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I had the very same rust issue with my 2002 EB. I bought it from someone that had no idea how to fix it so got a good deal on the price. Unless you have bodywork experience you are at the mercy of an autobody shop. There is no way to properly repair it unless you cut out all the rust and buy...

Only a post mortem of his unit will verify my theory. Yes the vast majority of alternator brush wear is equal, but I have seen this problem multiple times over the last 40 years of repairs. Sometimes unequal wear is caused by manufacturer or material defects, and sometimes it's caused by dirt or...

What happened was one of the brushs in your alternator wore out but not the other. You need both brushs making firm contact to create full voltage. When the one brush was deteriorating but not quite worn out, you get varying voltages at different rpm's. Higher rpm's were just enough to keep your...

If it's the original filler pipe then I would replace it. There may be a lack of clearance between the vent and filler tube causing enough back pressure to trigger the auto shut off.

Then try this, remove the hose at the tank and check the flapper or baffle at the entry of the tank to make sure it's free and moving easily.

I have the 2004 EB and experienced the same issue recently. I found that where the filler pipe takes a 90* turn to enter the gas tank that the hose was pinching flat. I didn't want to replace it now as I'm a little cheap, and winter is here (Winnipeg Canada) so I simply took 2 ring clamps and...

My lift gate cracked too, right in the center.

Yah, I kind of intended it to be more of a suggestion for future bigger ticket items, usually when I go, I find things like those in addition to what I went there for, no offense, you found a good deal. Plus my wrecker is only a mile away so very convenient for me.

Your doing this the hard way. Just go to your nearest pic a part or wrecking yard and grab some used ones. Cheap, and even free if you know what I mean. It's always a good idea to locate explorers for parts in local salvage yards, you can save a lot of money getting original Ford parts for your Ex.