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Rebuilding a 2nd gen Explorer with a 1st gen rear clip

Discussion in 'Modified 1991-1994 Explorers' started by CDW6212R, November 11, 2005.

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    1. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Ditto, my 93 driver's seat bolt was hell to remove in 1999, it came out very slowly. I replaced the bolt, and it was worse this time. On that one I couldn't use the bit, it stripped. But I did get a good enough bite with a vise-grip from below, until it was loose enough to do from above.

      BTW, for legal purposes vehicles have to have matching seat belts. I had to use 99 model belts. The short belt on the side of the front seats is very tight, they have locktite red on them.
       
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    3. Dre

      Dre Elite Explorer

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      I always use anti-seize on those bolts and seat bolts but I also remove seats at least once a year for one reason or another... I have broken at least three T-bits in the past year alone... always buy Sears - they guarantee their stuff - just take it in when it breaks and they will replace it no questions asked...

      but you know that... :rolleyes:
       
    4. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Yes, I use and did use anti-seize on those bolts. It helps a ton. BTW, I have a cheap $5 set of torx bits, and the first torx bit I bought was this Snap-On back in 1988. I've twisted the T30 doing a front driveshaft bolt, but this T50 is really good. Invest in the best for all high stress tools, like 1/2" drive 6-point sockets.

      The pic here is the stock hatch hole for wiring. I had to open that up a bunch to accept the 1997 model hatch harness. I used the 95-97 wiper motor because it had four wires, the 91-94 use three.
       

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    5. Dre

      Dre Elite Explorer

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      been there too... when I ran wires for the rear license plate light. That's quite a task to splice wires in this spot. Also, replacing wiring when installing the newer (2nd gen.) tails on the 1st gen.
       
    6. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      I used the entire 2nd gen. wiring, the hatch wiring was the last to go. It was easier to replace that then to cut new holes and splice etc. That hole and the hole going into the hatch were the hardest part of that project. I left the right side wiring in, and made a defrost power wire to lead from the left side over to the right side wiring. That enabled me to leave the 91-94 defrost wiring untouched, and not have to add a ground point like the 95-01's.

      That experience will make it easier to add the 2003 Sport hatch I found, to my 98 Mountaineer. I bought the harness with it also, so it should be rather simple.
       
    7. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      This is showing my relay box I needed for the ARC relay, and auxilliary turn signal flasher/relays. See that I ziptied it directly underneath the master cylinder. Regards,
       

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    8. Glen4X4

      Glen4X4 Explorer Addict

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      I know its been a very long time since this thread has been posted and done but I still wanted to comment and say awesome job I think I spend 45minutes to half hour viewing and reading, its pretty damn awesome/incredible.
       
    9. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Thanks, I'm almost done with it. I've just been putting off searching for what I think is a vacuum leak under the lower intake(PCV hose). I still need to mount my air supply tanks, lines etc, and then the running boards.

      I will finish here then by posting pictures that I had forgotten etc. Regards,
       
    10. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      I thought that I had posted some of the last pictures of my project, here's a few more. I have still yet to do the running boards and front flares, but I've got about 25,000 miles on it since last February. Regards,
       

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    11. CBII

      CBII Active Member

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      Wow...very cool.

      The last pic there...you just cut off the bubble part of the Gen 2 tail light and it fit the gen one spot? How did you seal it back up?

      Very cool...might have to steal that idea from ya.
       
    12. Glen4X4

      Glen4X4 Explorer Addict

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      Looks awesome Don, did you order the passenger side window switches from a UK explorer or did you make that up yourself? Do you leave the air bag out to stick your mail in there?
       
    13. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Yes the 95-97 tail light can be used for a 1st gen, but remember that there are three bulbs starting in 95. I have a 1999 wiring harness so it plugged in for me. For an older wiring system it would take more work to separate the turn signal from the brakes on the steering column.

      Glen, I made the right hand window switch panel from a normal RF and old LF panel. Look at my post #147 to see the pictures of those side by side on a chair. Regards,
       
    14. Dre

      Dre Elite Explorer

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      Yeah, I did modify the taillights on my 94 Un-Limited (using the steering column mod) and I did cut the rear fenders to fit 97 lights... check posts back a few pages back. Since I have moved to Europe my truck has to conform to local codes so that was not the only mod I made.

      But... really admire what you've done with the truck - huge challenge to cut it up like that and put it back together... especially "at home".

      again :thumbsup:
       
    15. Glen4X4

      Glen4X4 Explorer Addict

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      Oh yeah, I forgot about reading over that post Don.
       
    16. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Thanks Dre for the compliments, and the rear bumper cover too. My original was a bit more faded, and they are all obsolete now from Ford.
       
    17. CBII

      CBII Active Member

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      Ok cool, thanks.

      Did you re-seal it with hot glue or melted plastic?

      I think the hot glue would work?
       
    18. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      I used the slick plastic epoxy, clear from Walmart for about $4. It's good stuff,
       
    19. CBII

      CBII Active Member

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      Awesome...thanks a lot for the tips.:thumbsup:
       
    20. 1998rollover

      1998rollover Active Member

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      Easier than that, get a set of those diodes made for connecting up lights between a towed car and an RV.

      For this tail light transplant you'd use the configuration for connecting a car with separate turn signals to a tow vehicle with combo brake/turn signals. The difference is the two systems are in the same vehicle.

      Google for RV towing diodes and you'll get a lot of hits and a wide range of prices. Best ones come potted in aluminum heat sinks, there are some cheaper ones encapsulated in plastic, but some outfits want more for those than the ones in aluminum.
       
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    21. deamon3

      deamon3 Active Member

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      Wow , great project. I've been wanting to do somthing like that. I wanna fit a sport trac front on mine.

      I think you should use the stock 94 lights on the back , make it a true half 94 half 99.
       
    22. ford8.8

      ford8.8 New Member

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    23. Sparky94

      Sparky94 Active Member

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      Gotta question. To do this exact swap, do you HAVE to swap the firewall?
       
    24. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Well as I changed the title after beginning the project, really what I did is just swapped the back half of the 95-01 vehicle.

      I started out wanting to retain the whole 91-94 body to use on a 95-01 chassis. It had been discussed a time or two before I began my project. But no one had really gone into trying to swap just a firewall or enough of a front end to swap the front body parts.

      Ryan more recently swapped the firewall to allow the use of the later dash, and wiring etc.

      I could have kept the 93 front end and still used the 99 firewall, but the work would have been harder to "section" the front clip to mesh the 91-94 radiator support and upper fender aprons, with the lower portions of those.

      Parts are cheaper now so it's easier to pick and choose what you like best or want. The earlier front end is only better visually for the people who like it the best. The later 1995-01's are better for everything else, functionally, for cooling, engine fitment etc.
       
    25. iheartbeams

      iheartbeams Member

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      extremely insane attention to detail and the amount of work you did is insane!

      i would swap the hatch off an 01 and up hatch and use the new tail lights that go with it to set it all off. i did it to mine and it looks like a 2003 explorer. ill post pics if you are interested
       
    26. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Thanks, back then the project was already fairly expensive.

      I might do more if I was keeping it. Since it was a mail vehicle and now I have a provided LLV, it's a spare vehicle.
       
      Last edited: May 6, 2012

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