01 Expedition build - Lightning Forum | LightningRodder.com
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post #1 of 8 (permalink) Old 05-18-2018, 06:40 PM Thread Starter
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01 Expedition build

Hey everyone! Finally decided to start a build thread on this swap. So it all started when I saw a picture of the Expedition "Thunder" on the Expedition forums. I had just picked up a Black 97 4x4 Eddie Bauer from a customer that had left it sitting at our shop for a year. Paid 500 and got to work. Changed the old worn air suspension out for coils. Slapped some Belltech drop coils in the back and Belltech torsion bar keys in the front. Also picked up some 20" reps. Quickly realized I didn't like the ride at all. The front with the lowered torsion keys was super soft and bouncy and just didn't even feel safe. I found you could run stiffer bars from the F150 7700 but they weren't super easy to find and didn't think it was going to improve it as much as I'd like. In the mean time I had picked up a supercharger setup from a local junk yard type place. They said they had a contract with Ford where they got a hold of a bunch of the test motors and they had like 6 assemblies from lower manifold up with like 15k on them just collecting dust. Vacuum lines and all. Just didn't come with injectors because he wanted 350 for them. Knew I could find them cheaper. I then found a motor from a local guy. 25k on his rebuilt stock Lightning motor. He was going built so I got a good deal. Everything looked great on it so I scooped it up. I decided to go ahead and yank the old tired motor get some things ready. I redid the engine harness putting sensors where they needed to be for the lightning setup and then wrapping it all in tech flex (totally inspired by Harley#356 and his beautiful work). Spent a few months collecting various parts needed to complete the swap and as I got down to only a few parts left (HX w/bracket and the bumper brackets, IC pump and bracket, stock hose from IC res to pump and pump to HX, and an adjustable fpr as suggested by JJ) to get I decided one day I was bored to toss in the motor. I did just that but as I was thinking about putting the rest together the concerns of if I'd ever get the suspension right and the cost of beefing up all the 4x4 stuff started getting at me. That on top of some electrical concerns made me decide to go ahead and get a newer 2wd. The search began.
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post #2 of 8 (permalink) Old 05-18-2018, 09:39 PM
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Nice!! Can't wait to see it come along, that will definitely be a cool swap
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post #3 of 8 (permalink) Old 05-19-2018, 05:25 AM
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The 'Thunder" Expedition....there's a reboot from the past! I always wanted to do an Expedition/L swap. I believe a few here have...
Best of luck with your swap and keep us updated!
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post #4 of 8 (permalink) Old 05-19-2018, 10:29 AM Thread Starter
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Thanks guys. It's something that immediately caught my eye. Always loved Lightnings and will have one someday but thought it was so neat to have a big ol SUV Lightning. Especially since that Expedition fell in my lap.
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post #5 of 8 (permalink) Old 06-06-2018, 06:13 PM Thread Starter
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So I've actually had the new Expedition for awhile now but been lazy and haven't updated this thread lol. As soon as I decided to ditch the 4WD Expy I started looking. Found one for $500 that had a real high mileage motor and just a few cosmetic issues that weren't a big deal. Called pick n pull to pick up the black 4WD and jumped in on the new one. It's an 01 RWD that's Dark Toreador Red. Got it home and immediately started in on it. Pulled the Belltech rear springs from the 4WD and the navigator rear seats. Put them in the new one and the black one got picked up. They have me $320 for it so I was only out $180 for the 01. Pulled the motor that was in the new one real quick and dropped in the Lightning motor.
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post #6 of 8 (permalink) Old 06-06-2018, 07:08 PM Thread Starter
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Some more pics. Got the fuel pump installed and the wiring kit from Harley#356 all spliced in and the original harness side of it done in tech flex. That stuff makes wiring look soooo juch better. Also got a bunch of ARP 12 point stainless steel bolts for the motor (thanks to Harley#356 and his OCD on his build for the idea) and painted lower manifold up in wrinkle black. Looks pretty wicked. Coming along quickly now. Also replaced the heater core and added those beautiful heater hoses made by Tim. Cleans up the engine bay like crazy. The Expeditions are even worse than the stock lightning setup. They have rear heat so there is even more of a spider web of hoses and hardlines that run to the back. I deleted AC (removed everything for it when I did heater core) and rear heat so the engine bay got cleaned up big time.
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post #7 of 8 (permalink) Old 08-06-2018, 08:11 AM Thread Starter
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So here are some more pics. Got everything done except some stuff to suspension. Accufab adjustable fpr (that gauge is just to set idle pressure I'll be getting a better one inside the cab), lfp 100mm idlers, the beautiful battery kit by HDCircuitry (inspired the harness wrap in tech flex) and all the other finishing touches including JLT oil seperator. Got the custom tune loaded and data logged at idle. Actually just sent off idle data log for revision 2 a couple days ago. Picking up the rim that had a crack today and it will be back on the ground and just waiting for the okay to cruise data log.

Sent from my SM-G950U
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Last edited by 5starChad; 08-06-2018 at 10:08 AM.
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post #8 of 8 (permalink) Unread 04-11-2019, 11:47 AM
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How s this project going?
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