Well, I finally found the motivation to finally go ahead and replace the rear window today. Since I had the seats out anyways, it made it so much easier to do the back window. I went ahead and changed the out trim also, while I had it out.

If anyone does this, remember, change the molding first when reinstalling. It has a ring around it that fits behind the glass a little, so it can not be added with the window installed. I almost put the window in first, but remembered the ring. I'm glad I stopped when I did. I would of hated to remove the window again, and waste a ribbon-weld kit. Almost, but not quite. LoL. Glad I looked before I leaped.

I also pulled the headliner to give it a good cleaning, and the side panels in the rear. Everything went together perfectly. Tomorrow I reinstall the seats, and put on the exhaust.

 

Right on. What holds the trim in there? What do you use the seal that?

Hey AK, would you look at this video below and see if you have any ideas? I am wondering about this weird check valve too. I can't seem to find it on Tasca.... so I don't know if it is somebody's handy work, or if it's factory.

 

Looking at the gear clamp, that shows that someone has changed it or worked on it. Factory doesn't use gear clamps. It is a vacuum booster check valve that you are showing. If you think back, that was a common vacuum leak in the older vehicles. A bad check valve can throw a lean code. It might be your problem. So could the booster be leaking, throwing those codes.

As far as the trim, the window has to be removed to replace the trim. It is bolted into the body, just like the window. It has a piece of seal that goes around the outer lip, which I used contact cement to hold in place. That seemed to do the trick. As far as the bolts, they have special washers to seal it to the body. I used some black 598BR Permatex around each bolt hole. That is what the seal for the window does, so I just took it one step farther and did the trim the same way. Also, you must start with the middle bolts for tightening the window. If not, since it is a fairly tight fit, you can possibly crack the window frame, if you are not careful. I used a friend to set the window straight, and I went inside to pull it up evenly. When it was done, all the screws were pulled tight, and I don't see any possible leaking areas. I won't be sure until later today when I do a water test. I have sealer coming thru each bolt hole, so I don't think there is any way of leaking.

 

06 has two options for the Expy's. One is roll over stability and the other is without. That valve must be for the Stability control model, I'm guessing.

 

That was my initial thought. However, it doesn't have stability control. The booster is also different with that option. The booster came with a different valve in it.... I am thinking about just using that and hooking the other two into a tree/tee... The only thing I don't understand is, it appears to have two diaphragms inside. Not sure just what the hell that's all about.

On a side note, although the fuel trims are still high - the CEL shut back off. Think I might be doing the intake manifold on this thing. If I spray water back on the cylinder 8 injector/manifold it starts to miss. There is definitely more than one issue going on here.

Do any of you know where the vacuum line connects under the intake manifold? Someone has most definitely been messing around with this thing. The metal vacuum pipe has been pulled out of its retainer. Also, in that pic I posted of the booster valve you'll see some black on it. That is black RTV. The grommet on the old booster was caked with it.

 

It's held in by bolts around the perimeter, you have to get to them from the inside of the truck. They're about parallel with the bolts for the rear window.

 

Well, I finally got the seats in today. It has been windy as hell all day, so my work went slow.

The 04 Expy seats bolted right in without any problems. You do have to change the seat belt seat halves, to make the belts fit correctly. I changed those and everything is set up like it should be. I've included a couple pictures of the Expy's in my 98. (For anyone who wonders, YES, 04-08 F150 and Expy seats will work fine, and nothing needs changed other than your seat belt ends. Nice Direct fit).

 

That looks great AK! Those seats are nice. I wish they matched my rear seats on mine.

Wanted to get some stuff done today, but I was without power for a couple hours. By process of elimination, I was able to tell one leg was gone and it was on the power company's side. Turns out that the splice connection coming into the house was bad. When he cut the wire, a bunch of water came out of it.

This house is giving me a run... LOL.

 

Thanks for the props White. I think it fits fairly well. Tomorrow I'll either do the exhaust and shocks, weather permitting. If not, then I'll go inside and do the steering wheel swap to the Navigator one.

Glad to hear you got it figured out on the electrical for your house. I hope you get it done soon enough so that you can sell it and move on to a bigger, more efficient house for you and the wife.

 

What exhaust are you doing? Was it Borla.... or am I thinking of Brew?

Check this out AK. I asked the guy for the pieces he cut out of my main feed. This is quite obviously the problem. Sucker fell right apart in my hand after I removed the tape.