Ford Expedition - Second Generation (2003–2006)

Second Generation (2003–2006)

The redesigned second generation Ford Expedition was developed under the U222 program code name. The new Expedition was introduced in 2002 for the 2003 model year and featured an new four-wheel independent long-travel suspension system, becoming the first full-size body-on-frame sport utility vehicle to use a fully independent suspension.

The new independent rear suspension (IRS) was perceived as being controversial by some at the time of its introduction. A misconception was that the Expedition’s towing and off road capabilities would be reduced, in comparison to the previous generation’s rear live axle. Nevertheless, underbody obstacle clearance improved by half an inch, and up to two inches under the axle differentials. The new suspension reduced rear unsprung mass by 110 pounds, and allows for a full 9.4 inches of suspension travel (how much the wheels can travel up or down) improving its ability to traverse uneven terrain for improved control and ride quality. The four-wheel independent long-travel suspension itself, is a purpose-built version of race suspensions found on off road desert race vehicles.

Towing capacity increased by 800 lbs (363 kg) for a high towing capacity of 8,900 lbs (4,037 kg) when properly equipped with the appropriate axle ratio and heavy-duty trailer tow package. Payload capacity was increased up to 1,614 lbs (732 kg). Expedition also gained a hydroformed fully boxed frame providing a 70 percent improvement in torsional stiffness.

Along with the high towing capability came all-new steering, braking and electronic systems to help the Expedition better control and maneuver long heavy trailers. Adaptive variable assist power rack-and-pinion steering was introduced along with the largest brake rotors in the segment at that time (13.5 inches up front, 13 inches in back) with brake calipers 100 percent stiffer than the previous generation Expedition. The 4-speed 4R70W automatic transmission received all-new control software to allow the transmission to automatically adjust to the demands of towing, using new computer logic that recognizes changes in load and road conditions.

The automatic ControlTrac four-wheel drive system remained available, with an uprated two-speed dual range BorgWarner 4416 transfer gearbox. The new transfer gearbox featured an intelligent locking center multi-disc differential that could now "torque bias" in Auto mode. A new dedicated microprocessor with new control software was added allowing the system to detect different terrain and surface conditions to predict traction loss before it happened. Two High mode was also reintroduced. Four-wheel electronic traction control was now available as an option, and simulated front and rear differential locks.

The V8 engines offered on the previous generation were carried over, but not without major changes and improvements. Both the 4.6 and 5.4 liter Triton V8 engines received further refinements in design and overall efficiency. Expedition qualified as an Ultra Low Emission Vehicle (ULEV) and was certified under the Environmental Protection Agency Tier 2 regulations one year earlier than required. The 4.6 liter engine received an all-new redesigned cast aluminium engine block optimized for weight reduction and NVH improvements. The 5.4 liter engine received an all-new redesigned cast iron engine block with computer designed ribbing and bracing, along with thicker side skirts and reinforcement at the oil pan flange. The new engine block helped reduce engine vibration and unwanted noise while providing refined performance.

Both engines featured piston skirts coated with a teflon based friction reducing material, and fitted with low tension, low oil consumption rings. In addition, a new fail-safe cooling mode provided protection even in the case of a catastrophic coolant loss (such as a punctured radiator). In the event of coolant loss, the engine control unit shuts off fuel to alternate cylinders to reduce the risk of engine damage from overheating. The valves continue to operate, in order to pump cooling air through the cylinders. The cooling system was designed to maintain an ideal engine temperature even when subjected to a prolonged 15 percent gradient in 46 °C (115 °F) weather. A returnless fuel supply system helped to reduce evaporative emissions by providing consistent pressure to the fuel injectors through a high-pressure pump.

New active hydraulic engine mounts were introduced to prevent the powertrain from inducing vibrations into the chassis. By optimizing these engine mounts the engine block can act as a mass damper, absorbing chassis resonance, improving ride comfort.

Expedition’s passenger cabin was better sealed than before, in an effort to eliminate intrusive outside noise from reaching the occupants. Wind, powertrain, road and vehicle body noise was reduced by improving interior acoustics through new damping materials, a total of 10 shear-style isolating body mounts, heavier sealing of body and panels, redesigned rubber door seals, and extensive use of interior structural acoustic foam in the upper B-pillars, upper and lower D-pillars and floor pan. Road noise was reduced by 2 decibels, body air leakage reduced by 56 percent, chances for sealant noise disturbances reduced from 15 percent to less than 0.5 percent and wind noise measured at 80 mph (130 km/h) was reduced from 35 sones to a world class level of 29 sones.

The Expedition also received a thorough exterior and interior cosmetic redesign. Expedition featured an all-new front fascia, grille work, headlamps, body trim, rear fascia, tail lamps and liftgate. Interior fit & finish were improved with an all-new interior featuring new dash, door panels, genuine aluminium trim, and plush carpeting. Premium perforated leather seating surfaces were standard on Expedition Eddie Bauer (optional on Expedition XLT). Expedition FX4 models featured all of Expedition's optional off road equipment as standard equipment. Expedition’s drag coefficient was 0.41 Cd.

Three row seating was standard with all-new manual fold-flat stow away third row seats. No longer did owners have to remove the third rows seats for more storage. The third row could simply "disappear" into the floor. Power assisted PowerFold fold-flat third row seating was available as an optional extra. Available features included in-dash CD-ROM based navigation system, DVD based rear entertainment system, ultrasonic rear park assist/back up sensors, power moon roof, power adjustable accelerator and brake pedals (introduced on the first generation Expedition), Gentex auto dimming electrochromatic rear view mirror, lane departure indicators on side view mirrors, second row captains chair luxury seating, premium Audiophile sound system with in-dash 6-disc CD changer and rear subwoofer and four-wheel independent pneumatic air-ride suspension system.