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Post number 3327 has been selected as best answered.

Whats In A Name?

It was hot humid august night. The winds have all but vanished. I was doing my best to keep the sweat out of my eyes. The A/C was dying in my 94 Explorer, lovingly named "Pugly", and there was no relief in sight. I decided it was time to stop throwing good money into bad. I was gonna do the unthinkable,.......I was going to commit the most heinous crime of them all! I was going to trade Pugly in for a newer model! Oh the heart break! The insanity of it all! I couldn't believe the thoughts were even going through my head.

I managed to get the old girl back home, to her resting place. She seemed at ease in her familiar surroundings. I had to come up with an explanation to let her know of my evil plan. So i just gave her that old wink and grin that she likes to see from me as we made it back home from another day of adventure in the treacherous Midwestern terrain. I did my best in hiding my cynical thoughts, as I walked around to her rear flank and gave her that little pat on her bumper, as I always have when we part for the night.

The next morning I gave her a real good bath, cleaned behind her mirrors, and brushed her grill. She still looked pretty good for her age. Oh sure she had the tell tale signs, gravity has got its firm grip on her, and I am not the best cosmetics guy in the world. she didn't seem to mind too much, she still kept her nose up and drove with pride.

After looking at many vehicles I just could not find anything that had the same feel as my old girl. Then it happened! Was I seeing a mirage? Was I so desperate to find another rig that I was blinded by insanity? I found my replacement! I quickly made a sale with the owner, and brought it home.

When I pulled in the driveway, my heart sunk as I looked into the yard to see my 94 looking at me in disbelief. She was sunning herself in the grass looking all shiny and then, she just looked away from me. My heart was tearing in two. I parked the new rig, and walked up to her and gave her a soft spoken "Hello". No reply. I tried to tickle her mirrors, no response. The tension was so great, you could have cut it with a 32 count fine tooth hacksaw. I had to explain to her that she gave me great satisfaction for many years, and we made a terrific team together, but the time has come for her to just relax and enjoy her final days. She finally revved up, and understood, her days as my work horse has ended (so we thought).

I introduced her to her daily driver replacement. The shiny new(er) next generation of her kind. The 95 Explorer XLT. She warmed right up to it. Before you know it they were swapping stories. Now I had to ask her for help. I needed a name for the new ride,
so I went to find her, and what did I see? Those two were grill to grill in the driveway. rubbing chrome! I had to get the water hose out and break them up! Sheesh, she was acting like a girl at the prom dance! I let the name thing drop for awhile.

The new(er) Ex needed to get its shots, and a physical. When I got the word on it's health, I about had a coronary. "What do you mean Doc"! I yelled. "Your kidding right"? I asked. The Doc just shook his head and gathered his tools. As he walked away, He said it had a 50/50 chance of survival. My stomach knotted up, my teeth ground, my heart raced, and I could feel the energy build up as I let it all out, "Why! Why! Why did this have to happen"! I screamed.

The prognostic exam from the doc was as such. It had a blown steering rack, the shocks were gone, the brakes were non existent, front sway bar was cracked in half, the 3rd brake light was out, none of the windows or the moon roof would work, the door locks were broke, the rear end LS clutch pack was burned up, the tires were all in need of replacement, the spare was a Firestone recall and flat, the engine had a nasty tick to it, the TPS was shot, the MAF was corroded, the battery had a dead cell in it, the hood shocks were not working, the rear hatch lock was jammed up and you couldn't open it with out a key in the lock, The carpet was stained to no repair, the rear window wiper didn't want to work, and we could not tell what year its engine swap came from. it was a mess, to say the least.

I went in the house to get my gun. I was gonna just put it out of its misery right there and then. I suddenly realized I was out of ammo, from shooting at the jeep that was in my field. I went to the computer to find a place to buy some cheap ammo, and I stumbled across this website, explorerforum.com that said it could heal any ford Explorer no matter what the problems were! I jumped for joy, I could not believe the things I was reading! I wore out the search button, asked a bunch of questions. I quickly broke out my pen and paper, feverishly writing down things as I was learning! I had found a cure for everything that was wrong with my new transport. It was a Godsend, an angel from the SUV heavens!

I sprung into action. I worked day and night, Pugly was right by my side the entire time, helping me in any way she could. I never seen this side of her, and was really amazed at how well she handled the pressure. She gently squeegeed the sweat out off my fore head with her soft wiper blades as I worked away. After an entire weekend of work, I collapsed. I needed some rest, and so did the 95. The sun crested over the hills, and awoke me to a new day. I shuffled my feet to the window facing the driveway, peeled the drapes gently back, and peered out at the 95. WOW!
It had a its color back, and was looking great! Now as the time went on, (and most of my paychecks), and the selling of almost everything I own, for funds to get the 95 to its former glory.

After some time to reflect on this name thing, I strolled up and whispered into Pugly's passenger side mirror, and she giggled with delight.

I climbed up onto the front bumper in my pajamas and robe half opened, with a cup of coffee in one hand and the daily newspaper in the other, I raised my arms with out stretched hands and proclaimed the new name of the 95.

BEHOLD...........THE BLACK HOLE!!!!!!!! (Then the neighbor yelled at me to close my robe)



The End................(or is it just the beginning?)


Actually, only some of this really happened. :D




View attachment 324381
 



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Nope & funny but nope.

It's going to be a while before it's installed and able to be shown. I am the test mule for this fabricated product, and if all goes well, it will be available to purchase for all interested.

All I can say is it is 2nd gen specific, and has rig saving value. ;)
 



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Got the new rack from Napa today. They had to order it. :)

Hoping I can get this done tomorrow before the rains arrive. :eek:

I always seem to be under some kind of deadline lately. It's driving me :crazy:.

Edit: Started thunder storming early this morning (about 12 hrs early). Now the weatherman says rains until Monday.
Looks like a couple hours here & there after work next week on this. :mad:
 






Rains stopped about 5 pm, so I went at it. Took me about 3 hours to get it out, and it looks like a crime scene. Lol!

Rack%20out_zps8zpjfltk.jpg


Got to use my Inner TRE tool. Turns out the pass side was about to give up the goods. Silver lining for all this I guess.

TRE%20Tool_zpsjzpvjqnu.jpg


Now to figure out how to get that check valve out of the old rack. Tried a pick and a magnet, didn't work. :dunno:
 






Once again, this rig is fighting me with the small stuff, and this project is on hold until I can figure this out. :(

I can't get the check valve out of the old rack. I do not see or feel the valve retainer to remove it. I have tried the following with no luck:

Turned over, and tapping the unit with a hammer, in hopes it would fall out.
Plugged the return port and cycled the unit, hoping the fluid pressure would force it out.
Used a pick to feel for the retainer, and pry it out.
Used a magnet to pull it out.

It is sitting at the bottom of the port, and will not budge. It's almost as if the pressure line jammed it into place, and is stuck, but... I can get it to move a tiny bit with a pick.

So, even with my glasses on, if there is a retainer above it, I just can't see it. :banghead:

The instructions say it HAS to be installed or it can cause failure, and will void the warranty. Then it says if it is damaged it can be omitted. WTF? :scratch:
 

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ok, wise guy show us the check valve please-:D

I posted a diagram of it, and a pic of it still inside the rack.

I went back at it with a magnifying glass, and moved it around with a pick. I was able to see the tiny tabs on the retainer sitting on top of the valve. Once I seen that, I knew i could pry on it and remove it. I got it out, crisis is over.

It's hell getting old and going blind. :banghead:

Ok, in this picture, we have a Inner TRE tool. It comes with multiple size inserts for diff size TRE's. You place the proper size insert on the nut end of the TRE, then slide this tool over the TRE shaft, then over the insert. Then you fasten the insert to the tool by sliding the retainer to lock it. Then a ratchet goes on the end of the tool, to loosen/tighten. Makes it easier then using a wrench and having to move the rack in/out to get at it.

Then if you look next to the tool, you can see the check valve and the damn retainer I fought with. I hope this little bit of info helps someone else searching one day, because it sure would have helped me! LOL!
 

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So the Napa rack ain't all that & a bag of chips.

After comparing the old rack & the new rack....

They used the wrong fluid lines and the cooler will not go back on as they are routed as such that the cooler mount isn't anywhere near close to fitting.

Edit: I just bent the lines to make the cooler rack fit. Not that bad a deal after all. :)

It's completely installed. I just have to fill it with fluids and bleed the air out. Now to figure out which fuse to pull to be able to crank it over without it starting.
 












unplug mr. coil pack

Thanks Tim. :thumbsup:
Turdle suggested that too, as well as pulling the fuel pump relay.

It worked. I bumped it a few times at first to be sure. It did some weird PCM reset deal and the door locks all went up & down. I went.. Meh, weird a$$ truck.

I bled it as best I could following the instructions, but when I look into the resi afterwards, it has a bit of bubbles on top. Whines a bit too. Tells me there is still air in it, and I have to keep at it some more.

Gotta tell ya, this job really kicked my butt. I am sore all over! I'm glad I did it, but I might bring it to a shop if I have to do it again. I haven't had that much fun in a weekend, since we installed Turdle's engine a year back. LOL!

Napa is closed already and can't bring the core back for my deposit refund. I haven't ate since 9pm last night, and I have been feeding the skeeters. I hope they drop dead from the low blood sugar. :D
 






Gotta tell ya, this job really kicked my butt. I am sore all over! I'm glad I did it, but I might bring it to a shop if I have to do it again.

I did that exact thing last year. I replaced the rack a few years ago and when it went out again last year I decided I really didn't want to do that again at the time. I'd be confident to do it again myself but I'd really rather not, lol. I didn't have the problems with the lines, cooler or check valve you had either, so I can only imagine your level of frustration.
 






for all the crap i have done on 2nd gens, the rack by far tops the list of "never do i want to do that crap again!" and i even did mine on a lift!
cant you put the front on stands, start the truck and turn from lock to lock? i do it that way, or just drive it and all the air will come out. might take a bit, but it will.
 






for all the crap i have done on 2nd gens, the rack by far tops the list of "never do i want to do that crap again!" and i even did mine on a lift!
cant you put the front on stands, start the truck and turn from lock to lock? i do it that way, or just drive it and all the air will come out. might take a bit, but it will.

I could if I had a working parking brake and a level driveway. LOL!

I just found the Body Lift bracket for the parking brake cable, and need to install it. If I had better wheel chocks that would hold the weight on my angled drive, that would help! I leave it in 1st gear with the front on the stands. I'm too afraid to take it out of gear, foot on the brake, and go lock to lock with it.

I will just take it too some parking lot and go lock to lock with it a bunch.

I agree with this job topping the crap list. Like I said earlier, I would rather pull the trans then do this. :banghead:
 






I did that exact thing last year. I replaced the rack a few years ago and when it went out again last year I decided I really didn't want to do that again at the time. I'd be confident to do it again myself but I'd really rather not, lol. I didn't have the problems with the lines, cooler or check valve you had either, so I can only imagine your level of frustration.

I also had to deal with the coil overs and limit straps. The springs push down on the LCA's, and the straps hold them in place, so the UCA's don't hit the springs and force the C/V axles past the point of safe travel.

Of course the straps partially block the opening in the cross member that you need to slide the rack threw. So I had to jack the pass side LCA up, hold it with a small stand, remove the strap, so I can manipulate the rack.

Oh, did I mention the 3/8" thick skid plate is about 75 lbs, and is a royal PITA to remove /install by myself? LOL!!
 






Congrats on the finished project, good job.


BTW, what kind of wheels do you have that they take that very odd "ET wheel" lug nut? I ask since I'm searching for the best lug nut to make fit my new/used wheels(cut to fit the lug nuts).
 






Congrats on the finished project, good job.


BTW, what kind of wheels do you have that they take that very odd "ET wheel" lug nut? I ask since I'm searching for the best lug nut to make fit my new/used wheels(cut to fit the lug nuts).

Thanks! :thumbsup:

Wheels: American Racing alum's.

Lug nuts:
I got them from a custom wheel shop. They called em "Mag wheel acorn lugs". Paid $30 for the complete set. I could use a new set. I remove these wheels so much that they show the abuse, that the impact has done to them over the years.

I wanted them to help with the deep holes on the aluminum wheels. The long shank on them, go deeper into the wheel hole, as standard lugs just sit flush to the wheels surface.

I also installed hubcentric spacers for a nice tight fit to the hubs.
I can't run the centercaps that came with the wheels anymore because of this tho. They won't fit anymore.
 






So the E-brake cable riser bracket I found in my misc bin, is not what I thought it was.

I searched PA website to see if I could just buy it, but it is not listed separately. So I emailed them and asked if I could, and within 10 mins I was talking to the same person that replied to my email on the phone. It will be here by this Friday. I thought that was a pretty cool service response time. :thumbsup:

Now if I could only get that same kind of service, from a fast food worker, demanding $15/hr min wage! LOL!
 






So the E-brake cable I found in my misc bin, is not what I thought it was.

I searched PA website to see if I could just buy it, but it is not listed separately. So I emailed them and asked if I could, and within 10 mins I was talking to the same person that replied to my email on the phone. It will be here by this Friday. I thought that was a pretty cool service response time. :thumbsup:

Now if I could only get that same kind of service, from a fast food worker, demanding $15/hr min wage! LOL!

Hey! They can guarantee your food by Friday, too.
 



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