Here's a general guide. Specific steps and difficulties may vary slightly depending on the engine (4.6L or 5.4L V8). Consult a repair manual specific to your Expedition's year and engine for detailed diagrams and torque specifications. A Haynes or Chilton manual is a good investment.
Tools You'll Likely Need:
* Socket wrench set (metric)
* Ratchet
* Extensions
* Torque wrench
* Jack and jack stands (essential for safety!)
* Wheel chocks
* Pry bar or similar tool (possibly)
* Wire brush (to clean connections)
* New starter motor
* Penetrating oil (like PB Blaster)
General Steps:
1. Safety First: Disconnect the negative battery cable. Chock the rear wheels and securely lift the front end of the Expedition using a jack and jack stands.
2. Access the Starter: The starter is typically located on the passenger side of the engine, near the bell housing (the area where the engine connects to the transmission). Access may require removing some components to get a clear shot. This often involves:
* Removing the air intake system (or parts of it). This varies greatly depending on the specific Expedition model and engine, so check your repair manual.
* Possibly removing the heat shield: This metal shield protects the starter and exhaust manifolds from heat. You may need to loosen or remove its fasteners.
* Possibly removing some wiring harnesses or brackets: These can sometimes obstruct access to the starter bolts.
3. Disconnect the Starter:
* Battery cable(s): Carefully disconnect the positive and negative cables from the starter. Note their positions for reconnection. Clean the cable ends with a wire brush.
* Starter wire(s): There are usually one or two wires connected to the starter solenoid. Disconnect them. Again, clean the connections.
4. Remove the Starter Bolts: The starter is held in place by typically two or three bolts. Apply penetrating oil to the bolts beforehand if they seem stuck. Use the appropriate sockets and extensions to reach the bolts and remove them carefully.
5. Remove the Starter: Once the bolts are out, the starter might be stubborn. Gently wiggle it and carefully remove it from its location. There may be some resistance from the starter's alignment with the engine block.
6. Install the New Starter: Carefully install the new starter in the reverse order of removal, ensuring it's properly aligned.
7. Reconnect Everything: Reconnect the battery cables and starter wires, making sure everything is securely fastened. Don't forget to reconnect the heat shield, air intake, etc. Tighten all bolts to the manufacturer's specifications (use a torque wrench!).
8. Lower the Vehicle: Carefully lower the Expedition using the jack.
9. Reconnect the Battery: Reconnect the negative battery cable.
10. Test the Starter: Attempt to start the engine. If it doesn't start, double-check all connections and steps.
Important Considerations:
* Repair Manual: A repair manual specific to your 1997 Ford Expedition is crucial. This guide provides a general overview, but specific procedures may vary.
* Bolts Can Be Stuck: Use penetrating oil liberally on all bolts before attempting to remove them. Rusted or seized bolts can snap, requiring more extensive repairs.
* Safety First: Working under a vehicle is dangerous. Always use jack stands and chocks.
If you're not comfortable with this repair, it's best to take your Expedition to a qualified mechanic. Replacing a starter incorrectly can lead to further damage.
