Dismiss Notice



Register Today It's free! This box will disappear once registered!

Bkennedy's SAS and Rebuild Thread

Discussion in 'Offroad Projects' started by BKennedy, June 4, 2013.

  • Searches ExplorerForum.com
    1. BKennedy

      BKennedy Elite Loser Staff Member Moderator Elite Explorer

      Joined:
      November 29, 2000
      Messages:
      5,806
      Likes Received:
      307
      Trophy Points:
      103
      Location:
      Location, Location
      City, State:
      San Diego, PRofK
      Year, Model & Trim Level:
      1994 XLT
      OKAY, my belief in AAA has been restored!!

      I got a call from the agent I visited earlier. She noticed the salvage title hasn't been completed so DMV just shows it as a regular vehicle. She asked her manager, who said go for it and see what happens. She entered it in the system as being insured and put in a note that I did not request cancellation. She said it didn't flag it and her boss approved it, so I am good to go. When the salvage title pops up when its renewal time, she said they will have to insure it since its already on the policy, but the policy will just need to be modified. Thank you Ruth Rodriguez, Sr Insurance Representative.

      I was so happy I went outside and pulled the rest of the doors, fenders, most of the wiring, radiator and a bunch of other stuff off the donor. I think I am going to sawzall the front clip off about mid-fender to make it easier to get the engine out. It will be good fun too. I just need to set up a date/time with a couple friends, one of which has an engine hoist.
       
      • Like Like x 2
    2. Support EF

      Join the Elite Explorers for $20

      Explorer Forum has probably saved you that much already, and will continue to save you money as you learn how to diagnose fix problems yourself, and learn which modifications work without having to experiment on your own. Elite Explorer members see practically no ads, can add their own profile photo, upload photo attachments in all forums, and Media Gallery, create more private Conversations, and more. Join Today. Your support is greatly appreciated.


      to hide adverts.
    3. R.J.

      R.J. Elite Explorer

      Joined:
      November 16, 2006
      Messages:
      2,087
      Likes Received:
      77
      Trophy Points:
      58
      City, State:
      La Habra Hts, CA
      Year, Model & Trim Level:
      91 Navajo, 90 Bronco II
      Good to hear. What's wrong with your motor?
       
    4. BKennedy

      BKennedy Elite Loser Staff Member Moderator Elite Explorer

      Joined:
      November 29, 2000
      Messages:
      5,806
      Likes Received:
      307
      Trophy Points:
      103
      Location:
      Location, Location
      City, State:
      San Diego, PRofK
      Year, Model & Trim Level:
      1994 XLT
      Nothing is wrong with my engine, its just a little tired. I am pulling the donor Explorer engine to keep because it only has 105000 miles, and ran great on the way home. I plan on slowly rebuilding it with performance parts to add more power, then swap it into my Explorer in a year or two. The transmission of the donor shifted great so I am going to sell it, and the transfer case belongs to RockRanger.
       
      • Like Like x 2
    5. Stic-o

      Stic-o Elite Movie Star Elite Explorer

      Joined:
      September 1, 2002
      Messages:
      13,121
      Media:
      3
      Likes Received:
      152
      Trophy Points:
      93
      City, State:
      Lake View Terrace, CA
      Year, Model & Trim Level:
      '91 Navajo '99 XL '16 XLT

      Hey hey.....don't get any ideas now:nono:

      :p


      Glad to hear AAA is pulling through again. We have been with them for about 12 years now, and they have always been great.
       
    6. R.J.

      R.J. Elite Explorer

      Joined:
      November 16, 2006
      Messages:
      2,087
      Likes Received:
      77
      Trophy Points:
      58
      City, State:
      La Habra Hts, CA
      Year, Model & Trim Level:
      91 Navajo, 90 Bronco II
      I still need a short block for the B2. That 2.9 won't last forever.
       
    7. Stic-o

      Stic-o Elite Movie Star Elite Explorer

      Joined:
      September 1, 2002
      Messages:
      13,121
      Media:
      3
      Likes Received:
      152
      Trophy Points:
      93
      City, State:
      Lake View Terrace, CA
      Year, Model & Trim Level:
      '91 Navajo '99 XL '16 XLT
      So Brian,

      Now that you have done basically a full wiring swap, what advice would you give someone?
       
    8. Spudhut

      Spudhut US Navy Submariner Elite Explorer

      Joined:
      August 14, 2017
      Messages:
      351
      Media:
      64
      Albums:
      2
      Likes Received:
      73
      Trophy Points:
      28
      Location:
      NW Arkansas
      City, State:
      Bentonville, AR
      Year, Model & Trim Level:
      1997 Explorer Sport - 4x4
      Callsign:
      KG5SPB
      Its great to see tragedies turn into happy endings! The Explorer looks fantastic, excellent work!
       
      • Like Like x 2
    9. BKennedy

      BKennedy Elite Loser Staff Member Moderator Elite Explorer

      Joined:
      November 29, 2000
      Messages:
      5,806
      Likes Received:
      307
      Trophy Points:
      103
      Location:
      Location, Location
      City, State:
      San Diego, PRofK
      Year, Model & Trim Level:
      1994 XLT
      Ahhhhhhhhh, start at one end and don't stop until you get to the last plug?? The OEM wiring was straight forward because all the plugs go to specific harnesses. The aftermarket wiring was a total pain. For that, you need a plan. Figure out how much wire you need and get twice as much. Write it all down. I went through 4 or 5 different versions of the wiring until I got it to where I felt comfortable to start actual work, then changed several things as I went along because it was easier. Keep it as simple as possible.

      Thanks.
      Today I got the brake and light inspections, the VIN verification and four hours at DMV later, I got my new registration and plates. I only need to install the transmission gauges and adjust the TV shifter cable because its going into OD way too soon and not downshifting out of OD. Cool guy doing brake and light inspection pointed out that my front corner marker lights are not working, but passed it anyway when I assured him I would fix them. I honestly didn't remember there being any corner lights. He spent more time asking me questions about my build than inspecting anything. When I got home I looked on the donor truck and there they are, plugs that you can't get too without pulling the headlight bezels off, which means removing the grille, again.

      Still need to read up on ham radio licenses and maybe take a class, then a test..
       
      • Like Like x 1
    10. Rick

      Rick Pumpkin Pilot Staff Member Admin Elite Explorer

      Joined:
      February 8, 1999
      Messages:
      30,584
      Media:
      40
      Albums:
      4
      Likes Received:
      415
      Trophy Points:
      113
      City, State:
      Wayoutin, Aridzona
      Year, Model & Trim Level:
      '93 XL Pumpkin Edition
      Callsign:
      AB7FH
      Study the book, then take the practice exams here:
      AA9PW FCC Exam Practice » Amateur Radio Exam Practice

      The practice exams use the exact questions from the "real" question pool. If you keep passing the tests online you'll pass in person.

      It's great to see that your Explorer is all road worthy and legal again:chug:
       
    11. Spudhut

      Spudhut US Navy Submariner Elite Explorer

      Joined:
      August 14, 2017
      Messages:
      351
      Media:
      64
      Albums:
      2
      Likes Received:
      73
      Trophy Points:
      28
      Location:
      NW Arkansas
      City, State:
      Bentonville, AR
      Year, Model & Trim Level:
      1997 Explorer Sport - 4x4
      Callsign:
      KG5SPB
      I used "Technician Pool" Exam Tech App on iOS/iPhone - worked like a charm, simple and easy to use. It's updated with current exam questions; you can sort hard questions, do repeat tests, it saves results...

      I hope to take my General Test this year.
       
      • Useful Useful x 1
    12. BKennedy

      BKennedy Elite Loser Staff Member Moderator Elite Explorer

      Joined:
      November 29, 2000
      Messages:
      5,806
      Likes Received:
      307
      Trophy Points:
      103
      Location:
      Location, Location
      City, State:
      San Diego, PRofK
      Year, Model & Trim Level:
      1994 XLT
      Thanks for the tips.

      I finally officially moved the Explorer into its garage spot. Now, I can work on it in the dark because my garage has awesome lights. Noticed a small puddle of coolant after it was parked. A quick search told me either the hose loosened up at the upper radiator mount, or the plastic mount is cracked.

      Edit: I loosened the hose clamp, twisted the hose around and re-tightened the hose clamp. No more leak.

      Adjusted the transmission TV cable with the wife's help. She watched the pressure gauge while I adjusted the cable. Pressure is where it is supposed to be, and a test drive will tell if I got it right.

      Also need to adjust the shock sensor on the alarm. If you touch the dash with the alarm activated, it goes off. Never liked shock sensors so I usually turn them all the way down, but forgot when I was doing the install.
       
      Last edited: December 30, 2017
    13. BKennedy

      BKennedy Elite Loser Staff Member Moderator Elite Explorer

      Joined:
      November 29, 2000
      Messages:
      5,806
      Likes Received:
      307
      Trophy Points:
      103
      Location:
      Location, Location
      City, State:
      San Diego, PRofK
      Year, Model & Trim Level:
      1994 XLT
      Made some progress with the donor. I told the wife it would look worse before it looks better. I didn't lie...
      20180101_151502.jpg

      20180101_151509.jpg

      20180101_151521.jpg

      20180101_151532.jpg

      It was fun cutting the front clip off. I think I have removed all the connections to the engine, except for the driver side exhaust flange. I tried to remove the ball joint from the pitman arm, but its real stuck. I ended up cutting the drag link off next to the ball joint so I could remove the steering gear box. I should have the engine/trans/transfer case out by Wednesday.

      Anyone local want the bumpers? I wasn't planning on taking them off, but the front bumper was in the way. They are in great shape. If no one says they want them by Friday, they are going to the wrecking yard with the rest of the donor.

      The plan is to have the donor out by Friday, RV back home and all the donor body panels stored at parents house, Saturday or Sunday. Then I can start packing for the Truckhaven run and make sure the wiring between RV and Explorer are correct, and the supplemental braking system is functional.
       
      • Like Like x 1
    14. BKennedy

      BKennedy Elite Loser Staff Member Moderator Elite Explorer

      Joined:
      November 29, 2000
      Messages:
      5,806
      Likes Received:
      307
      Trophy Points:
      103
      Location:
      Location, Location
      City, State:
      San Diego, PRofK
      Year, Model & Trim Level:
      1994 XLT
      RockRanger was right, engine, transmission and transfer case all came out together. TJ Mike came over to help and it only took a few hours, Had to cut the rusted out transmission cross member out, and I had to cut the front drive shaft off at the axle because the bolts were rusted solid. Its a lot easier when I don't have to put the stuff back. Got a stuck bolt, Diablo blade, exhaust, Diablo blade, cut all the fuel, transmission and AC lines out, cut off the radiator hoses. It was therapeutic. I got the transmission separated and on a cart, and the engine is on its stand.

      20180102_113748.jpg

      Matt, this chain look familiar??
      20180102_113802.jpg
      20180102_114329.jpg
      20180102_114630.jpg
      I figure I can spend a full day on clean-up tomorrow, remove the back windows, throw the parts back in that I am not keeping, and bolt the front tires back on to make it a roller again.
       
      • Like Like x 1
    15. Rick

      Rick Pumpkin Pilot Staff Member Admin Elite Explorer

      Joined:
      February 8, 1999
      Messages:
      30,584
      Media:
      40
      Albums:
      4
      Likes Received:
      415
      Trophy Points:
      113
      City, State:
      Wayoutin, Aridzona
      Year, Model & Trim Level:
      '93 XL Pumpkin Edition
      Callsign:
      AB7FH
      You are definitely getting your money's worth out of the parts truck:chug:
       
    16. BKennedy

      BKennedy Elite Loser Staff Member Moderator Elite Explorer

      Joined:
      November 29, 2000
      Messages:
      5,806
      Likes Received:
      307
      Trophy Points:
      103
      Location:
      Location, Location
      City, State:
      San Diego, PRofK
      Year, Model & Trim Level:
      1994 XLT
      Me and a few others....:thumbsup:

      If I lived where I had more space, I would have a few parts Explorers.
       
    17. Rick

      Rick Pumpkin Pilot Staff Member Admin Elite Explorer

      Joined:
      February 8, 1999
      Messages:
      30,584
      Media:
      40
      Albums:
      4
      Likes Received:
      415
      Trophy Points:
      113
      City, State:
      Wayoutin, Aridzona
      Year, Model & Trim Level:
      '93 XL Pumpkin Edition
      Callsign:
      AB7FH
      I have the room, but no one locally that plays with Explorers :(
       
    18. Spudhut

      Spudhut US Navy Submariner Elite Explorer

      Joined:
      August 14, 2017
      Messages:
      351
      Media:
      64
      Albums:
      2
      Likes Received:
      73
      Trophy Points:
      28
      Location:
      NW Arkansas
      City, State:
      Bentonville, AR
      Year, Model & Trim Level:
      1997 Explorer Sport - 4x4
      Callsign:
      KG5SPB
      Fabricators dream! I love having spare parts - of all sizes! Great work!
       
    19. BKennedy

      BKennedy Elite Loser Staff Member Moderator Elite Explorer

      Joined:
      November 29, 2000
      Messages:
      5,806
      Likes Received:
      307
      Trophy Points:
      103
      Location:
      Location, Location
      City, State:
      San Diego, PRofK
      Year, Model & Trim Level:
      1994 XLT
      Today I spent most of the day cleaning up the mess where my RV is supposed to be parked. I got the donor ready to travel, and boxed up all the stuff I pulled. Also pulled the rest of the wiring harnesses. Its only three boxes of stuff, plus the body panels. Donor will be taken to its final resting place Friday.
      20180103_111534.jpg
      20180103_131909.jpg

      I spent the rest of the day and into the evening loading the Explorer with all the stuff a trail rig needs. If you have never removed everything from your trail rig, you might be amazed how much crap is in there. I had two banana boxes worth. I put about 3/4 of it back. Also spent a few hours removing and replacing a bunch of stuff to get to the alarm control box to adjust the shock sensor sensitivity. Its all better.

      Still need to take it for a drive to see how its shifting, but it should be fine. Last time I adjusted it, it worked well.
       
    20. BKennedy

      BKennedy Elite Loser Staff Member Moderator Elite Explorer

      Joined:
      November 29, 2000
      Messages:
      5,806
      Likes Received:
      307
      Trophy Points:
      103
      Location:
      Location, Location
      City, State:
      San Diego, PRofK
      Year, Model & Trim Level:
      1994 XLT
      Josh came by and hauled off the donor. Its good to have the RV parking space back. Dropping off all the body panels, and picking up the RV tomorrow. Thanks Josh.

      20180105_114853.jpg
       
      Last edited: January 8, 2018
      • Like Like x 1
    21. BKennedy

      BKennedy Elite Loser Staff Member Moderator Elite Explorer

      Joined:
      November 29, 2000
      Messages:
      5,806
      Likes Received:
      307
      Trophy Points:
      103
      Location:
      Location, Location
      City, State:
      San Diego, PRofK
      Year, Model & Trim Level:
      1994 XLT
      Josh sent me this.
      IMG_2983.jpg
       
    22. josh40601

      josh40601 Elite Explorer

      Joined:
      January 17, 2011
      Messages:
      496
      Likes Received:
      99
      Trophy Points:
      38
      City, State:
      La Mesa, CA
      Year, Model & Trim Level:
      Ranger & Explorer
      [​IMG]

      Thanks again Brian for all the parts and liquid bread! You were definitely right with how rusty and crusty this pile was. I'm sure it will be melted down into a fender for a camry or something. Good chattin with ya too. Can't wait to hit some trails with you and see how well the Explorer performs.

      For those who follow this thread that haven't seen this truck in person, it is one of the cleanest, most thought out rigs I have seen. Everything has a purpose, and everything is done so professionally. It does have dents and some pretty significant body damage, but you would never notice it if you were not looking to find it. By far the nicest explorer I have seen in person.
       
      • Like Like x 2
    23. BKennedy

      BKennedy Elite Loser Staff Member Moderator Elite Explorer

      Joined:
      November 29, 2000
      Messages:
      5,806
      Likes Received:
      307
      Trophy Points:
      103
      Location:
      Location, Location
      City, State:
      San Diego, PRofK
      Year, Model & Trim Level:
      1994 XLT
      Thanks Josh. I can tell I am going to worry about beating it up because its never been this nice before. The body has been straighter, but the overall rig has never been this well put together. Hopefully its just a phase and will wear off soon so I can go back to where I was before the redo. I did not go looking for body damage, just did not care that much when it happened.

      I posted earlier that the speedo was now 5 MPH fast after I changed out the gear. Its actually very close at speeds of 45-65 MPH, but gets progressively faster as I go slower. Huge improvement over the old speedo gear.

      Weird thing happened the other day while I was test driving the Explorer. I took it out for about an hour to get some highway time and make sure all was right again with the world. Shifted great, just a little early. I can adjust that out later. Drives fine, did not catch on fire, which was good. Then I noticed the tachometer was not working. Upon closer inspection, the needle was on the wrong side of the stop. What the ?? I removed the stereo and the ash tray, pulled the front piece of the dash, and unscrewed the clear cover off the instrument cluster. Sounds like a lot of work, but I have gotten good at it by now. The needle stop for the tachometer had to be removed to get the needle above it, because there is not enough play in the needle to get it over the stop. I have no idea how that could possibly have happened. Works fine now.
       
    24. BKennedy

      BKennedy Elite Loser Staff Member Moderator Elite Explorer

      Joined:
      November 29, 2000
      Messages:
      5,806
      Likes Received:
      307
      Trophy Points:
      103
      Location:
      Location, Location
      City, State:
      San Diego, PRofK
      Year, Model & Trim Level:
      1994 XLT
      I posted these pictures on the Truckhaven 2018 thread, but felt they should be here as well. I did not get a picture of the nice dent I put in the driver side quarter panel while at Truckhaven, but here a couple of pictures of it after I got most of the dent out. I could have spend another hour or two smoothing out the ripples. I decided to leave them, since I have hit that exact spot at least five times.
      20180121_154545.jpg
      20180121_154553.jpg

      A little bit of information I did not know; If you remove the transfer case off the back of a A4LD transmission that is resting on a cart with the tail angled down, about 4-5 quarts of ATF come with it. I did not realize the transmission uses the transfer case as the rear seal/cover. My 700R4 and NP231 are completely separate units. A little messy, but its ready for pickup, RJ.
       
      • Like Like x 2
    25. josh40601

      josh40601 Elite Explorer

      Joined:
      January 17, 2011
      Messages:
      496
      Likes Received:
      99
      Trophy Points:
      38
      City, State:
      La Mesa, CA
      Year, Model & Trim Level:
      Ranger & Explorer
      Guess that phase wore off quickly. haha

      and now you have a nice clean spot of concrete thanks to the detergent wash you gave it yesterday :D
       
    26. BKennedy

      BKennedy Elite Loser Staff Member Moderator Elite Explorer

      Joined:
      November 29, 2000
      Messages:
      5,806
      Likes Received:
      307
      Trophy Points:
      103
      Location:
      Location, Location
      City, State:
      San Diego, PRofK
      Year, Model & Trim Level:
      1994 XLT
      Yeah, red detergent
       

    Share This Page







    We Support Our Troops!