DVDSWAN 02 Sport Trac Build/Maintenance thread

[dvdswan]

Been busy fixing issues with the truck that have been showing up. Lots of maintenance stuff too.
March I installed a F150 turn signal stalk because my knee kept hitting the ST T/S stalk.

In April, alternator was making noise after washing it. Serp belt was cracked so I just replaced the lot. Belt, tensioner, idler, and alt. Also found a gas cap leash at the junkyard so I installed that too.

In May I replaced the Brake Light Switch and Oil Pressure Switch. Brake light switch was causing the shifter to stick and the o/p was causing fluctuations in the gauge. Or so I thought, found out it is just an on/off switch. I have an oil leak that I haven't found (haven't looked too hard yet) but I'm thinking it's the RMS or pan gasket. Hoping for the pan.

Also started getting a misfire and finally got a code P0303. Replaced the plugs and wires, plugs were gapped .027 to .033 and FSM says they should be .061 to .067. 1st mistake was buying cheapo wires. After install I got a P0301, 3, 4, and 5. Ends would not snap on to the plugs. So, I ordered ford wires. Ran a lot better but still had the miss on #3. Ordered an injector, when it arrived, I went to install it and found the sleeve was cracked. Ran down to the parts store and shelled out way too much for the sleeves but got the sleeve installed and the miss was gone.

Unfortunately, 2nd mistake was not buying injector O-rings for the other 2 injectors. Ended up with an O-ring leaking fuel. So, tore off the intake again and replaced the 1 and 2 injector O-rings and sleeves.

Maintenance wise during that I replaced the t-stat housing and tensioners, and had a small victory.

End of May, I broke the dr. window while mowing the lawn... what was worse I broke a window on the topper as well. (sigh).

June, I started the process off hooking up a rear backup camera.

 

[Ranger850]

Any updates on the upgrades?

 

[dvdswan]

Got to spend some quality time with the ST today.

Replaced dash lights with LEDs. Found out the 4WD quit working again. No lights on dash again. Fat electron doesn't seem to be the problem this time, at least at the switch like last time. Time to test the motor and control module.

I installed the BOSS radio I got a while back. Hooked and installed the Charger and ApplePlay port also.

Finished installing the backup camera... punched a hole in the center plate and drilled a hole at the bottom of the tailgate...

I bought some grommets to seal the bottom of tailgate and installed a weatherproof connector...

All connected up... I need to power it with reverse still.

I also fixed my connections for the topper for a cleaner look...

When I get a back glass and side glass for the topper, I'll hook up the connector to it...

 

[dvdswan]

Bought some more parts...

Tires - 265/75R16s Americus Rugged ATRs (Walmart.com made in Taiwan) 1st hurdle passed, they balanced fine. They're a 50k tire and they were on sale, so for the price which was over half less of what a BFG AT was I thought I'd give Wally a try. Aside from the time it took they (Walmart) did a lot of extra little details compared to the Discount or Les Schwab do. Cleaned mating surfaces, anti-seized the studs, cleaned the rim edge for weights, and had a 2nd person re-check the torque.

I put some highway miles on them and they are quiet on the freeway and a low rumble on the streets. Went to the j/y and picked up the overhead console and mirror.

I now have front dome lights again...
and the parts I hope to install sooner than later...

UCAs and LCAs l&r...

TREs; inner and outer, and front shocks

Rear shocks and sock...

Had a little rubbing in the rear with tires on turns so I bought some wheel spacers. They'll be here tomorrow, and I should have them install either Wednesday or Thursday.

The 4WD quit working so I'm going to investigate that. I don't believe it's the fat electron this time.

Update on the radio install. Not happy at all with the BOSS radio. It has a very hard time connecting with phone. I would say about 75% it won't connect right away and take up to 30 seconds to connect so I have to have the phone on speaker to talk hands free. Would not recommend.

 

[rumblecloud]

Making me "jelly" as they say. I have an 02 ST as well, which I've been using as my daily lately. When it was warmer out I knocked down a few rust spots that were rearing their ugly little heads on the front fenders and in the door sills. POR'd them and rattled canned em.

But you my friend have gone far beyond my intentions --- at least for now.

Thanks for the inspiration though.

 

[dvdswan]

So, weather has been cold and no heated shop/garage, so work has been slow on the ST. I did do the 4 driver side body mounts and stopped because my butt was freezing. I hate working on the ground, lifts make things so much easier. Yes, I was lying on cardboard from the new HW Heater I had to buy.

I will say that the Boss radio that I installed is turning into an item that I would highly NOT recommend. Since posting in November, it is now about 50% of the time an incoming call will not stay connected to the radio. The volume needs to be turned up on the radio to hear (If I listen to radio at 15, the phone needs to be at 25) so when radio drops the phone the radio takes over and blares at the phone volume. It has trouble connecting to Apple play as well.

Next weekend and following week it's calling for snow the cold continues. The 4WD selector, well actually the 4x4CM, connection has been giving me troubles if it is not used often, so now I switch to 4HI to ensure it locks in then I switch back to 2WD. I do notice that when the front driveline engages it gets groanny, if that's a word. I haven't checked my u-joints as of yet, but I get the feeling those might be in the near future. Incidentally, do STs have a center support bearing on the driveline? edit: I don't see one on RockAuto. So I'm guessing no.

Still need to install the passenger side body mounts and take out the front spacers as the tires rub on both sides in front now, install the 3rd LED brake light, driver side door jamb switch, among others stuff that I have already ordered.

As it warms up I will be doing more to the ST and taking pictures.

 

[Rick W]

So, weather has been cold and no heated shop/garage, so work has been slow on the ST. I did do the 4 driver side body mounts and stopped because my butt was freezing. I hate working on the ground, lifts make things so much easier. Yes, I was lying on cardboard from the new HW Heater I had to buy.

I will say that the Boss radio that I installed is turning into an item that I would highly NOT recommend. Since posting in November, it is now about 50% of the time an incoming call will not stay connected to the radio. The volume needs to be turned up on the radio to hear (If I listen to radio at 15, the phone needs to be at 25) so when radio drops the phone the radio takes over and blares at the phone volume. It has trouble connecting to Apple play as well.

Next weekend and following week it's calling for snow the cold continues. The 4WD selector, well actually the 4x4CM, connection has been giving me troubles if it is not used often, so now I switch to 4HI to ensure it locks in then I switch back to 2WD. I do notice that when the front driveline engages it gets groanny, if that's a word. I haven't checked my u-joints as of yet, but I get the feeling those might be in the near future. Incidentally, do STs have a center support bearing on the driveline? edit: I don't see one on RockAuto. So I'm guessing no.

Still need to install the passenger side body mounts and take out the front spacers as the tires rub on both sides in front now, install the 3rd LED brake light, driver side door jamb switch, among others stuff that I have already ordered.

As it warms up I will be doing more to the ST and taking pictures.

Internet says yes, but Miriam Webster dictionary says no. Maybe we should split this off to a new post

Just trying to help…

 

[dvdswan]

Small update. Drove to Portland one morning and left the headlights on, killed the battery. Got it jumped and everything seemed fine. Tried 4WD and its not working again and realized the headlight warning bell/buzzer didn't go off when I shut the truck off. So, this weekend is going to be a nice weekend I plan on working on it and finishing some items that I hadn't completed and some troubleshooting now.

 

[dvdswan]

Body mounts are now completed. FINALLY! I really hate doing only half at a time. But, in all the passenger side only took about hour and a half compared to the driver side which fought me. While I had the pass. kick panel out I disconnected/reconnected the 4x4CM plugs. 4WD started working again. So, I disconnected the connectors again and cleaned pins with electronics cleaner and a Q-Tip. Next time I pull the center dash bezel out I'll do the 4x4 selector switch. Earlier in the week I purchased a jumper box of amazon I got a rare screaming deal, with coupons and flash sale I saved 87%. Yeah me. Oh, this is actually the booster I got.

 

[dvdswan]

Another update. Since the mounts were non-existent on the front 3 body mounts on both sides. The truck now rides a lot better and not as noisy. Yes, the poly mounts do transfer noise, but it is far quieter than having the bad mounts in there.

 

[dvdswan]

Fixed and installed a few things today.

Installed a new 3rd LED brake light.

Also, fixed my driver's door jamb switch so the interior lights come on now. Turns out it was just disconnected. Not sure if I knocked it off when I replaced the dr. window or if it was always disconnected. It's out of the way so it is a very good chance that it was just disconnected.

 

[dvdswan]

So, today I gave the ST some much needed love. Wash, rubbing compound, polish, and wax.

Before:

After:

Before:

After:

Before:

After:

Debating on buying new headlamp/turn signal assemblies or polishing them. Most likely will buy as the t/signals and dr. side h/lamp have moisture in them.

I plan on pulling off the steps and redoing them, but I need to find a restore or repaint for the front bumper, side molding, and rear bumper gray color. All I can find is the black trim restore which I'm not going to use.

 

[SenorNoob]

If you can find a consumer friendly source for this:

Per-Fix

It does an mazing job of hiding flaws in any color of plastic parts. There are few variants for different plastics. That's for polypropylene, the other common one is for ABS.

 

[rumblecloud]

All done by hand of course --- no power tools involved

Big job. I have a short attention span, so I need power tools

 

[dvdswan]

All done by hand of course --- no power tools involved

Big job. I have a short attention span, so I need power tools

We are the same. I used my buffer... my arms still hurt.