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PRICE: $7,000
LOCATION:
Palmdale, CA - just over an hour from Los Angeles. I can pick buyer up from LAX or BUR for an additional fee.
SPECS:
Reliable 5.4 2v Engine (long block replaced by Ford in 2013)
5R110W 5-sped transmission
Bilstein Shock Absorbers in Front
Transmission Cooler
6’4” floor to ceiling - no roof raise required
Durable fiberglass roof
Rear heater runs with hot engine coolant
Mini Split w/ WiFi 9k BTU
138,537 miles (may increase slightly due to use)
NEW PARTS:
Overwhelming majority of parts are OEM Motorcraft/Ford installed over the last 2 or less years by me according to the Ford service manuals. Many parts weren’t necessarily needed and were replaced for preventative maintenance.
Exhaust manifolds, gaskets, w/ upgraded stainless steel hardware (quoted $7,000 by Ford for just the exhaust manifolds because the engine had to be pulled)
Head gaskets & Head Bolts (weren’t needed at all but I had the engine out of the bus to replace exhaust manifolds)
Radiator
Harmonic Balancer
Harmonic Balancer Bolt
A/C Compressor
A/C Condenser
A/C Drier/Accumulator
Belt Tensioner
Idler Pulley
Serpentine Belt
Left and Right Valve Covers w/ Gaskets
Coolant Tube running through block valley (commonly rusts out)
Lower Radiator Coolant Hose
Coolant Thermostat
Coolant Thermostat Gaskets
Spark Plugs
Rear Main Seal & Plate
Front Main Seal
Timing Chains, Guides, Tensioners, Chain Sprocket
Water Pump
Engine Oil Pump Pickup Tube
Engine Oil Pan w/ Gasket
Engine Block to Bellhousing Plate
Oil Pump
Intake Manifold Gaskets
Flexplate
Bilstein Shock Absorbers (front)
All 4 Brake Rotors, Calipers, and Pads w/ Brake Flush
PCV Valve
Transmission Filter, Fluid, and Pan Gasket
Transmission Fluid Dipstick Tube
Engine Oil Cooler
Engine Oil Filter Adapter Casting w/ Pressure Switch
Engine Oil Dipstick Tube
HVAC Blower Motor
HVAC Blower Resistor
MORE DETAILS:
I stripped this bus down to the bare framing and discovered that the non-Ford steel tubing added by StarTrans had severe rust so I cut most of it out around the perimeter base and upgraded it to 1/8” steel tubing that will never rust out in the vehicle’s lifetime like the original thin steel. I think the original steel was probably half the thickness.
I replaced the steel tubing of pretty much the entire base perimeter of the shuttle bus body, with the exception of a remaining 7 or so feet which I didn’t get to but am including 1/8” steel tubing to complete the job. I also replaced some of the vertical supports with the same heavy duty steel.
You’re probably wondering why it has painted OSB siding. I had to add it hastily because my lease was ending and I was about to make a cross country move. My long term plan was to add luan plywood glued to filon.
I framed in and installed a Dometic S4 800x350mm window. Unfortunately I had left the window open and the acrylic pane flew off going down the highway so you can either replace the window or just delete the window when you reside the bus.
With as much love I’ve put into this project, it’ll still need your dreams and hard work put into it. The nice thing is that I’m not hiding anything with the walls being exposed like this. So many buses are hiding bad rust under the windows or are made out of waxed cardboard.
I put in 3/4” OSB for flooring and that was supposed to be temporary just like the OSB siding. It’s structurally sound but I didn’t make nice cuts or use interlocking subfloor.
The mini split lines are connected but I decided against releasing the refrigerant because it would’ve been a waste once I moved it to its permanent spot. This means that you can disconnect the lines, move the mini split, and the refrigerant won’t come out because it’s still in the outdoor unit.
The floor pan on the driver’s side was repaired previously because it had some sheet metal rust which is common on these E-series vans. Passenger bus door opens electrically but won’t close electrically. I’ve never investigated this.
Tires have good tread and are safe to drive but are mismatching and will need to be replaced eventually. Check engine light is due to minor EVAP leak that was on when I took it into the Ford dealership originally. I declined their further diagnosis of it after getting the $7,000 quote just for the exhaust manifold replacements. This was on my list of things to look at, but I never got around to it.
This bus ran flawlessly packed with my stuff and towing my car behind it driving the several thousand miles across the country.
I’ve described this as honestly and thoroughly as I can. Please let me know if I missed anything or if you have any questions.
