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1997 Ford Explorer - V8 - 5.0 - AWD

Discussion in 'Offroad Projects' started by Spudhut, November 21, 2017.

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    ?

    Should I pick this up?

    Poll closed January 4, 2018.
    1. Yes

      6 vote(s)
      100.0%
    2. No - Its junk

      0 vote(s)
      0.0%
    1. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      Year, Model & Trim Level:
      1997 Explorer Sport - 4x4
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      KG5SPB
      Thanks @CDW6212R - it will not fit past the garage door :cool:. I kept the stock tires to be able to lower and roll it out when its ready

      Thanks @WormsExplorer
       
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    3. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      :bounce: I cut the upper spring posts and rubber mounts from the body of a Cherokee. Since Im using Cherokee springs for the SOA to utilize the factory rubber mount and its function w/out having to bolt in/hard mount the top part of the spring into the custom spring perch top hat. This will be a bolt in unit to hold the spring in place. The spring will be able to slide up and down and re-set itself as it was designed. Thoughts?

      [​IMG]
       
    4. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      Location:
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      Bentonville, AR
      Year, Model & Trim Level:
      1997 Explorer Sport - 4x4
      Callsign:
      KG5SPB
      New Trans Crossmember fab'ed in to make room for front drive shaft. Cutting stock crossmember out once new mount is installed.

      Credit for idea goes to @johnny499 - Thank you!

      [​IMG]
       
      Last edited: May 29, 2018
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    5. WormsExplorer

      WormsExplorer Elite Explorer

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      98 4.0 ohv sport 5
      I like that
       
    6. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      That's heavy duty there. Do you need a skid plate there too?
       
    7. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      1997 Explorer Sport - 4x4
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      I could build something off the cross member but will have to set up suspension links first to figure mounting. Sky is the limit at this point.
       
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    8. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      Location:
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      KG5SPB
      Spring mount tacked in place and frame notched for clearance:
      [​IMG]


      Started mocking up the link suspension. I was going to countersink the mounts into the trans cross-member, but I may just weld them in place and gusset as needed to keep them more parallel to the ground. Let me know your thoughts, I'm open for discussion....A few photos a different angles for different visuals.

      [​IMG]

      [​IMG]

      [​IMG]

      [​IMG]

      [​IMG]


      This view to show clearance to header pipe:
      [​IMG]
       
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    9. WormsExplorer

      WormsExplorer Elite Explorer

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      Looking good sir. I like how you have them set up.
       
    10. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      Can anyone provide any recommendation for the steering rods? I'm thinking GM 1 ton tie rod ends or Heim Joints. I'm not particular in spending another $60-$100 for a reamer to make the 1-Ton conversion....but...I want to go with what's best.

      Any input is appreciated.

      @Turdle ; @Rick ; @CDW6212R ; @johnny499 ; @yostyexplorer94 ; @BKennedy ; @Styx
       
      Last edited: June 6, 2018
    11. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      Project still on the go....Been a little distracted at home...hope to get more done this weekend - at least get the trailing arms mocked in placed to make ready to get panhard in place.
       
    12. Turdle

      Turdle I bake stuff Staff Member Moderator Elite Explorer

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      I tried copying the desert guys and used heims. However, they are not the proper choice for moist conditions IMO, so, I would do the 1 ton ball joints which are a "wet" joint rather than he "dry" joint of a heim. heims get kinda squeeky and noisy when exposed to moisture
      .
       
    13. WormsExplorer

      WormsExplorer Elite Explorer

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      Do you have a full picture of the Trans mount?
       
    14. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      @WormsExplorer - Ill take some and post them for you.

      Thanks @Turdle for your feedback. That explanation helps me immensely
       
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    15. yostyexplorer94

      yostyexplorer94 1st Gen Mod Staff Member Moderator Elite Explorer

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      I really like my one ton tie rod ends. I have replaced 2 tie rod ends since I sas years ago. I grease them quite often though
       
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    16. WormsExplorer

      WormsExplorer Elite Explorer

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    17. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      @WormsExplorer

      Sorry my friend...been crazy here at home.

      I used @johnny499 idea to create mine (see page 3 about 1/2 way down - great photos): Mn Mountaineer V8 SAS


      Im hoping to jump on this thing this weekend to get front panhard completed/mocked and hopefully the steering box in place. :)
       
    18. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      Location:
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      1997 Explorer Sport - 4x4
      Callsign:
      KG5SPB
      I made the time to work on my Explorer this weekend...Lets dive in.

      2 things I needed to get accomplished: Mount F150 steering box and get front panhard bar installed.

      :thumbsup: I got the front pretty much mocked up (tacked) in place. This is the first swap of this type that I have ever done, I ENCOURAGE ANY AND ALL FEEDBACK IS MUCH APPRECIATED. Especially before I start to final weld everything in place. :) PLEASE COMMENT. :)

      Steering:
      ***Before I start on the install of the steering box. Its important that you pick up a oil filter relocation kit. Its a tight fit between the engine and frame.

      Im going to talk mainly the steering shaft and the modifications I did to make this work. Unfortunately the Stock 93' F150 shaft wont mate to the 97 Explorer steering column. The box install has been touched by many others. ie: @johnny499 Mountaineer thread was a huge help.

      93' Ford F150 Shaft - there are 2 spot welds on each side of the shaft that need to be removed. You need the lower section/rag joint to mate to the steering box.
      [​IMG]

      Stock 97' Ford Explorer Steering Shaft-
      [​IMG]

      97' Ford Explorer Steering Shaft - Where to cut? there is a 'keyed' shape that matches F150 steering shaft.
      [​IMG]


      F150 and Ford Explorer Shafts joined[​IMG]


      Final completed shaft. Note that a large section of F150 shaft has been removed and spliced at the rag joint. I TIG welded the butt weld to ensure good penetration. This shaft still slips like the original Explorer shaft. Tight Space in there.
      [​IMG]

      Steering Box installed - Clearance of final installation. Zero binding, smooth turning from inside. Sure is a great feeling to be at this point.
      [​IMG]

      F150 Steering Box installed:

      Added info. If you want to convert your pressure port to accept an AN6 type fitting, there is an adapter that you can pick up. The port has 1/2-20 threads in it (smaller port). (AN6 to 1/2-20 Inverted Flare) This adapter will allow you to have a standard high pressure hydraulic hose with AN6 fitting made for this application. Part number for adapter is FRA-491955.

      You can take your stock Explorer hose (if in good condition) and have a 90 degree AN6 fitting crimped on at steering box side to mate the box to your stock power steering pump. Return line should be made easily.

      [​IMG]
       
      Last edited: September 17, 2018
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    19. Mbrooks420

      Mbrooks420 High Voltage. Elite Explorer

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      Looks like a great job. You might want to slap a piece of loom over those fuel lines to avoid the zip tie from sawing through in time.
       
      Last edited: July 30, 2018
    20. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      Panhard Install - Suspension Photos: All I have left to do is finish steering rods using 1ton GM Y-Steering setup.

      [​IMG]

      [​IMG]

      [​IMG]

      [​IMG]

      [​IMG]

      [​IMG]
       
    21. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      KG5SPB
      Thanks. The zip tie is to get stuff out of the way of the plasma cutter and to get my hands in there. I plan on re-doing all the lines or re-mounting the factory lines. Got too many things 'mocked up' at this point...thank goodness for task lists. :)
       
    22. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      KG5SPB
      Upper spring bushing/keeper shaft thing :crazy: cut from Jeep Cherokee - bolted to upper spring mount plate.

      [​IMG]
       
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    23. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      Bringing back up for feedback before I start welding this beast together. Im ready to set on all 4 tires. :)
       
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    24. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      I currently have my caster set to 8 degrees from this location.

      [​IMG]
       
    25. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      Location:
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      1997 Explorer Sport - 4x4
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      KG5SPB
      The time has come. I pushed hard last week and finally got the beast on the ground on all 4's. I have read so many times how great it feels to be at this point - It certainly feels great and accomplished. I still have much to do, but for this being my first 4x4 type build vs Hot Rods the past 17 yrs, I'm pretty proud of what I have done so far.

      Here she is right after she touched down on the ground
      [​IMG]

      @CDW6212R - As for getting her out - I had to put new shoes (stock tires) on her to bring her into the sunlight.
      [​IMG]

      [​IMG]

      [​IMG]
       
    26. Spudhut

      Spudhut US Navy Submariner Elite Explorer

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      Location:
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      KG5SPB
      I slapped the 33's on them and decided to take a 'family' photo

      [​IMG]

      [​IMG]

      [​IMG]

      [​IMG]
       
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