We bought this 2002 Ford 7.3 diesel Excursion with 300k miles on the clock. We drove it and loved it for about 40k miles, but 300k on the vehicle started to show so we decided to completely rehab the vehicle. It’s still a work in progress. We picked this project because we have 5 kids and needed a large vehicle that could tow/haul, off-road, and hold a lot of people. None of the newer trucks have the carrying capacity and towing capacity that the excursion has, and a newer vehicle is way out of a decent price range. The kids and I added a PSC steering kit with n-type pump and hydraulic assist steering. We are currently getting ready to change the front Dana 50 axle to a Dana 60 and match the rear axle to the width of the new Dana 60. The diffs are changing to Eaton true trac in the rear and either an E-locker or ARB in the front. We are planning on getting rid of the unit bearing setup and going to a Dynatrac free spin kit as well. Suspension plans are changing the front suspension from leaf spring to coil over suspension and rear suspension to a Kelderman air ride. Motor plans are to have the 7.3 freshened up and bore honed and aligned, then to delete the fuel bowl and add a regulated return system and larger stage 2 turbo. My kids and I will add oversized injectors: 200/30’s or 238/80. I’m looking to get 450 to 500 reliable horsepower.
