Offroad Projects

Brian1's Twin Trail Build 1991 Ford Explorer 4-Door XL 5-Speed Manual 4x4 Project Background and Goals: I bought this Explorer at a Police auction in August of 2015. I really didn't know what I was going to do with it when I bought it but I couldn't pass up the great deal I got. I stored it away for a bit while deciding to part it out, build it up or just flip it. In the end I decided to build it into a cheap trail truck and use it to R&D some new ideas I had on how to build an Explorer and develop some new parts. The goal of the build was to do it cheaply while keeping it low, lightweight, and simple. Another goal was to completely transform the Explorer into a trail machine and debut it at the 20th anniversary forum run in Moab...

I picked up my transfer case last night. Two t cases were included in the deal, one is strictly for parts. The t case I will be using in my 96 5.0L AWD explorer is a 2001 F-150 BW 4406 manual shift :) this makes me very happy. I will no longer have full time AWD, instead I will have 2wd, 4hi and 4 low, increased RWHP, better MPG, and less tire wear. Also a more capable truck off road for light wheeling (getting to the fishing spot, colorado winters, etc) I have ALOT of research to do before I get started collecting more parts and modifying the t case so it can be installed...I am just beggining this conversion. Once I get a better picture of everything that is needed I can post more. I know I need to get the manual shifter...

Hi, My name is Sævar and I´m 22, I live near the capital Reykjavik Iceland and I recently bought a slightly modified 91 Explorer I have owned a lot of cars in my short yet life, but only 3 american made, first an AMC Eagle 82 and a Cherokee Country 1995, and now this Explorer Ive mostly had Suzukies in the past, and for the longest time, since 2007 until recently I had a Vitara of which I also modified a little bit, heres a photograph It has 38" super swampers and toyota pickup axles with locker, toyota transfer box and gearbox and 2.5 turbo diesel intercooled Hyundai engine my plans with the explorer so far are unknown, Im thinking of finishing it up and using this winter and seeing what needs better finishing, but before...

Okay here we go 09/13/05 In march of 05 I rolled my new to me 96 5.0L AWD 86K miles, just after driving it back to CO from OR and putting $1000 into it. You see I bought this truck from my brother with 86K miles on the clock, it would not pass emissions for him and he drove it into the ground. This was the same explorer he bought new when I got the BII from him for $500 12 something years ago. Well I payed him $500 for the green Explorer and $1000 later (shocks, tune up, 02 sensors, etc) it was in primo condition. Then I rolled it in an ice storm... RIP 96 EB: So in April my buddy Brett found this great deal here in town for a 96 XLT 5.0L AWD, $900 is what I paid, it has front end damage and air bags deployed, picked it up...

LD50 Full-size axle thread `93 Ex SAS Hey fellow Explorer enthusiasts! Well I never thought I`d do it, but it`s time. I originally thought I would go to a smaller rig one day but I`m going to beef up the Explorer instead. Since I already have a huge thread on my previous work I decided to start fresh. If you would like to see my previous mods, you can navigate from my signature link, or click here: http://www.explorerforum.com/forums/showthread.php?p=523171#post523171 ~ My plans are to install a D44 and 9-inch into the station wagon and run 35 inch tires. Hopefully she`ll still get in the garage, but if it don`t then oh well. During this I also have some body work to do. Right now I have the rear end out, I took off...

Some of you may know, and some may have suspected, but I'm starting a new project and it starts with a truck you all will recognize. I picked up R.J.'s Navajo today. She is a little tired and was facing being parted out, but now will start a new chapter, a very different chapter. I give you Plan B. (dead links) So let's start off as to why "Plan B"? Well, it has multiple meanings. It starts off as I really wanted a early Bronco. I first learned to drive on Zukmans '71 Bronco he had years ago. But myself owning a early Bronco was not going to happen. There just way to ridiculous priced these days.:eek: So this is My Plan B. JP is not going anywhere, I really just wanted to to do another build and JP is...well, JP!. It works, but it...

I have a thread up in modified 95-01 Explorers, but since mine is mainly off-road I figured it would be more suitable to have a thread in here. What I am working with 97 2wd Explorer 4 door with 5.0L V-8 Front suspension: 14" Wheel travel Modified LCA to accept a 1" uniball as the outer pivot then boxed in accordingly. Custom UCA with 7/8" heim as outter pivot and 3/4" heim on frame pivots. Fabtech lift spindle tapped out for the heim and drilled knuckle for a 7/8" on the outter tie rod as well. Fox twin tube bypass shocks as well as a 2.0 body air shock per side assist the stock torsions with spring rate. Fox hydraulic bump stop off of the UCA Rear suspension: 18" wheel travel 62" race leaf springs by Deaver with custom 12" long...

So you think you want to put a 302 in your 91 to 94 Four Wheel Drive Explorer? My advice is plan, then plan some more. Ask questions, then plan, and finally ask more questions then plan. You get the point. There are several sources for doing this swap with Rangers. Most of this info is usable on the Explorers. However, some options do change the way things fit. My ABS motor on the 94 XLT is making it tough to mount a radiator. Also, Size does matter! 302’s are the easiest fit. There is not much room in the older Explorers, so anything bigger than the 302 ( Size wise, not Cubic inch wise ) is hard to squeeze in there. Yes 427’s can be made to work, but why spend all the extra money redesigning the frame? Doing this conversion...

Got a '99 ford explorer 5.0 V8 AWD looked everywhere online for a lift kit for it all i can find is people saying to just add a leaf. Does anybody know a lift kit? Trying to get 3-6 inches wanting to fit 36 tires on it thanks

I guess this is what happens when you take someone like me, add someone like Kevin (DWD), and throw in some beer! Here's the plan. This weekend I'm looking at buying a '79 F250 longbed. It has a 300 straight 6, leaf sprung dana44 front, dana 60 rear. Basically, I'm going to put my Explorer body on the F250 frame. First things first. I need to rebuild the 6banger, trans and axles. Then, I cut some of the frame out of the F250, bring the dana60 forward a bit. Fab up some body mounts, get creative with the engine compartment and steering linkage coming out of the Explorer firewall. Then I spend 200 or so manhours rewiring, fabbing fuel and brake lines. Then I slap on some new tires (38s?) with 8lug rims and bingo....I go...

Body mount replacement and custom Heavy duty 3/4" body lift. Several of my body mounts had deteriorated such that the lower flanged washer and rubber mount were falling off. In the picture below I have loosened the bolt but not removed it completely. I had ordered the DayStar Body mount (KF04009) replacement kit to replace all mounts. Unfortunately the kit only includes the Poly Bushings and no hardware. As such I had purchased the following additional hardware. Qty - Grade 8 Bolts 2 @ 1/2" x 4.5" (Mount #1) 6 @ 1/2" x 5â€￾ (Mounts #2 and #4) 2 @ 1/2" x 7â€￾ (Mount #5) 10 @ 1/2" Grade 8 washers and nuts. 30 @ 1/2" ID x 3" OD x 1/4" thick (dock washers) The process is similar to that of a body lift but...

Goal is to convert the D35 to 6 lug while increasing strength and durability. Please save your breath about why I should just save all the time time and money and just do a SAS because it’s better in every way. I’m a nerd and TTB is one reason I love old midsize Ford Junk. Subject is currently 200% stock 93 X 3.73 5spd Build goal - Budget minded daily driver with good road manners, decent flex, max traction (lots of snow) Family friendly trail rig for hunting camping and dicking off. I’m aiming for comfy suspension and will retain small tires for now so I can still hit highway speeds with the stock gearing. Will probably go to a max of 33’s if I get the hybrid gear swap done in the trans. After looking at current wheel tire...

Got it done yesterday, few questions please: - How much will 4.10's and TM Headers improve my MPG? I am currently running 3.73's. - I would like to run some wheel spacers, but I won't if it is going to add any additional stress to the truck. Thoughts on this? I am getting some rubbing in the front and I think if my front tires stuck out a bit more that it would clear completely.

I'm almost ready to hit the trails with my 99 5.0 D60/Sterling 10.5/Atlas 4.3 explorer on 40" TSL. The one item I need to address is belly protection for the tcase & auto. Does anyone have any pictures ideas of what has worked well?

This is a very handy tool for adjusting the springs on coil over shocks. The head locks in three positions to make it easier to insert the wrench in tight spots. www.coilclaw.com Various sizes are available on their website.