Excursion or SAS?
Q I have a ’99 AWD Ford Expedition and a set of axles out of a ’99 Ford F-350. I was hoping to find a way to put these axles under the Expedition. I noticed that there were no kits or mention of doing the conversion on any Ford. Can you tell me why? I have four kids and need a vehicle that can accommodate six people. I am hoping to build a vehicle with a wheelbase close to 120 inches. I would also like to use my Super Duty axles, as they are already geared and locked and paid for. I would prefer to build the Expedition, as I have owned and maintained it since new and it fits all the other criteria I am looking for. But I would opt for a substitute vehicle if the Expedition is deemed too impractical for the conversion. Any advice you can provide me would be greatly appreciated.
I also realize that the transfer case, drivelines, etc., would have to be replaced and or modified. I have budgeted $10,000 for this project. This amount is all for the conversion and does not include the cost (if necessary) of a different vehicle. I really need some good knowledgeable advice.
A I see no issue with your doing the solid axle swap on your Expedition, though I would recommend finding a part-time transfer case to replace the all-wheel-drive one, most likely from an F-150. There have been solid axle swaps on these before, and most involve some sort of custom leaf spring hangers or a custom linked suspension with coils or coilover shocks. The leaf springs will probably be cheaper, but when you add up a new set of driveshafts, steering, the new case, and the labor to put it all under your Expedition along with new tires and wheels, you may be heading into a big project and I think your $10,000 will be spent pretty quickly. I’m not saying don’t do it, but if you’re a hardcore Ford guy and you need all that room I’d take a moment and search for a 4x4 Excursion first. I think you could find one for around $10,000 and it will already have big axles under it.
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