2003 Expedition Billet Grille Insert - Tech

Every time a new truck or SUV is released into the market, we sit back and watch as the entire aftermarket world scrambles to perform whatever research and development is necessary to get their product out for a given vehicle. Each year, there are one or two vehicles that grab everyone's attention because it is obvious to all that they will become the hot ticket for the next year and will be the vehicles to watch at SEMA come November.

This year, one of those vehicles is the newly redesigned '03 Expedition. Leaner and meaner than its predecessor, we're sure its chiseled good looks will serve the aftermarket industry well.

One of the first on a soon-to-be long list of enhancements available for the '03 Expys is the polished billet grille from Carriage Works. This high-quality grille looks right at home on the new-model Fords, especially since the cool factory chrome bezel is retained to accent the insert. Another bonus is that Carriage Works also makes a matching insert to fit the opening in the bumper below the grille.

We caught up with the folks at S.A. Motorsports as they installed one of the first Carriage Works billet inserts in a fresh-off-the-lot Expedition. As always, don't forget to check the Web sites for additional information and give Carriage Works or S.A. Motorsports a call if you have any questions.

We really like the newly designed '03 Expedition, but like always, the stock grille leaves a lot to be desired. And what's with the gaping hole in the bumper?
We really like the newly designed '03 Expedition, but like always, the stock grille leaves

The solution is the new upper and lower polished billet grille insert from Carriage Works. They come complete with all the hardware and can be installed in about an hour.
The solution is the new upper and lower polished billet grille insert from Carriage Works.
The grille and bumper cover will come off as one piece, but they will need to be removed to install the grille insert. The first step was to remove the eight plastic rivets that hold down the plastic top cover.
The grille and bumper cover will come off as one piece, but they will need to be removed t

Next, the S.A. Motorsports crew removed the two Torx bolts that hold the top of the shell to the core support.
Next, the S.A. Motorsports crew removed the two Torx bolts that hold the top of the shell
The two 7/32-inch bolts on the lip of the wheelwells were removed.

Then the two 7/32-inch bolts at the bottom of each fender were removed.
Two more 10mm bolts reside under each wheelwell. These bolts secure the fender to the grille and bumper cover. They must also be removed.
Two more 10mm bolts reside under each wheelwell. These bolts secure the fender to the gri

Under the front end, the foglight assemblies were disconnected and hung out of the way.
The rivets that secure the bottom of the cover were pried out with this handy tool from Snap On that was made just for such an occasion.
The rivets that secure the bottom of the cover were pried out with this handy tool from Sn

There are four tabs across the top of the grille that must be pushed down to release the assembly from the core support. Once free, the entire unit was placed on a bench topped with a blanket.
There are four tabs across the top of the grille that must be pushed down to release the
These eight U-clips were then pried off to allow the insert and chrome bezel to be freed from the shell. Be gentle because you'll be reusing these clips in a minute.
These eight U-clips were then pried off to allow the insert and chrome bezel to be freed f

Another set of clips holds the bezel onto the insert and was carefully pried apart.
The bezel was then remounted to the grille shell using the eight U-clips we carefully pried off.
The bezel was then remounted to the grille shell using the eight U-clips we carefully prie

On the Carriage Works insert, the four mounting brackets were loosely attached to each corner with the provided screws and clips.
On the Carriage Works insert, the four mounting brackets were loosely attached to each cor
Now the insert was set into the shell and the locations of the brackets were marked.

Four 3/32-inch holes were then drilled into the back side of the grille shell.
Using the screws and clips, the insert was then secured to the shell.

Four brackets were attached to the bottom insert, and it was set into place.
It was attached to the bumper and valance by screwing the clips to the existing brackets.

The holes in the brackets are oblong, so any minor fitment adjustments can be made at this time.
The holes in the brackets are oblong, so any minor fitment adjustments can be made at this
The entire assembly could now be set back onto the vehicle, and the four clips across the top were used to temporarily hold it in place.
The entire assembly could now be set back onto the vehicle, and the four clips across the

The twelve bolts that hold it all together were replaced accordingly.
Underneath, the foglight assemblies and plastic rivets were popped back into place.

Finally, the eight plastic rivets holding the top cover down were replaced.
Why are billet inserts one of the all-time most popular mods to a truck or SUV? Compare this shot with the before photo and it's easy to see why.
Why are billet inserts one of the all-time most popular mods to a truck or SUV? Compare th