Originally Posted by iamdf1
Hello - want to tow a 10000 lb tt with the ford excursion. Does any one know if I can beef up the Excursion to do the job.
It's easy to pump up the drivetrain so it can pull that load easier and have a more pleasant towing experience.
With the 6.0L diesel in a 2004, you can replace the 3.73 axle ratio with 4.30. 4.30 was optional in the V-10 X-Car, so Ford parts are available. X-Car is the nickname for an Excursion. However, the 6.0L diesel needs lots of mods to make it a bullet-proof tow vehicle. Not my area so I won't get into it, but the experts hang out on 1999-2007 Ford Super Duties - Diesel Forum - TheDieselStop.com
. Go there and get knowledgeable about what it requires to bullet-proof the 6.0L engine so it will last at least 400,000 trouble-free miles. The X-Car is basically an F-250, so whatever works for an F-250 will also work for an X-Car.
With the much more reliable 7.3L engine in the earlier X-Cars, you don't need anything to bullet-proof the engine except change the oil and filter every 5,000 miles and use Shell Rotella T or Chevron DELO 400 motor oil.
Nothing you can do officially to change the GVWR and payload capacity of an X-Car - within a reasonable effort of time and money. All you can do is install air bags in the rear suspension and pump them up to hide the sagging rear end and headlights aiming at the stars symptoms of being overloaded. I'm not a fan of an overloaded tow vehicle, but lots of folks do it.
A 2002 7.3L X-Car in good condition will probably cost you more than a comparable 2004 6.0L X-car in comparable condition. That's because you and I are not the only ones that know a stock 6.0L requires lots of expensive mods to make it reliable.
If you can find a 7.3L X-car you like, then it still requires some mods to make it bullet-proof. Mainly, you must replace the oil-to-air tranny cooler with the much bigger one from a 6.0L, and you must install a good tyranny temp gauge and watch it when poking along with a 10k trailer. The weak sister in the drivetrain is the tranny and torque converter, so even with the good tranny temp gauge, the life of the tranny is about 100,000 miles before it requires an overhaul. And the power of the 7.3L is "adequate" for dragging a 10k trailer, but barely.
Here's what I did to my 7.3L way back when:
1: gauges. Tranny temp, and pyrometer (for engine exhaust gas temp = EGT), and turbo boost. Tranny temp is required, and the red line is 225°. Pyrometer is required only if you hot-rod the engine with a "tune" to pump it up to around 290 HP (230 stock plus a 60-tow tune), Boost gauge is not needed for towing, if you never allow more than the 1,250° red line for EGT. My source for gauges was the complete gauge package from ISSPRO EV1 Gauge Kits for Ford Powerstroke from DieselManor
. Read the install instructions. Main points are to install the thermocouple for the pyrometer before the turbo (pre-turbo), then use 1,250° as the red line for EGT when working the engine hard. Install the sender for the tranny temp gauge in the side of the tranny where the instructions show. That will give you "sump" temp, then use 225° as the red line for tranny temp.
2: Tune. My 7.3L had 230 HP and 500 lb/ft torque stock. Adequate, but no fun. I used DP-Tuner 80-tow tune to pump up the HP to 300 and the torque to 600. Much, much better, indicated by how often the tranny downshifted out of OD for overpasses and minor hills.
Your 10k trailer is a bit much for an 80-tow tune (mine was only 8k), so back off to 60-tow.
F5 1-16 Position Switch on the fly Chip - Chips - Chips, Programmers and Tuning - 2000 - 2003 Powerstroke 7.3L Excursion - Ford Powerstroke
The least expensive way is with the F-5 chip and 60-tow tune. I would also add the decel tune (exhaust brake) and a tune switcher so you can switch tunes "on the fly". You need to be able to instantly switch from 60-tow to decel when you top out of the pass and head down the mounain, then instantly switch back to 60-tow at the bottom of the pass. Another neat tune is the 1,200 RPM fast-idle tune. Use that to warm up the engine oil on freezing mornings, or to cool down an overheated tranny if you don't have adequate tranny cooling capacity. Each tune for an F5 chip will cost $50, but I spend a lot more for an exhaust brake and an idle RPM controller. Mine also had the best of the stock Ford tunes. If you take your X-Car to a Ford dealer for some diagnostic work, you need to have a stock tune installed before you drop it off to the dealer. With the F5 chip and tune switcher, adding that stock tune will cost you only $50. Ask Jody at DP-Tuner which is the best stock tune for your X-Car.
3. Tranny cooler. Back before the 6.0L tranny cooler was available, as part of step 4 below I replaced my small stock oil-to-air (OTA) tranny cooler with the bigger one from a V-10. That helped, but the better answer today is to replace the OTA cooler with the much bigger one from the 6.0L.
4. Tranny overhaul. My stock original 4R100 tranny lasted 112,000 miles before the torque converter began acting up. I was on the road in Oklahoma and decided to go with the best in the business- Brian's Truck Shop (BTS) in northeast Arkansas near Branson Missouri. E4OD | 4R100 | 5R110 Ford Diesel Powerstroke Transmissions
. Expensive but then the tranny will outlast the rest of the drivetrain. Brian uses only the best parts to overhaul a 4R100, including a Precision Engineering torque converter.
If your 4R100 tranny goes south, there are several options to get it fixed.
1] Last choice is to have a tranny shop or Ford dealer overhaul your tranny and replace the torque converter.
2] Better is to have a Ford dealer replace your 4R100 tranny and torque converter with a Ford factory rebuilt 4R100.
3] More money but better than a normal 4R100 rebuilt tranny is a Ford 4R100HD tranny. Yes, Ford makes them. Probably not as good as a BTS, but much better and longer lasting than the stock 4R100.
4] Even more money, but the last transmission you'll ever need for your X-Car is a BTS (or a similar rebuilder in SoCal whose name I cannot remember, but the guys on TheDieselStop will remember it).)
If you go for the 2004 6.0L X-Car, then the 5R110 tranny is good, so it probably won't need an overhaul anytime soon. So instead of paying out the big bucks to overhaul the tranny, you'll spend it bullet-proofing the 6.0L engine. (There is no free lunch!)
But just in case your 5R110 tranny needs an overhaul, BTS does those too.