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Scott B's 2006 Ranger FX4 Level II

Discussion in 'Ranger / Mazda Registry' started by Scott B., August 22, 2008.

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    1. Scott B.

      Scott B. Well-Known Member

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      I have a set of steel braided lines and fittings waiting to be installed. When I install the rear disk brake conversion, I will be fitting all new brake lines.

      I would like to install a lift - but RCD no longer builds their kit. I would go with Dixon Brothers, but I don't want to increase the track width (this is a daily driver.) So for now, no lift. :(
       
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    3. Scott B.

      Scott B. Well-Known Member

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      New Shocks

      I just ordered new rear shocks - Bilstein 5100. I thought about the new 5165 reservoir shock, but figured it was overkill for this truck. And, twice the price of the 5100. (I think I will run the 5165s on my other truck...)

      The front is going to take some customization - Bilstein doesn't make a direct replacement shock. (I really want to get rid of that funky shock anyway.) I will get a shorter 5100, and use a limiting strap. Stay tuned for part numbers, etc.
       

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    4. Scott B.

      Scott B. Well-Known Member

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      Rear Disk Brake Conversion

      This weekend, I decided to empty one of the parts shelves in my garage - I installed the rear disk brakes! I've been collecting parts for over a year for this project (where does the time go??) and I still had to make 2 trips to the parts store.

      The conversion is complete, with the exception of the emergency brake cabling. That will be completed in the next day or so.

      This conversion used Ford Explorer caliper assemblies (bracket, mounting plate, drum e-brake), Raybestos rebuilt calipers, new Bendix rotors, and Russell DOT brake lines.

      Parts

      [​IMG]

      Lokar emergency brake cable:

      [​IMG]

      Before:

      [​IMG]

      Assembly

      Caliper bracket/backing plate installed:

      [​IMG]

      A visitor:

      [​IMG]

      When reassembling the axle, initially the axles wouldn't push in to the differential far enough to slip on the C-clips. It turns out the axle flange was hitting part of the e-brake lever system. I ground down the raised up portion, and removed the outer main return spring. This allowed to slide into the differential sufficiently to install the C-clips. Re-attaching the spring with the axle in place was a PITA.

      [​IMG]

      [​IMG]

      Completed assembly:

      [​IMG]

      Plumbing

      I had an assortment of parts from Russell - I planned out this project, measured everything, and had all the parts I needed. Well, not exactly. Yes, I had all the pieces - however, once I put the fittings in place, things were slightly different than what I measured...

      I ended up getting a different chassis-to-axle hose and chassis-to-caliper hoses for the front. The new hoses have 90 degree angles at one end. These hoses fit so much better - very sanitary if I say so myself!

      [​IMG]

      Axle Mount

      [​IMG]

      Wheel

      [​IMG]

      Front

      [​IMG]
       
      Last edited: June 11, 2011
    5. Tbars4

      Tbars4 Moderator Emeritus Elite In Memoriam

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      ..Haha, I heard you bangin on stuff all the way to my place..:bsnicker:

      ..Your visitor, a water moccasin?

      ..Waiting for lot's of pics and info of the Lokar set up..:popcorn:
       
    6. Scott B.

      Scott B. Well-Known Member

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      I wasn't banging that much - everything went back together, more or less...

      The visitor was a non-poisonous snake - probably a black racer. He was just curious as to the activity in the garage...

      I started installing the Lokar assembly. Should finish tomorrow evening.
       
    7. Scott B.

      Scott B. Well-Known Member

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      Finished the Lokar installation. A very nice product - super clean install. Pictures this weekend.
       
    8. Tbars4

      Tbars4 Moderator Emeritus Elite In Memoriam

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      ...Care to share the part numbers while we are waiting on the pics??..:bounce:
       
    9. Scott B.

      Scott B. Well-Known Member

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    10. Tbars4

      Tbars4 Moderator Emeritus Elite In Memoriam

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      ...You didn't have to get the Explorer one or anything special?

      ...I now see it is the Explorer/wilwood package. Does it come with 2 different style clevis' ?

      ...I was thinking about getting the black set up, fu package but they are still pricey..:(
       
    11. Scott B.

      Scott B. Well-Known Member

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      The Explorer model has cable ends that fit the factory caliper bracket perfectly.

      Yes, they are a little pricey - but the fit is perfect. (Wait 'til you see the pictures!)
       
    12. Tbars4

      Tbars4 Moderator Emeritus Elite In Memoriam

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      ..:bounce:...It's the weekend and we are anxiously waiting to see the pics...Detailed on the routing would be a plus..:biggthump
       
    13. Scott B.

      Scott B. Well-Known Member

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      E-Brake Cable Routing

      Here are the pictures of the Lokar emergency brake cables and routing.

      I made a bracket from a piece of angle, and mounted it to the factory e-brake cable mount on the front spring hanger.

      [​IMG]

      Unfortunately, the factory piece bent, putting some slack in the cables. I also need to trim the cable ends sticking through the equalizer block, but I'm going to wait until all adjustments are final.

      [​IMG]

      Here, you can see where I took the end of the factory passenger side e-brake cable, cut it, and put a loop at the end. This allowed me to use the original cable from the pedal, and easily adapt it to the Lokar assembly.

      [​IMG]

      Driver's side attachment

      [​IMG]

      Passenger side attachement

      [​IMG]

      Passenger side routing over differential - the Lokar cable is tie-wrapped to the factory cable support on the top of the diff...

      [​IMG]
       
    14. reapereviltwin

      reapereviltwin Keep on wheelin John Rock Staff Member Moderator Elite Explorer

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      Nice work Scott!!!! :thumbsup::thumbsup::thumbsup:
       
    15. Scott B.

      Scott B. Well-Known Member

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      Thanks. It came out really well.
       
    16. Scott B.

      Scott B. Well-Known Member

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      Bilstein 5100s Installed

      I also got the rear shocks installed.

      [​IMG]
       
    17. Tbars4

      Tbars4 Moderator Emeritus Elite In Memoriam

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      ...I have a couple questions...:D

      The factory bracket needs to be replace or it will bend?

      The black mounting block attached to your angle iron, is that included in the kit?

      Did you use the clips on the ends for quick release at the assemblies?

      Where did you get your clips to cinch your hoop?

      Your pass side cable looks like it's running to the rear of the truck. How did you run it over?
       
    18. Scott B.

      Scott B. Well-Known Member

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      I am going to replace the factory bracket with another piece of angle.

      The "black mounting block" is the factory bracket (if I understand your question.)

      The "clips on the ends" - I assume you mean where the cable attaches to the brake. Yes, I used the clips (included in the kit.)

      To "cinch my hoop" - I assume you mean the passenger side e-brake cable. I used 5/32" cable ferrules and a thimble, and crimped on the cable.

      In the last picture, the cable running approximately horizontal across the middle of the picture is the e-brake cable. It runs from the equalizer, through a loop on the frame (not pictured), across the top of the differential, through a retaining clip (attached to the u-bolt) to the brake.
       
    19. Tbars4

      Tbars4 Moderator Emeritus Elite In Memoriam

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      ...Thanks an I'll check back in later...:hammer:

      ..:eek:..and your factory bracket looks purdy that's what threw me off...Not even the new stuff on my trucks look that purdy...:D
       
    20. Tbars4

      Tbars4 Moderator Emeritus Elite In Memoriam

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      ..May be a dumb question...Where did you mount your hose bracket (that meets the hardline)?..I'm thinking of mounting mine to the block but I just can't see where yours are mounted to..:scratch:
       
    21. Scott B.

      Scott B. Well-Known Member

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      I'm not sure I understand what you are asking, but I'll take a shot...

      The soft line comes from the frame to the top of the differential, where it attaches to a junction block. Also attached to the junction block are the hard lines going to each caliper. (Remember, soft line between hard line and caliper.)

      The junction block is mounted to the top of the diff via a 5/16" bolt (threaded hole in the top of the diff.)

      (Look at the 6th picture in post #87.)

      Between the junction block and diff, you will see a thin, flat piece of steel sticking out (facing forward.) This is from the original junction block, and holds the emergency brake cable.
       
    22. Tbars4

      Tbars4 Moderator Emeritus Elite In Memoriam

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      ..This is the area I have a question..Usually there is a mounting point at the connection of the hard line and soft line as the soft line flexes when braking..
       
    23. Scott B.

      Scott B. Well-Known Member

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      Look at this.

      On the left side of the picture, you can see a "tab" that I welded to the axle. This tab holds a fitting that connects the hard line to the AN-3 flex line.

      Here is part at Summit.
       
    24. Scott B.

      Scott B. Well-Known Member

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      Air Compressor

      I pulled the ARB compressor out of the other truck - it is getting replaced with a Viair compressor and tank.

      So, I mounted the ARB compressor in the bed of this truck. It's up in the front corner, in the dead space between the tire and the side of the bed. Not super convenient to get to, but not too difficult, either.

      On this truck, the compressor will be for emergencies rather than a regular routine of airing up tires - should work just fine.

      (As soon as I get some 12 gauge wire, I can wire it up!)
       

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    25. Scott B.

      Scott B. Well-Known Member

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      The battery in this truck is 5 1/2 years old, and no longer shows the green indicator. I am upgrading to an Optima Red Top, and a Ruff Stuff battery cage.

      Here's the cage, fresh from the powder coater's (thanks Turdle!)

      Sometime soon, I will replace the battery, switch to military-style battery clamps, and replace the clamps on the cables with terminal lugs. Not too much work, and a much more reliable and corrosion resistant connection.
       

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    26. gmanpaint

      gmanpaint Torsion Bar Free Elite Explorer

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      Scott, I just read this entire thread. Amazing work you have done here. :thumbsup:

      Everything you have done to this rig is top notch, and thoughtfully carried out. My hat is off to you sir, you done good. :)
       

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