Pugly

*gmanpaint* · 08-03-2010, 07:29 PM

The Good, The Bad, & the Pugly

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-2nd gen disc 8.8 rear 4:10 gears

Front C-Clip eliminator Mod

Slight lift with F-150 coil spacers & rear built lift leaf packs

3" PA body lift

Swapped to warn manual hubs

33" x 12.5" x 15" BF KM2 mounted on 15x8.5 polished alum - full size spare

Front Rancho 9000xl adjustable shocks
Rear James Duff 70/30 shocks

Sway bar quick disconnects front & rear

100w off road lights
55w rock lights--2 front--1 rear over diff
8 LED pods for rocker lights
Wireless Led interior pods

Full brush guard.

Custom ladder bars bolted to the roof, reinforced with plates underneath

Class V hitch-front tow hooks

Cobra19 CB mounted in custom console & rear hatch mounted 4' firestick antenna.

JVC DVD/CD/MP3 Head unit with 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/ Led pod lights on sides with wireless switch

'99 Eddie Bauer Leather buckets

Hayden Sever duty fan clutch.

How it sits today.

Stock

1st time it has been off road at the 1st annual SMORR09 meet

Zukman piloting Pugly

Trying to fit in with the bigger dawgs

Lazy creek trail

3" BL-2" suspension lift on 31"x10.5" BF AT's

The hood release Mod

*zukman* · 08-03-2010, 10:06 PM

but but but Pugly is cute!!!!!!!!!!!!! I liked driving it to SMORR!

*corkey* · 08-03-2010, 11:04 PM

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,,

*Sams01XplrSprt* · 08-04-2010, 03:15 PM

nice lookin x

*gmanpaint* · 08-04-2010, 03:33 PM

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.

*gmanpaint* · 09-15-2010, 11:21 AM

Thinking of dumping the exhaust on this. Wonder what a stock muffler would sound like dumped?

Right now the tailpipe sounds like a wet fart with higher RPM's.

dislexiclawyer · 09-15-2010, 08:37 PM

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

*gmanpaint* · 09-15-2010, 09:04 PM

Quote:

Originally Posted by dislexiclawyer

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

After the rear quarter is patched and painted I might update it if it looks good...lol

I'm not sure if the BL would have helped yours or not.

*corkey* · 09-15-2010, 09:38 PM

wow, how much this rig has changed, as well as mine,,,

*gmanpaint* · 10-29-2010, 05:38 PM

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.

*Willard* · 10-29-2010, 07:08 PM

Maybe the tapping was a coincidence. It could always be the solenoid on the fender.

*gmanpaint* · 10-31-2010, 03:10 PM

Quote:

Originally Posted by Willard

Maybe the tapping was a coincidence. It could always be the solenoid on the fender.

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.

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

*corkey* · 10-31-2010, 03:38 PM

glad it works now,, it is a good rig,,

*gmanpaint* · 10-31-2010, 04:11 PM

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.

MrQ · 10-31-2010, 05:01 PM

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.

*gmanpaint* · 10-31-2010, 05:16 PM

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

*gmanpaint* · 11-17-2010, 03:47 PM

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.

*gmanpaint* · 11-18-2010, 06:53 PM

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.

*gmanpaint* · 11-20-2010, 06:30 PM

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.

*gmanpaint* · 11-21-2010, 03:48 PM

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.

08-03-2010, 07:29 PM	#1
gmanpaint Torsion Bar Free since 2010 94 XLT-95 FX4 Join Date: Aug 2008 Posts: 6,926 Vehicle Specs (Original Poster)	Pugly The Good, The Bad, & the Pugly 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-2nd gen disc 8.8 rear 4:10 gears Front C-Clip eliminator Mod Slight lift with F-150 coil spacers & rear built lift leaf packs 3" PA body lift Swapped to warn manual hubs 33" x 12.5" x 15" BF KM2 mounted on 15x8.5 polished alum - full size spare Front Rancho 9000xl adjustable shocks Rear James Duff 70/30 shocks Sway bar quick disconnects front & rear 100w off road lights 55w rock lights--2 front--1 rear over diff 8 LED pods for rocker lights Wireless Led interior pods Full brush guard. Custom ladder bars bolted to the roof, reinforced with plates underneath Class V hitch-front tow hooks Cobra19 CB mounted in custom console & rear hatch mounted 4' firestick antenna. JVC DVD/CD/MP3 Head unit with 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/ Led pod lights on sides with wireless switch '99 Eddie Bauer Leather buckets Hayden Sever duty fan clutch. How it sits today. Stock 1st time it has been off road at the 1st annual SMORR09 meet Zukman piloting Pugly Trying to fit in with the bigger dawgs Lazy creek trail 3" BL-2" suspension lift on 31"x10.5" BF AT's The hood release Mod __________________ The Black Hole Pugly Last edited by gmanpaint; 06-26-2012 at 06:33 PM.

08-03-2010, 10:06 PM	#2
zukman "Home of Misfit Crawlers" arcadia calif. '91EB, '86Sami, '85Ranger Join Date: Aug 2005 Posts: 1,648 Vehicle Specs	but but but Pugly is cute!!!!!!!!!!!!! I liked driving it to SMORR! __________________ 1986 Suzuki Samurai JX(under reconstruction) 1991 ExplorerEddie Bauer http://www.explorerforum.com/forums/...d.php?t=263112 1991 Explorer XLT http://www.explorerforum.com/forums/...40#post2995740 1985 Ranger (waiting for elec surgery) Tow vehicles-Theirs- '99 Cruise Master, His '01 F-250 4x4,Hers'98 Expedition XLT Flags http://www.explorerforum.com/forums/...ight=Wave+Flag Light Covers http://www.explorerforum.com/forums/...45#post2625145

08-03-2010, 11:04 PM	#3
corkey Elite Canuck, Eh ?? In the Great White North where winter never seems to end ,Ontario,, still ice fishing,, 96xl,99xls,old Rangers Join Date: Jan 2008 Posts: 5,448 Vehicle Specs	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,, __________________ Log Roller,, Fox Coilovers 35's and others, , Truck of the month Ranger Of Danger,,,project truck, also look for Blues Traveller Elite registry, ,

08-04-2010, 03:15 PM	#4
Sams01XplrSprt Southern Cali Explorer Newport Beach California & Bay Area California 2001 Sport (sold) Join Date: Nov 2004 Posts: 15,633 Vehicle Specs	nice lookin x __________________ 2001 Ford Explorer Sport 4.0 sohc engine. Mods include: dual 40 series flowmasters & high flow k&n air filter & removed silencer & yellow fog lights (sold for $1,800) as of 2-26-12

08-04-2010, 03:33 PM	#5
gmanpaint Torsion Bar Free since 2010 94 XLT-95 FX4 Join Date: Aug 2008 Posts: 6,926 Vehicle Specs (Original Poster)	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. __________________ The Black Hole Pugly Last edited by gmanpaint; 08-16-2010 at 09:37 PM.

09-15-2010, 11:21 AM	#6
gmanpaint Torsion Bar Free since 2010 94 XLT-95 FX4 Join Date: Aug 2008 Posts: 6,926 Vehicle Specs (Original Poster)	Thinking of dumping the exhaust on this. Wonder what a stock muffler would sound like dumped? Right now the tailpipe sounds like a wet fart with higher RPM's. __________________ The Black Hole Pugly

09-15-2010, 08:37 PM	#7
dislexiclawyer Wannabe Elite Explorer Join Date: Apr 2008 Posts: 206 Vehicle Specs	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 __________________ My Registry

09-15-2010, 09:38 PM	#9
corkey Elite Canuck, Eh ?? In the Great White North where winter never seems to end ,Ontario,, still ice fishing,, 96xl,99xls,old Rangers Join Date: Jan 2008 Posts: 5,448 Vehicle Specs	wow, how much this rig has changed, as well as mine,,, __________________ Log Roller,, Fox Coilovers 35's and others, , Truck of the month Ranger Of Danger,,,project truck, also look for Blues Traveller Elite registry, ,

10-29-2010, 05:38 PM	#10
gmanpaint Torsion Bar Free since 2010 94 XLT-95 FX4 Join Date: Aug 2008 Posts: 6,926 Vehicle Specs (Original Poster)	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. __________________ The Black Hole Pugly

10-29-2010, 07:08 PM	#11
Willard Elite tree-smasher Bloomington, Indiana 04 Ranger Edge Join Date: Mar 2007 Posts: 3,293 Vehicle Specs	Maybe the tapping was a coincidence. It could always be the solenoid on the fender. __________________ Jesse '94 Eddie Bauer DD/Beater "Old Faithful" RIP '04 Ranger Edge DD "Black Knight" You want to see my face?

10-31-2010, 03:38 PM	#13
corkey Elite Canuck, Eh ?? In the Great White North where winter never seems to end ,Ontario,, still ice fishing,, 96xl,99xls,old Rangers Join Date: Jan 2008 Posts: 5,448 Vehicle Specs	glad it works now,, it is a good rig,, __________________ Log Roller,, Fox Coilovers 35's and others, , Truck of the month Ranger Of Danger,,,project truck, also look for Blues Traveller Elite registry, ,

10-31-2010, 04:11 PM	#14
gmanpaint Torsion Bar Free since 2010 94 XLT-95 FX4 Join Date: Aug 2008 Posts: 6,926 Vehicle Specs (Original Poster)	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. __________________ The Black Hole Pugly

10-31-2010, 05:01 PM	#15
MrQ Moderator Emeritus Houston, TX '98 Eddie Bauer Join Date: Oct 2008 Posts: 2,172 Vehicle Specs	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. __________________ -Dan Red Flyer I - 1994 Explorer XLT 4WD Conversion "Resting Comfortably" Red Flyer II - 1998 Explorer Eddie Bauer Custom *"The Daily Driver"* **Dark Thunder - 1998 Dodge Ram 1500 V8 "Tow Rig/Backup Daily"**

10-31-2010, 05:16 PM	#16
gmanpaint Torsion Bar Free since 2010 94 XLT-95 FX4 Join Date: Aug 2008 Posts: 6,926 Vehicle Specs (Original Poster)	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 __________________ The Black Hole Pugly

11-17-2010, 03:47 PM	#17
gmanpaint Torsion Bar Free since 2010 94 XLT-95 FX4 Join Date: Aug 2008 Posts: 6,926 Vehicle Specs (Original Poster)	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. __________________ The Black Hole Pugly

11-18-2010, 06:53 PM	#18
gmanpaint Torsion Bar Free since 2010 94 XLT-95 FX4 Join Date: Aug 2008 Posts: 6,926 Vehicle Specs (Original Poster)	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. __________________ The Black Hole Pugly

11-20-2010, 06:30 PM	#19
gmanpaint Torsion Bar Free since 2010 94 XLT-95 FX4 Join Date: Aug 2008 Posts: 6,926 Vehicle Specs (Original Poster)	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. __________________ The Black Hole Pugly

11-21-2010, 03:48 PM	#20
gmanpaint Torsion Bar Free since 2010 94 XLT-95 FX4 Join Date: Aug 2008 Posts: 6,926 Vehicle Specs (Original Poster)	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. __________________ The Black Hole Pugly