Here's a general outline. Specific steps and difficulty may vary slightly depending on the engine (4.6L or 5.4L) and whether you have 2WD or 4WD. Always consult a repair manual specific to your vehicle's year, engine, and drivetrain for precise instructions and diagrams. A Haynes or Chilton manual is a good investment.
Tools You'll Likely Need:
* Socket wrench set (metric)
* Ratchet and extensions
* Torque wrench
* Jack and jack stands (crucial for safety)
* Wheel chocks
* Pry bar or similar tool (may be needed)
* Wire brush (for cleaning terminals)
* Battery terminal cleaner
* Penetrating oil (like PB Blaster)
* New starter motor (ensure you get the correct one for your Expedition)
* Gloves
* Safety glasses
General Steps:
1. Safety First: Disconnect the negative battery cable. Some recommend disconnecting the positive as well, but the negative is sufficient to prevent accidental shorts.
2. Access the Starter: This is the most challenging part. The starter is typically located on the passenger side of the engine, towards the bottom. You'll likely need to:
* Raise the vehicle: Use a jack and jack stands to safely lift the front of the Expedition. Secure the vehicle properly.
* Remove components: You may need to remove various things to gain access. This could include:
* Parts of the exhaust system (heat shields, etc.)
* Air intake components
* Possibly the upper engine mount (depending on the exact location and access)
* Some engine protection/skid plates
3. Disconnect the Starter:
* Locate the starter's electrical connections (large positive and smaller negative cables). Use the wrench to loosen the nuts securing these cables to the starter. Spray penetrating oil if the connections are stubborn.
* There's usually a ground wire connected to the starter's housing. Disconnect this as well.
4. Remove the Starter Bolts: The starter is usually held in place by two or three bolts. These can be very difficult to access and often require extensions and wobbly sockets. Apply penetrating oil if needed, and carefully remove the bolts.
5. Remove the Starter: Once the bolts are out, the starter should come loose. You might need a pry bar to help carefully wiggle it free. Be mindful of the weight and its location.
6. Install the New Starter: Clean any corrosion or debris from the mounting surface. Install the new starter, making sure it's properly seated. Tighten the bolts to the manufacturer's specified torque (consult your repair manual).
7. Reconnect the Wires: Reconnect the electrical connections to the new starter, making sure they're secure and tightened properly.
8. Reinstall Components: Reinstall any components you removed to access the starter (air intake, heat shields, etc.).
9. Lower the Vehicle: Carefully lower the Expedition using the jack.
10. Reconnect the Battery: Reconnect the negative battery cable.
11. Test the Starter: Try to start the engine. If it doesn't work, double-check all connections and the work you've done.
Important Considerations:
* Consult a Repair Manual: This is absolutely crucial. Pictures and diagrams will be invaluable.
* Safety: Work in a well-ventilated area, use jack stands properly, and never work under a vehicle supported only by a jack.
* Torque Specifications: Use a torque wrench to tighten the bolts to the correct specifications. Over-tightening can damage the starter or engine block.
* Professional Help: If you're uncomfortable with any of these steps, consider seeking professional help from a mechanic. The cost of a repair might be less than the cost of damaging your vehicle.
This is a general guide. The exact procedure will vary based on your specific vehicle. Always refer to a repair manual for your specific 2005 Ford Expedition.
