT 771 (VT/YE) FOR A SHORT TO GROUND Ignition OFF. Disconnect: Transfer Case C350. GO to D13.
• Page 16 2003 Expedition/Navigator Workshop Manual Page 16 of 18 Is any voltage present? D15 CHECK CIRCUIT 777 (YE) AND CIRCUIT 778 (OG) FOR AN OPEN Measure the resistance between 4WD control module C3184a, pin 9, circuit 777 (YE), GO to D16. harness side and transfer case C350, pin 4, circuit 777 (YE), harness side;...
• Page 17 2003 Expedition/Navigator Workshop Manual Page 17 of 18 Lift and support the vehicle off the ground until the front tires can be spun freely. Refer to GO to E2. Section 100-02. NOTE: The engine is required to be at idle during the following steps to supply the vacuum required for the hublocks to engage and disengage.
• Page 18 2003 Expedition/Navigator Workshop Manual Page 18 of 18 GO to F3. side and ground. Is the resistance greater than 10,000 ohms? REPAIR the circuit. CLEAR the DTC. REPEAT the self-test. F3 CHECK CIRCUIT 605 (RD) FOR AN OPEN (TO MODULE) Measure the resistance between IWE solenoid C1157 pin 2 harness side and four GO to F4.

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Ford Excursion Coil Spring Conversion

Every off-roading enthusiast knows a vehicle's suspension system is crucial in providing a comfortable and safe ride, particularly when driving on rough terrain. The suspension system absorbs shocks and vibrations, reduces body roll, and keeps the wheels in contact with the ground while improving traction and stability.

In this article, we'll take a closer look at the 2000-2005 Ford Excursion coil spring conversion process along with a detailed description and the benefits of doing so, as well as examples from one of our own projects involving a 2000 Ford Excursion Limited.

Why upgrade your Excursion to Coil Spring suspension?

The Ford Excursion is a heavy-duty SUV built to tow and haul heavy loads. However, its suspension system is designed for on-road use and requires more to be suitable for true off-road driving. Upgrading to a later model F250 coil spring suspension can significantly improve its capability and provide several benefits for daily driving, towing, and especially off-road performance. So, when it comes to the 2000-2005 model Excursion, you may want to consider upgrading your suspension to a more robust, battle-tested setup such as the popular later model F250 coil spring conversion, which uses critical components such as radius arm suspension to provide better ride quality, improved steering, and superior ground clearance capability. All that said, here are some of the benefits you get from this upgrade:

• Improved ride quality: With its advanced coil-spring system, the suspension setup of the F250 offers better control over bumps and vibrations, resulting in superior ride quality and comfort compared to the original suspension of the Excursion.
• Increased ground clearance: The F250 coil spring suspension provides increased ground clearance compared to the original Excursion suspension, allowing the vehicle to clear obstacles with greater ease and reducing the risk of getting hung up on rocks, roots, or other barriers.
• Better off-road performance: By utilizing more robust and durable components, the improved stability, traction, and handling of the coil spring system used in the F250 suspension setup provide better off-road performance through increased suspension articulation than the original leaf suspension of the Excursion.
• More customization options: Upgrading to the F250 coil spring setup provides more customization opportunities for Excursion owners. Also, many aftermarket upgrades are available for the F250 suspension that can improve performance and give greater adjustability.
• Improved towing capacity: Designed for heavy-duty use, the suspension setup of the F250 is an excellent upgrade for Excursion owners who need to tow heavy loads or trailers, as it can easily result in improved towing capability.
• Better Turning Radius: The later model F250 has an increased turning radius ability resulting in more agile off road performance and increased ability to fit in stubbornly tight parking spaces.

How to install Coil Springs on your Excursion

Converting a 2000-2005 Ford Excursion to a coil-spring suspension involves:

• Removing the original suspension.
• Preparing the frame.
• Installing the new coil-spring suspension components of the drivetrain and steering system.
• Aligning and testing the vehicle.

This process significantly improves the Excursion's off-road capabilities and overall on-road and off-road performance. However, it is complex, and we always recommend having the procedure done by a qualified off-road shop.

Here is a basic outline of the Coil conversion:

• Remove the old suspension system - The first step in upgrading your suspension is to remove the old system by removing the front axle assembly, leaf springs, track bar bracket, and shocks.
• Next, install a later model F250 coil spring and radius arm suspension system. This system is an improvement over the Excursion's original suspension system because it provides better ride quality and increases the ability of the suspension to articulate and increase traction when going over obstacles or rough terrain, making it more suitable for off-road driving.
• Upgrade steering components - Upgrading the steering components is also necessary when upgrading the suspension by installing later model f250 steering linkage or upgraded aftermarket linkage such as PMF Suspension or Synergy Suspension and or single/dual stabilizers based on desired usage and tire size. These upgrades improve steering response and reduce the risk of damage to the steering system during off-road driving.
• Replace the drivetrain components - When upgrading the suspension system, it's also a good idea to upgrade drivetrain components such as axles, differentials, and driveshaft to ensure the entire system is solid and reliable for driving off-road.
• Install aftermarket parts - Aftermarket parts can also be added to the suspension and steering system to improve performance. These can include longer shocks, adjustable sway bars, and upgraded control arms. Such upgrades can provide even better stability, suspension travel, and ground clearance.

Our very own Excursion Coil Spring Conversion

At Adrenaline Offroad Co., we recently had the opportunity to perform a complete coil spring conversion on a customer's 2000 Ford Excursion. This was an exciting project for us, as we love nothing more than taking on a challenge and seeing the transformation of a vehicle for optimal performance, especially the beloved Ford Excursion.

To begin the project, we started by searching for a donor chassis that would provide us with all the necessary components for the conversion. This makes the process much easier, as it can be time-consuming to source individual parts and, most importantly, save some downtime for our customer. Of course, after some searching, we found a 2007 F250 4wd bare rolling chassis that was a perfect fit for the job.

Once we had the new chassis, we disassembled the donor frame and sent the usable pieces out for blasting. Once everything was cleaned up, we refinished the axle housings and began rebuilding both front and rear differentials with Detroit Truetrac carriers, a new Motivegear master bearing kit, and a 3:73 ring and pinion for each to start fresh from any previous wear.

Next, we shifted focus to the front components and added Ford Motorcraft OEM ball joints to the suspension for optimal performance and a Timken wheel bearing/hub assembly with a set of Warn premium sleek black super-duty locking hubs to provide the extra grip. Of course, this also included replacing all seals and bearings as a precautionary measure, as always.

When it came to stopping power, we added a Power Stop Z-36 Truck and Tow performance brake kit to ensure that the Excursion would stop on a dime. This included drilled and slotted rotors, performance brake pads, and new red powder-coated caliper assemblies with a nice Russell stainless steel brake hose kit as a bonus.

For the actual coils and suspension, we chose to go with Icon dual rate 4.5" lift coils with new F250 05-07 Ford OEM spring retainers/buckets (because the PMF version looked too boxy) and a set of ATS leaf springs with Sulastic shackles in the back to increase rear suspension ride quality.

However, when it came to steering components, we utilized several PMF products (per customer request), including a 2004-16 F250/350 adjustable track bar, 4.5" drop bracket, 05-22 Superduty adjustable link arms, and 05-16 F250/250 heavy-duty (stock height) replacement radius arm mounts.

To assist with steering, we added a PMF 05-22 Superduty HD tie rod bar, PMF 05-22 Superduty single-piece drag link, and PSC Motorsports steering box (due to the variant in the sector shaft spline count and size required by the new suspension geometry and prevent bump steer). Lastly, we installed a PMF dual steering stabilizer bracket paired with Bilstein 5100 series stabilizers to dampen the road impact and smooth the steering.

Finally, when it came to altering the frame, we welded in a custom threaded bung we fabricated to accept the (new) later model PMF track bar bracket. This was necessary due to the curvature of the 99-04 frame configuration and the original track bar bracket mounting being different from the new track bar bracket requirements.

Overall, this project was exciting for both our team and our customer. The transformation of this Ford Excursion was impressive, and our customer was amazed at the increased ride quality and turning radius. At Adrenaline Offroad Co., we constantly strive to push boundaries and attain new levels of performance for our clients, and like on all projects, this project was no different.

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10pc Complete Front Suspension Steering Kit replacement for Ford Excursion F-250 F-350 Super Duty 2WD Models Only Inner & Outer Tie Rod Ends & Upper & Lower Ball Joints & Sway Bar End Links

Purchase options and add-ons.

• Fits 2WD Models with Twin I-Beam Axle ONLY
• Includes: 1x Front Right Inner Tie Rod End - DS1433, 1x Front Left Inner Tie Rod End - DS1434, 1x Front Left Outer Tie Rod End - ES3418
• 1x Front Right Outer Tie Rod End - ES3417, 2x Front Lower Ball Joints - K80027, 2x Front Upper Ball Joints - K80028
• 2x Front Stabilizer/Sway Bar End Links - K80043 (6.85" Center to Center of Eyelets)
• Fits: Specific Models - Check Fitment Chart and Product Description to Make Sure You Buy The Right Kit.

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Product description.

Compatibility: Replacement for 2000-2005 Ford Excursion All RWD / 2WD Models w/ Twin I-Beam Axle Replacement for 1999-2004 Ford F-250 Super Duty All RWD / 2WD Models w/ Twin I-Beam Axle Replacement for 1999-2004 Ford F-350 Super Duty All RWD / 2WD Models w/ Twin I-Beam Axle

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2003 Ford Expedition Suspension Parts

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MasterPro Strut And Coil Spring Assembly - 33FD1114

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Rancho quickLIFT Loaded Strut And Coil Spring Assembly - RS999933

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Upper Control Arm - Ford (6L1Z-3084-AA)

2003-2006 Ford Expedition - 6l1z3084aa

• MSRP: $149.27
• Discount: $55.02 ( 36.9% off)
• Sale Price: $94.25

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• SKU: 6L1Z-3084-AA
• Positions: Right
• Other Names: Arm Assembly Front Suspension, mcsoe156

4wd, std. Expedition. Right. Without adjustable suspension. From 12/1/03.

• Notes: Includes upper ball joint.
• Applications: 2WD.
• Sold In Quantity: 1

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• Ford Expedition Forum

Suspension Diagrams - labeled - 3rd Gen 2011 Exped?

• Thread starter hawkman71
• Start date Oct 29, 2018

Disclaimer: Links on this page pointing to Amazon, eBay and other sites may include affiliate code. If you click them and make a purchase, we may earn a small commission.

• Oct 29, 2018

Full Access Members

I'm looking for labeled diagrams of the rear (and front maybe) suspension for a 3rd Gen Expedition. The rear looks a little more complicated that my previous vehicle's - a 07 Town&Country. If I want to ask questions, I want to be sure I'm calling the part by its proper name. I haven't turned up the right diagram on a google image search yet. I'm also on ebay now, looking for a Haynes manual, which should help.  

Sometimes, I forget what I've googled hard enough for and what I haven't. I had this thread bookmarked which should help me. That being said, I'd still like to find a true parts diagram. https://www.ford-trucks.com/forums/...not-springs-on-a-2007-3rd-gen-expedition.html  

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