Bronchole's 1997 5.0 Mountaineer/4406/SAS/SOA
I lucked in to an awesome deal on this Mountaineer in June of 2012. I picked it up from Jim (nssJ2) for a screaming deal of $4500. Only catch was I had to go to Colorado to get it. That ended up being a great vacation for my family. We spent a few days visiting with friends and broke the drive home up with a couple stops on the way back (Moab, Brice canyon, Zion and Las Vegas). The rig was everything I expected it to be and some. It has a few quirks, but all-in-all Jim did a fine job with all the projects he did to it. By far the cleanest set of PO installations I have ever dealt with.
Interesting factoid here. My friend Pete has been instrumental in the purchase of my last 2 off road toys. My previous toy (1967 Bronco) was partially financed by him for 2 weeks. He was my remote eyes and ears for purchasing, pickup and short term storage of this rig until I could come pick it up for myself. Thank you Pete (and Carrie) for all of your help keeping my addictions going!
The Specs:
- 1997 Mercury Mountaineer
- Mfg date 06/97
- Millage = 155K at time of purchase in June 2012
- Mostly stock 5.0 with 155K miles on it. Jim had pretty much replaced everything except the long block
- MAC intake
- 4R70W transmission (rebuilt at something like 120K)
- 4406 transfer case replaced at 165K
- New (or professionally rebuilt) rear driveshaft with CV/slip yoke
- New (or professionally rebuilt) front driveshaft with CV/flange
- Ford 8.8 full width axle from a 1994 F150
***Detroit locker
***4.56:1 gears
***5 on 5.5" Superior chromolly 31 spline axles, OD of flange turned down to fit in Currie rotors
***original Explorer brake calipers and brackets
***Currie Enterprises custom rotors (These may be Jeep CJ rotors re-drilled)
***Rear end cover with "pre-loading" bolts for bearing caps
- Dana 44 high pinion full width axle from 1979 Bronco
***Open diff
***Superior Chromoly axles
***Dana 760X u-joints
***Warn premium locking hubs
***some sort of HD diff cover
- Wild Horses extended radius arms
- Early Bronco 5.5" lift coils
- Rear Superlift Explorer 4.0" lift leaf spring (over axle)
- Some sort of lifting shackel
- 5 on 5.5, 15x10 Rock 8 beadlocks
- 35" x 12.5" x 15" BFG MT's
- 92-95 Toyota 4-runner steering box A1 Cardone p/n: 27-8475
- Sony MEX-BT3700U head unit
- Infinity 6812cf 2 way front speakers
- Infinity 6812cf 2 way rear speakers
- Rockford Fosgate R1 Bassworx 12" sub (5" mounting depth, recomended box volume of 1.02 cu ft) in a 1.02 cubic foot enclosure
- Boss Audio CXX502 amplifier driving the sub
- Clifford RSX3.5 alarm system
- Flaming gauge faces
- UltraGauge OBDII gauge message center
Links to builds that Jim (nssj2) did to it prior to my ownership:
- 4406 upgrade, March 2008
- Learning to shift the 4406, March 2008
- Front Driveshaft custom construction, March 2008
- Gathering parts for the SAS, April 2010
- The SAS, April 2010 - September 2010
Things I have done since I got it:
- August 2012: CB antenna mount was shorting due to the lock washer being in the wrong location - Fixed
- August 2012: Cleaned up disconnected wires to the Sub-Woofer. May have come disconnected when all of the "extras" that Jim gave me with this were packed in the back.
- September 2012: Rear driveshaft CV was rubbing on gas tank after I got it home. BFH = fixed
- September 2012: Removed remaining plastic tank protector to keep it from hitting VSS wires
- September 2012: Attempted to calibrate speedometer. It has a 20 tooth gear installed, it needs a 22 tooth gear, I installed a 21 tooth gear and am living with it.
- September 2012: Added wiring so that the CEL on the right side instrument cluster (pre 1997 gauge faces) lit up with the stock location light
- September 2012: Mounted Cobra 29 in center console area. Will eventually be replaced with my HR2510 and my Alinco Dual band ham radio.
- October 2012: Installed Ultra Gauge
- October 2012: Replaced drivers side headlight bulb with a used one (temporarilly) from my F350
- October 2012: Installed projector headlight
- November 2012: Made/installed new CB antenna mounts
- November 2012: Installed rear differential cover
- December 2012: Reworked the track bar frame side bracket
- January 2013: Replaced the original 4406 transfer case (The other one died from the front driveshaft coming loose, wedgeing in to the housing of the case and splitting it in half)
- January 2013: Reworked front gas tank mount to improve clearance to the 4406 transfer case.
- February 2013: Replaced the stero head unit for one that works better with Ipods
- March 2013: replaced the transfer case again. It had some sort of internal failure that locked it in to 4 low.
- June 2013: replaced broke rear axle with new pair of hardened axles.
- July 2013: Installed mostly hidden 9500 pound winch
- August 2013: Added gusseting to rear axle housing to stiffen housing and add provisions for traction bar.
- August 2013: made a temporary hitch mounted tire carrier to get the tire off the roof.
- August 2013: Reworked transmission cross member to accept 1985 Mustang transmission mount.
- October 2013: Built 12" sub woofer cabinet
- October 2013: mounted my ham radio and antenna
- November 2013: Alignment to see if I could reduce the Death wobble tendancies
- June 2014: Replaced trac bar bushing in an attempt to get rid of some death wobble (didn't work)
- June 2014: Replaced steering box. It sprang a leak in the middle of John Bull trail in Big Bear.
- July 2014: Finished installing the rear traction bar.
- July 2014: Install new set of rear springs.
- July 2014: Installed the TMH Torque Monster Headers on it.
- July 2014: Reworked the lower steering column to have a mid support and the correct end on it for the Toyota PS box.
- July 2014: New pair of tires for the front. (Death wobble gone)
- November 2014: LED light bar on front
- April 2015: replaced the sub woofer with a new one
Links to pictures and albums from when Jim (nssj2) owned this rig:
- From one of Jim's trail runs
- From one of Jim's trail runs
- From one of Jim's trail runs
- From one of Jim's trail runs
- From one of Jim's trail runs
- From one of Jim's trail runs
- From one of Jim's trail runs
- From one of Jim's trail runs
- From one of Jim's trail runs
- From one of Jim's trail runs
- From one of Jim's trail runs
- From one of Jim's trail runs
- Photobucket album from one of Jim's trail runs
- Another album from Jim
Links to my other photos and albums for this rig:
- Bronchole photobucket account
- 2
- 3
- 4
My "To Do" list (in no particular order):
- Rear swing out tire carrier
- PA speaker
- Full halo roof rack to protect roof, allow for heavier hauling on roof and mounting for ham/CB antenna.
- Internal roll cage
- Push the front axle forward 1"-1.5" so the tires clear the nerf bars
- Good pair of off-road lights on the bumper
- Front seat covers
- Front traction aid (probably ARB)
- RCV front axles
- Perhaps ram assist, need to get some more time serious off-roading before I make a final decision on this.
- On-board 1000W continuous or better power inverter. For running all but the most powerful power tools.
- On board air. For ARB, air horn, air tools, airing up tires…
- Air horn. I got it, just need to get it in there.
- Secured set of on-board misc. basic tools. Thinking an ammo box where the spare tire used to be.
- Aluminum deep transmission oil pan
- Second/dual battery for using my ready-welder as well as additional reserve power
-
Trails Conquered:
- August 2012:
***Colorado trails:
******1
******2
******3
***Moab Utah:
******1
******2
******3
- September 2012:
***Hungry Valley ORV area / Gorman & 4WPW customer appreciation day
- October 2012:
***Mojave Road 10/19-10/21
- January 2013
***Bear Camp Snow run that blew up my transfer case
- February 2013
***KOH
***Rohwer Flats
- March 2013:
***Barstow to Vegas
- June 2013:
***Hungry Valley
- July 2013:
***Lockwood/Miller Jeep trail
-August-September 2013:
**Colorado trip
***Halfmoon South (CO)
***Mosquito Pass (CO)
***Taylor Pass (CO)
October 2013:
***Cherry creek area trails
March 2014
***Hungry Valley for CORVA Family Fun Days
June 2014
***Big Bear
August 2014
***Bald Mountain
-------Coyote Lake trail
-------Swamp Lake trail
-------Mirror Lake trail
-------Strawberry Lake trail
May 2015
***Mojave Road
Upcoming trips/trails I plan to conquer:
- August 2015 Rubicon
- August 2015 Some stuff in Washington
- August 2015 Oregon Dunes
-
-
-
I have noticed that allot of people on this site like to make their threads several miles long by doing everything in one thread..... not me. It makes for a PITA for people researching things. Believe me I know from attempting to research on this site. I will be starting other threads for each of my individual builds and link to them from the first post in this thread. If it is significant or I think it’s been a while since this thread has been pulled back to the top I'll post in here to bring it back up.
Notice: I have reserved several posts for anything else I wanted to include later on.
I lucked in to an awesome deal on this Mountaineer in June of 2012. I picked it up from Jim (nssJ2) for a screaming deal of $4500. Only catch was I had to go to Colorado to get it. That ended up being a great vacation for my family. We spent a few days visiting with friends and broke the drive home up with a couple stops on the way back (Moab, Brice canyon, Zion and Las Vegas). The rig was everything I expected it to be and some. It has a few quirks, but all-in-all Jim did a fine job with all the projects he did to it. By far the cleanest set of PO installations I have ever dealt with.
Interesting factoid here. My friend Pete has been instrumental in the purchase of my last 2 off road toys. My previous toy (1967 Bronco) was partially financed by him for 2 weeks. He was my remote eyes and ears for purchasing, pickup and short term storage of this rig until I could come pick it up for myself. Thank you Pete (and Carrie) for all of your help keeping my addictions going!
The Specs:
- 1997 Mercury Mountaineer
- Mfg date 06/97
- Millage = 155K at time of purchase in June 2012
- Mostly stock 5.0 with 155K miles on it. Jim had pretty much replaced everything except the long block
- MAC intake
- 4R70W transmission (rebuilt at something like 120K)
- 4406 transfer case replaced at 165K
- New (or professionally rebuilt) rear driveshaft with CV/slip yoke
- New (or professionally rebuilt) front driveshaft with CV/flange
- Ford 8.8 full width axle from a 1994 F150
***Detroit locker
***4.56:1 gears
***5 on 5.5" Superior chromolly 31 spline axles, OD of flange turned down to fit in Currie rotors
***original Explorer brake calipers and brackets
***Currie Enterprises custom rotors (These may be Jeep CJ rotors re-drilled)
***Rear end cover with "pre-loading" bolts for bearing caps
- Dana 44 high pinion full width axle from 1979 Bronco
***Open diff
***Superior Chromoly axles
***Dana 760X u-joints
***Warn premium locking hubs
***some sort of HD diff cover
- Wild Horses extended radius arms
- Early Bronco 5.5" lift coils
- Rear Superlift Explorer 4.0" lift leaf spring (over axle)
- Some sort of lifting shackel
- 5 on 5.5, 15x10 Rock 8 beadlocks
- 35" x 12.5" x 15" BFG MT's
- 92-95 Toyota 4-runner steering box A1 Cardone p/n: 27-8475
- Sony MEX-BT3700U head unit
- Infinity 6812cf 2 way front speakers
- Infinity 6812cf 2 way rear speakers
- Rockford Fosgate R1 Bassworx 12" sub (5" mounting depth, recomended box volume of 1.02 cu ft) in a 1.02 cubic foot enclosure
- Boss Audio CXX502 amplifier driving the sub
- Clifford RSX3.5 alarm system
- Flaming gauge faces
- UltraGauge OBDII gauge message center
Links to builds that Jim (nssj2) did to it prior to my ownership:
- 4406 upgrade, March 2008
- Learning to shift the 4406, March 2008
- Front Driveshaft custom construction, March 2008
- Gathering parts for the SAS, April 2010
- The SAS, April 2010 - September 2010
Things I have done since I got it:
- August 2012: CB antenna mount was shorting due to the lock washer being in the wrong location - Fixed
- August 2012: Cleaned up disconnected wires to the Sub-Woofer. May have come disconnected when all of the "extras" that Jim gave me with this were packed in the back.
- September 2012: Rear driveshaft CV was rubbing on gas tank after I got it home. BFH = fixed
- September 2012: Removed remaining plastic tank protector to keep it from hitting VSS wires
- September 2012: Attempted to calibrate speedometer. It has a 20 tooth gear installed, it needs a 22 tooth gear, I installed a 21 tooth gear and am living with it.
- September 2012: Added wiring so that the CEL on the right side instrument cluster (pre 1997 gauge faces) lit up with the stock location light
- September 2012: Mounted Cobra 29 in center console area. Will eventually be replaced with my HR2510 and my Alinco Dual band ham radio.
- October 2012: Installed Ultra Gauge
- October 2012: Replaced drivers side headlight bulb with a used one (temporarilly) from my F350
- October 2012: Installed projector headlight
- November 2012: Made/installed new CB antenna mounts
- November 2012: Installed rear differential cover
- December 2012: Reworked the track bar frame side bracket
- January 2013: Replaced the original 4406 transfer case (The other one died from the front driveshaft coming loose, wedgeing in to the housing of the case and splitting it in half)
- January 2013: Reworked front gas tank mount to improve clearance to the 4406 transfer case.
- February 2013: Replaced the stero head unit for one that works better with Ipods
- March 2013: replaced the transfer case again. It had some sort of internal failure that locked it in to 4 low.
- June 2013: replaced broke rear axle with new pair of hardened axles.
- July 2013: Installed mostly hidden 9500 pound winch
- August 2013: Added gusseting to rear axle housing to stiffen housing and add provisions for traction bar.
- August 2013: made a temporary hitch mounted tire carrier to get the tire off the roof.
- August 2013: Reworked transmission cross member to accept 1985 Mustang transmission mount.
- October 2013: Built 12" sub woofer cabinet
- October 2013: mounted my ham radio and antenna
- November 2013: Alignment to see if I could reduce the Death wobble tendancies
- June 2014: Replaced trac bar bushing in an attempt to get rid of some death wobble (didn't work)
- June 2014: Replaced steering box. It sprang a leak in the middle of John Bull trail in Big Bear.
- July 2014: Finished installing the rear traction bar.
- July 2014: Install new set of rear springs.
- July 2014: Installed the TMH Torque Monster Headers on it.
- July 2014: Reworked the lower steering column to have a mid support and the correct end on it for the Toyota PS box.
- July 2014: New pair of tires for the front. (Death wobble gone)
- November 2014: LED light bar on front
- April 2015: replaced the sub woofer with a new one
Links to pictures and albums from when Jim (nssj2) owned this rig:
- From one of Jim's trail runs
- From one of Jim's trail runs
- From one of Jim's trail runs
- From one of Jim's trail runs
- From one of Jim's trail runs
- From one of Jim's trail runs
- From one of Jim's trail runs
- From one of Jim's trail runs
- From one of Jim's trail runs
- From one of Jim's trail runs
- From one of Jim's trail runs
- From one of Jim's trail runs
- Photobucket album from one of Jim's trail runs
- Another album from Jim
Links to my other photos and albums for this rig:
- Bronchole photobucket account
- 2
- 3
- 4
My "To Do" list (in no particular order):
- Rear swing out tire carrier
- PA speaker
- Full halo roof rack to protect roof, allow for heavier hauling on roof and mounting for ham/CB antenna.
- Internal roll cage
- Push the front axle forward 1"-1.5" so the tires clear the nerf bars
- Good pair of off-road lights on the bumper
- Front seat covers
- Front traction aid (probably ARB)
- RCV front axles
- Perhaps ram assist, need to get some more time serious off-roading before I make a final decision on this.
- On-board 1000W continuous or better power inverter. For running all but the most powerful power tools.
- On board air. For ARB, air horn, air tools, airing up tires…
- Air horn. I got it, just need to get it in there.
- Secured set of on-board misc. basic tools. Thinking an ammo box where the spare tire used to be.
- Aluminum deep transmission oil pan
- Second/dual battery for using my ready-welder as well as additional reserve power
-
Trails Conquered:
- August 2012:
***Colorado trails:
******1
******2
******3
***Moab Utah:
******1
******2
******3
- September 2012:
***Hungry Valley ORV area / Gorman & 4WPW customer appreciation day
- October 2012:
***Mojave Road 10/19-10/21
- January 2013
***Bear Camp Snow run that blew up my transfer case
- February 2013
***KOH
***Rohwer Flats
- March 2013:
***Barstow to Vegas
- June 2013:
***Hungry Valley
- July 2013:
***Lockwood/Miller Jeep trail
-August-September 2013:
**Colorado trip
***Halfmoon South (CO)
***Mosquito Pass (CO)
***Taylor Pass (CO)
October 2013:
***Cherry creek area trails
March 2014
***Hungry Valley for CORVA Family Fun Days
June 2014
***Big Bear
August 2014
***Bald Mountain
-------Coyote Lake trail
-------Swamp Lake trail
-------Mirror Lake trail
-------Strawberry Lake trail
May 2015
***Mojave Road
Upcoming trips/trails I plan to conquer:
- August 2015 Rubicon
- August 2015 Some stuff in Washington
- August 2015 Oregon Dunes
-
-
-
I have noticed that allot of people on this site like to make their threads several miles long by doing everything in one thread..... not me. It makes for a PITA for people researching things. Believe me I know from attempting to research on this site. I will be starting other threads for each of my individual builds and link to them from the first post in this thread. If it is significant or I think it’s been a while since this thread has been pulled back to the top I'll post in here to bring it back up.
Notice: I have reserved several posts for anything else I wanted to include later on.