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Pugly

Discussion in 'Elite Explorer Registry' started by gmanpaint, August 3, 2010.

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    1. gmanpaint

      gmanpaint Torsion Bar Free Elite Explorer

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      City, State:
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      Year, Model & Trim Level:
      94 XLT-95 FX4
      The Good, The Bad, & the Pugly :D

      1994 Purple Explorer XLT 4wd

      I decided to have a registry for my "Other" rig so I can post things done and have a reference for it.

      Pretty much stock drive train.

      4.0 OHV-A4ld-1354e.
      D35 front 4:56 Yukon gears, Aussie Locker.
      2nd gen disc 8.8 rear 4:56 gears, Spartan Locker.

      Front C-Clip eliminator Mod.

      Slight lift with 2" Skyjacker coils & rear F-150 hybrid leaf packs.

      3" PA body lift
      Helpful thread with pics for the front body mounts
      Pics of front body lift mounts

      Swapped to manual hubs.
      Double U-joint XJ steering shaft.

      35" x 12.5" x 15" BFG A/T's mounted on 15x8.5 alum wheels - full size matching spare.

      Shocks:
      Front Rancho 9000xl
      Rear Rancho 9000xl
      Duff Stabilizer shock.

      Sway bar quick disconnects front & rear.
      Custom tube sliders w/kickouts

      22" LED light bar.
      18w amber fog Led pods.
      55w rock lights--2 front--1 rear over diff.
      8 LED pods for rocker lights.

      Full brush guard.
      2.5" Fender Flares.

      TTB Diff guard & Skid plate.

      Custom roof rack with 48" Extreme Hi-Lift jack.

      Flipped Tow hitch & front hooks for tow points.

      Cobra19 CB & rear hatch mounted firestick antenna.
      Rear view HD camera.
      JVC DVD/CD/MP3 Head unit with 7" HD Monitor.
      Sony 6.5" front speakers.
      Rockford Fosgate 5.25" component rear speakers.
      8" JL Audio sub in 2001 enclosure with 500w amp mounted on enclosure.

      Custom made center console with CB/Rear view color monitor/2-12v outlets/ in-out temp display. D cell Maglite mounted on cargo panel. Truck bed liner on cargo floor.

      '99 Eddie Bauer Front Leather buckets.
      '94 Limited Rear leather split bench.


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      Last edited: February 27, 2018
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    3. zukman

      zukman "Home of Misfit Crawlers" Elite Explorer

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      City, State:
      arcadia calif.
      Year, Model & Trim Level:
      '91EB, '86Sami, '85Ranger
      but but but Pugly is cute!!!!!!!!!!!!! I liked driving it to SMORR!
       
      • Like Like x 1
    4. corkey

      corkey Moderator Emeritus Moderator Emeritus

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      Location:
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      City, State:
      Elite Canuck,multiple ifs offender,, and musky maniac,, i wheel and i fish,,
      Year, Model & Trim Level:
      99 xls,96 xl,91,08 Ranger
      it is a more than capable rig with great throttle response ask the other poster that was a passenger when i drove this rig at SMORR,

      great rig,,
       
    5. Sams01XplrSprt

      Sams01XplrSprt Southern Cali Explorer

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      City, State:
      Newport Beach California & Bay Area California
      Year, Model & Trim Level:
      2001 Sport (sold)
      nice lookin x
       
    6. gmanpaint

      gmanpaint Torsion Bar Free Elite Explorer

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      Year, Model & Trim Level:
      94 XLT-95 FX4
      Thanks guys! :)

      This rig had a few normal issues with it when it found its way home, in MO.

      Needed all new shocks, replaced with Monroe sensatracs.
      Complete new brakes. Master cylinder, calipers, new rotors, drums cut, pads & shoes, & fluid flushed.
      Replaced the T-stat. Flushed the coolant system. Replaced the heater bypass switch, upper & lower hoses, & heater hoses.
      New battery.
      Replaced dash trim, all door panels, and dr side cargo panel.
      New belt tensioner pulley, & serpentine belt.
      New plugs & wires.
      A/C leak fixed after a retro fit for 134a.
      Driver seat replaced with Eddie Bauer seat.
      Replaced rear dr door.
      Installed window vent visors.
       
      Last edited: August 16, 2010
    7. gmanpaint

      gmanpaint Torsion Bar Free Elite Explorer

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      94 XLT-95 FX4
      Exhaust sounds terrible so it will be changed asap!
       
      Last edited: February 19, 2016
    8. dislexiclawyer

      dislexiclawyer Active Member

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      2013 Toyota Tacoma
      Are you going to chronicle your Adventures fixing the door? After seeing it with the body lift I wish I would have done it before I sold mine. Maybe the fender wouldn't have gotten as banged up when the wheel came off :p:
       
    9. gmanpaint

      gmanpaint Torsion Bar Free Elite Explorer

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      94 XLT-95 FX4
      After the rear quarter is patched and painted I might update it if it looks good...lol :afro:

      I'm not sure if the BL would have helped yours or not. :dunno:
       
    10. corkey

      corkey Moderator Emeritus Moderator Emeritus

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      Location:
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      City, State:
      Elite Canuck,multiple ifs offender,, and musky maniac,, i wheel and i fish,,
      Year, Model & Trim Level:
      99 xls,96 xl,91,08 Ranger
      wow, how much this rig has changed, as well as mine,,,
       
    11. gmanpaint

      gmanpaint Torsion Bar Free Elite Explorer

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      94 XLT-95 FX4
      Seems Pugly has developed a bit of a starting problem.

      Turn the key, everything is normal, but the starter wouldn't engage. I tapped on the starter after it sat for awhile, and it turned over and the engine started. I figured it was a bad starter. No biggie, I have a couple of good starters laying around.

      Installed a new 1000 CA battery, and a good starter. Didn't change a thing on whats wrong. Same exact deal happens.

      So, what else could it be? A bad cable? A bad regulator? Why would it turn over when tapped, and with a new starter does the same thing?

      Sincerely,
      Royally confused.
       
    12. Willard

      Willard Well-Known Member

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      City, State:
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      Year, Model & Trim Level:
      04 Ranger Edge
      Maybe the tapping was a coincidence. It could always be the solenoid on the fender.
       
    13. gmanpaint

      gmanpaint Torsion Bar Free Elite Explorer

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      This might be what the problem was. I replaced the solenoid, and made a new ground cable. It works. Not only does it work, but it works better than it ever has. :D

      Positive cable, and alternator is the only thing on the start/charge system that wasn't replaced, I'm sure those will be next :rolleyes:
       
    14. corkey

      corkey Moderator Emeritus Moderator Emeritus

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      Year, Model & Trim Level:
      99 xls,96 xl,91,08 Ranger
    15. gmanpaint

      gmanpaint Torsion Bar Free Elite Explorer

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      94 XLT-95 FX4
      Thanks Corkey. For over 200k miles on it, It has been a dependable vehicle with some capabilities off the pavement. Little here & there to keep it going is fine by me. It has paid for itself over & over now. :)
       
    16. MrQ

      MrQ Take the Bull by the Horns Moderator Emeritus

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      City, State:
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      Year, Model & Trim Level:
      '98 Eddie Bauer
      Callsign:
      MrQ
      I have also found that the Not in Park Lock out switch or whatever its called, is very sensitive. Sometimes jiggling the gear shifter a little will get the truck to start. Has happened to me more than once.
       
    17. gmanpaint

      gmanpaint Torsion Bar Free Elite Explorer

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      That would be the Neutral safety switch. I tried the jiggling of the gear selector, and left/right of the steering wheel as well.

      I have had that happen to me in the past on other vehicles, more of a nuisance than anything..lol
       
    18. gmanpaint

      gmanpaint Torsion Bar Free Elite Explorer

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      That pesky Gremlin is back! The no start issue has returned :(

      This morning it did exactly as it did before. Turn the key, I hear the fuel pump, I hear the solenoid click, turn the key the rest of the way, and nothing, starter didn't engage. Have full power to everything. WTF?

      So I got under the hood, checked the battery terminals, they were tight. Checked the fender solenoid terminals, they were tight. Wiggled every wire connected to the battery, and tried again, it fired right up. Had to start it a few times during the day, no problems. At the end of the work day, it hesitated but fired up. This engine starts very fast, always has, just takes a bump of the key to fire. If it needed to crank for a couple of seconds, something tells me it wouldnt have fired as the starter would have stopped.

      I don't know if something that was replaced is going bad, or if it is something entirely different.
       
    19. gmanpaint

      gmanpaint Torsion Bar Free Elite Explorer

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      Pugly is feeling a bit under the weather today. Poor thing might have to be put to the pasture soon. Developed a coolant leak today, and I hear a rattle in the engine. Sounds like a bearing going bad on it. Originally thought it was possibly a water pump going out, but I'm not so sure now, as it sounds deeper in the engine. :(

      Although, Pugly started right up every time today. :)
       
    20. gmanpaint

      gmanpaint Torsion Bar Free Elite Explorer

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      Had to replace the radiator, upper & lower hoses (just in case) today. A tank had cracked or something, where it is crimped to the core.

      I fought & fought the clutch fan for over an hour. It just wouldn't co-operate and go back on. After every cuss word known to me spilled out of my mouth and after a broken shroud, bleeding knuckles, it went back on. Gawd I hate that damn clutch fan with a passion!

      The DD is back on the road again at least. The "nickle & dime me to death" has begun, and I really don't know how much longer I will keep relying on this vehicle.
       
    21. gmanpaint

      gmanpaint Torsion Bar Free Elite Explorer

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      Found a broken DPFE hose. Replaced with 5/16 fuel line. Made a big dif in itself.

      Finally got the correct VSS gear from the dealer. A white RH gear did the trick. Speedo matches the GPS perfectly at all speeds. The trans shift points are back to normal again...Woot!

      Pugly is good to go until the next batch of problems arise.
       
    22. gmanpaint

      gmanpaint Torsion Bar Free Elite Explorer

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      Boy, it didn't last long.....sigh.

      Starter Hell still plagues this rig. Have got stuck everyday somewhere for the last 3 days. I ordered a new Motorcraft positive cable a few days ago, it came in today. I installed it. No crank still.

      So in the last month, these parts have been installed for this problem:

      Starter (used)
      Fender Solenoid (new)
      Battery (new)
      Ground cable (new)
      Positive cable (new)

      Tomorrow, a 3rd starter is going in. I really am getting tired of this no start BS.
       
    23. yellowford

      yellowford Active Member

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      97 xj
      This is some of the same stuff I went through as well and why I ended up with a push button starter to elimate another variable from the equation.
       
    24. gmanpaint

      gmanpaint Torsion Bar Free Elite Explorer

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      Did either of you have the fender solenoid engage when you turned the key?
      This solenoid does engage when key is turned.

      Pugly will still crank over. It is just hit or miss with it. It will start with no problems, and then it wont turn over later. It seems to be the starter has been compromised due to bad cables. I have got it to crank by tapping it with a hammer. There is good voltage going to the starter.

      The cables were shot with corrosion going way deep under the insulation, and were stiff throughout.

      The starter I have to install is used, and is a known good starter. If it doesn't work, I will look into the ignition. Thanks for the suggestion.

      The temps are in the teens this morning, Brrrrr. I am going to wait a bit for it too warm up. :cool:
       
    25. yellowford

      yellowford Active Member

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      Mine was for awhile but then it just quit and that when I gave up on messing with the ignition, one thing that I ended up doing was adding a ground wire the the starter off of one of the mounting bolts. This was done since multiple times when I took it to the parts store to be tested it was fine and after looking at the mounting plate it was covered in oil leading me to believe a bad connection was happening, after that was cleaned it worked for a few days till it finally gave up the ghost and wouldn't start by tapping on it anymore.

      Don't know if that is a problem you are running in to, but figured it wouldn't hurt to mention.
       
    26. gmanpaint

      gmanpaint Torsion Bar Free Elite Explorer

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      Well, the other spare starter I have is out of a 97 SOHC, and the housing mount plate is smaller in size than the OHV. This is because the 5R trans bell housing is a diff shape for the starter. So thats a no go.

      After messing with it for awhile & conversing with another member in a diff thread, I was able to get it started, but it is still not repaired. There is a power loss even with the new cables, to the starter. Both starters worked with power to them, but a load test wasnt done. I'm not convinced yet that either of them are in good working order, and also not convinced they are both bad. I need to get them load tested.

      I will take a look for poor grounding from oil. That's a possibility.
       

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