MrQ's Red Flyer

1994 Ford Explorer XLT
3.73 LS 8.8 Rear
3.73 D35 TTB Front Axle
Tan Leather Interior
Power Seats/Windows/Locks
160,000 miles


The Name​

I know some people are wondering, why "Red Flyer" for a name? It sure isn't for speed, since these trucks are about as aerodynamic as a breadbox. Nor is it for looks, as this truck isn't going to win any car shows any time soon. The reason this truck got is name is due to a story, an event that happened nearly 5 months after I purchased it...

You see, Hitchhikingmike, a friend of mine who lives up in Dallas has another Explorer, a third gen, and I have been wanting to see him for a while. So, I pack up my gear and head out on a warm January afternoon (don't ask, it's Houston) and 6 hours later I wind up at his house in my "new" truck. So what do two friends with big SUV's do for fun? They drive 'em. And that's just what we did.

I used to live in the Dallas area, so Mike and I visited all our old hangouts. One of them was this wide open field behind a housing development I used to live in. What's a guy gonna do? So, there we are doing skid stops and circles and kicking up some dust in the late afternoon. We soon discover this little drainage ditch that ran right through the field and that livened things up. After playing around for a little bit, it started to get dark and cold. But, I wanted one last go around with the ditch before we left...you know, to do something spectacular. I pulled my truck up about 200ft away from the ditch and got squared away. My older brother in the passenger seat gave me a "are you kidding me??" look, shook his head and started the countdown. 5...4...3...2...1...GO!! I hit the accelerator with everything I had and broke loose the tires. The ditch was coming up mighty fast and for a split second I thought ..."WHAT THE HELL AM I DOING??" To late for such thoughts as the truck dove over the edge of the ditch. I saw nothing, but the ground through the window and just as I though that I had totaled the truck, the front end pops up, my pedal still on full throttle. Then there was nothing.

THUMP...THUMP...THUMP. I hear my heart beating as everything seemed to slow down. Clenching onto the steering wheel, I held on for dear life as gravity took a firm hold on my flying SUV. I dreaded what was next...

BAM!!

The truck had landed; the moment was over. A bunny hop later and the truck rolled to a stop, undamaged. I heard my brother gasping and groaning next me. (Turns out he had landed on, uh...a very delicate spot on the way down) The radio then crackled to life and my friend shouted over the comm "THAT-WAS-AWESOME!!"

That same truck got me home 600 miles away without a hiccup. And it is for this memory and that event she was nicknamed..."The Red Flyer."

3...2...1...Lift Off




4WD Conversion

Still 2WD​

I then got this silly idea to convert my truck to 4wd. The seed was planted by Kris Guilbeaux's "2wd to 4wd Conversion" on the explorer4x4.com pages. It was just something that lingered around in the back of my thoughts, not really something worth further consideration, but tantalizing nonetheless. Then on my first trip to the local junkyard produced a gem, a 4wd '93 Explorer with a blown tranny. From then on I swore that I would have that front suspension. Little did I know the issues and problems that would arise from this decision. I worked my butt off for two weeks to raise the $200 ( I only got 12 hours a week) for that front end. I indexed my Haynes manual and enlisted some help. Saturday, June 20 2010, was the day chosen for the operation. After several hours of sweaty work, we could not free the suspension. Tired, depressed and nearly heat stroked, I walked away to try again another day. One week later, I went back to grab another part an hour from the junkyard's closing time. I then got it into my head to try and get one of the workers to help me. A really nice guy, the worker brought out his electric impact wrench and we knocked out the front end and loaded it up. For the next 6 months it stayed in the garage gathering dust and wasps nests. In the meantime, I picked up a manual transfer case from a 91 Ranger for $170 off of ebay with two weeks of paychecks. Next up was a swap with 91blackEB for a set of lock nuts and a complete transfer case shifter. I also grabbed a set of manual locking hubs off eBay as well.

Pulled I-Beam Suspension/Stripped Front End​

After this my parts hunt came to an end as school finished up and the holidays came around. My parents were pushing for me to give up on the conversion. I caved and put my parts up for sale. I sold the shifter, the lock nuts and manual hubs and the autos I got from when I pulled the TTB. I regret doing this, especially losing the shifter as it had the boot and the floor plate. After some friendly pushing, black91EB got me to start back on my project. I had to recoup the lost parts and find a tranny. Kris Guilbeaux got in touch with me and pointed me to a friend of his who was parting out another 94 Explorer. I picked up the first 4x4 A4LD from him plus the two drive shafts, driver's side drop bracket and the manual hubs. Thanks to this site I also found out where to get a new set of lock nuts. I picked them up from 4wheel Parts for $20. Then in early January, I got 5 days in a row off from work and decided to move on Phase I of my conversion, the front suspension. After struggling with the rivets on the 2wd drop bracket after removing the I-beam suspension, I nearly gave up as my money started to run out. I had drilled, cut, hammered and cursed at them for two days. That night I grabbed my dad and used the last of my money to get an air hammer from Harbor Freight. The next day I knocked those rivets out and said goodbye to 2wd on this truck forever. Spent an all-nighter installing the new TTB, locknuts, and manual hubs. I was cutting it tight as I needed the truck for work the next day, so I cut some corners and left the 2wd steering setup in. I did a quick and dirty alignment and got to work, but found I had a terrible howl coming from my new suspension. A month later, on Valentines' Day, I slammed my truck into a tree, killing my 4x4 hopes till I could put the Explorer back together.

The Accident: Before and After​

After a day of work and a new fender I finally got the truck back in working order. I also figured out my howling problem was a set of bad bearings on the driver's side. Took me forever to diagnose that one. It would be another 4 months before progress began again. During this time I tore apart the A4LD and rebuilt it from the ground up.

Transmission Rebuild​

I also replaced the 2wd steering setup with the 4wd setup when I noticed several issues starting to develop with the steering geometry.

Showing Off​

When my friend, Hitchhikingmike, came down for a week in June, we spent 4 days pulling out the old tranny and installing the new one with the transfer case and 4wd drive shaft.

Transmission Install, Round 1/Hitchhikingmike
​

Unfortunately I snapped the nut off of the throttle kick down lever on the tranny which put me in limp mode for a month until I could address it. During this time the shifts were erratic and the fluid smelled burnt. I knew what was going on, but tried to ignore it as I needed the truck. It wasn't till I lost O/D that I knew I had to do something. I replaced my rebuilt valve body with the one from my 2wd tranny. Things continued to get worse. I knew what I had to do. I struggled with the tranny till I could find a replacement. I wanted a manual, but none were available, so I settled for another A4LD. So back into the garage went Red for another two weeks.

Flexing
​

I also put in the new shifter I grabbed from a guy on the rangerstation.com forum. This was the point were I noticed there was something missing on the transfer case...the little shifter arm. What a "DOH" moment. Oh well, with my truck finally working again, I moved on to Phase III, the rear end.

I had to hunt and peck for a good price on a good 3.73 8.8. I wanted one with a limited slip, as a locked rear was not really an option for me. After looking at another junk yard, since I had a falling out with my local one, I found it in the first Explorer I looked at. For a $100 I was riding home with a new rear end. Unfortunately, the yard workers cut the e-brake lines, so I had to replace them. I figured if I had to take apart the drums to get to the lines I might as well replace the drum brake parts. It was a good thing too, as one of the drums was cracked. After this was completed, I took three days to pull out the the old 8.8 and throw in the new one. At this point I also removed the rear sway bar. Those bolts and nuts were tough, but with enough brute force, I got them off. I also had to replace the diff cover on the new 8.8 as it was fiberglass and leaking, so I stole the metal one off of the old diff.

As the truck settled into its new, deeper gearing, there were still issues to address. I had a shifter that was merely eye candy and a front drive shaft to install. The drive shaft needed a new u-joint and I didn't have any t-case-to-drive shaft bolts. The u-joint was easy and a quick trip to AZ solved that. However, the bolts were another story. Imagine walking into Home Depot hefting a large heavy metal drive shaft on your shoulder, telling the clerk you needed automotive bolts. Yeah, I know. Anyway, they couldn't help so I was off to ACE. Lugging my big iron stick in, two clerks were able to help me find the right Grade 8 bolts to do the job. The next day, my Explorer had a new drive shaft and all that was left was to test the system. (Thanks to black91EB I wound up with the little shifter lever he made for the t-case two weeks later.)

On Saturday, October 9th 2010 I filled the front diff and headed to the beach. After using a wrench to pop the tcase into 4hi, I locked the hubs and took off. With 4WD pushing her through and over all obstacles, Red had finally become the truck I had dreamed of for over a year. With my truck ready to tackle off road challenges, who knows what's possible or what's next?

Finale
​

SHOUT OUTS
My Parents: Who put up with me while I destroyed tools, got the house dirty, took over the whole garage and messed it up, clogged up the washer with greasy clothes, left parts and pieces in the backyard and wound up really causing them some frustration.
Hitchhikingmike: The best friend I have ever had. He has done so much for me that I can't repay...
Matt: My brother. He is the man that I bounce off ideas with. He is a real pain in the ass, but I sure couldn't have done most of these things without him.
Gmanpaint: Thanks for the support on the site! I really appreciate the effort you have made to help me.
Unclemike: A great and supportive fellow Texan.
Kris Guilbeaux: The guy whose "How-to" got me into, and through, this conversion.
Nice59FordF100: My able FHDRS co-host and friend.
black91EB: Encouraging me to keep at it, even when I thought it was all too much...
Explorer Forum
All the the other guys and gals on the site who have made so many awesome contributions to this Explorer community

Maintenance:

New Cone Filter
Oil Change every 4K (Regular)
New Spark Plugs and Wires
New Front pads, new caliper and rotor
New Water pump
New Water Pump to Heater Core hose
New Idler Pulley
New Belt
New Fan
Fixed Passenger Front, Passenger Rear, and Driver Rear Power Windows
New Head Unit
Fixed Both Rear Door Armrests
Adjusted and tightened steering play
Replaced tie rod ends
All 4 tires replaced
Replaced shocks
New O2 Sensor
New Starter

Completed Mods

Sony Xplod CD/MP3/USB head unit that is HD/SAT ready (12/08)
Spectre Cold Air Intake Mod (3/09)
5 Cent Throttle Cable Mod (4/09)
Explorer Forums License Plate Frames (4/09)
Overhead Console (5/09)
Limited Auto Dim Mirror (5/09)
4DMaglite Flashlight and Holder (6/09)
Goodyear Wrangler Radials 235/75/15 (8/09 - 4/10)
55W Off-Road Lights (10/10)
Explorer Forum Vinyls Courtesy of Blee (9/09)
Reese Class III Tow Hitch (9/09)
Garmin Nuvi 255w (12/09)
Swapped D35 TTB w/ Manual Lockouts(2/10)
Beefed-up 2" Autozone Shackles (5/10)
4x4 A4LD Transmission (5/10)
Borg Warner 1354 Manual Transfer Case (5/10)
2.5" Skyjacker Nitro Shocks (7/10)
Midland CB (8/10)
Clear Turn Signals (3/11)

More Photo's

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[MrQ]

I have decided to get the transmission rebuilt, rather than throw in a manual. Its the quickest solution. I was a deadhead for thinking I could rebuild a transmission properly and it's also quite probable I fried the computer while throwing it in or putting in the new valve body. I did have fun and I learned a lot, but it was way out of my league. I needed the proper training to rebuild something this complicated properly. I have no doubt I could do it with training, however. But now I have backed myself into a corner and don't have much of a choice in this area. The heat and humidity are killer and my family and I need this vehicle back, because our other means of family transportation is a 95 Plymouth with 200,000 on the ticker, a blown freeze plug, a bad computer and no a/c or my brother's 2 seater 'stang.

 

[black91EB]

man that sucks. You gonna ready for SMORR? I would go but I am stuck in AL working.

 

[Hitchhikingmike]

that sucks, its too bad the rebuild didn't work out. It seemed like after we put it in it was working good and that was going to be it, it seemed to shift smooth and well at the time.

So how do you know for sure that your computer is bad?

 

[gmanpaint]

But now I have backed myself into a corner and don't have much of a choice in this area.

I completely understand how you feel here. Do what you must to get yourself square. Family first, fun later.

There will always be "Another" time for fun

 

[MrQ]

New tranny is in and working fine. No burned ATF and no problem with overdrive. Now if I can just get the engine to run correctly.

 

[MrQ]

Finally found out the engine problem. The computer displayed a 172 code which means a passenger side O2 sensor failure. I just need to get my paycheck in and I can get it replaced.

I still need to install the manual shifter and get a new u-joint for the front driveshaft. I also need to install the rear axle as well.

 

[MrQ]

Manual Shifter is installed, but I need the piece that connects it to the transfer case. That linkage is missing.

Anyway, here are the pics...

2 High

4 High

4 Low

 

[MrQ]

Threw on the nitro Skyjacker shocks I picked up from Darman and replaced the faulty o2 sensor that was causing a lot of my engine problems. So close to having this conversion done, but the weather down here is set to "flash-fry". Going outside for even a little while will make you sweat like crazy.

 

[reapereviltwin]

Glad to see the Red Flyer is comintg along, Dan. 106 here with a heat index of 110, hate to see what it is down near Houston. Not much humidity here. At least we're not in AZ or NM. (or Iraq, been there done that) Even tho now it has cooled down to 98.

 

[MrQ]

Just installed a new Midland CB. I have been wanting one for a while.

I am still hoping the weather will cool down at least...2 degrees. Dehydration is a big factor even in the shade and at night. The humidity is absolutely terrible. Man, I wish I lived further up north. I would fry, but at least I wouldn't boil...

 

[gmanpaint]

Speaking of "Up north" CCR10 is just around the corner

 

[MrQ]

Oh man, I so wanna be ready. I have been itching to try this rig out. The Houston suburbs have a law against flexing...on baseball fields.

 

[MrQ]

I am so mad right now!! Those stupid jerks at the salvage yard cut the parking brake cables on my replacement axle and I now have to pull apart both drum brakes to replace them!! :fire:

Another hold up to getting this done.

On a side note I removed the rear sway bar on the axle because it was getting in my way. Should I leave it off or put it back on?

Also, I have a huge pile of automotive parts piling up in my back yard and I need to get rid of them. Any idea how to do that?

 

[gmanpaint]

Leaving the rear sway bar off is not that big a deal. The front does most of the work anyways.

You can sell the extra parts to a steel scrap yard. They pay by weight, and the prices fluctuate on a daily basis from the DOW market. I would call around and see who is offering the best price.

 

[MrQ]

Ok finally got some pics of my new CB

And a nifty little fuse box I picked up.

I thought the ashtray was a perfect place for it. It has a tap directly off the battery with 10 ga wiring. The CB is tied into it. Also when I add any new equipment it will tie in here.

 

[black91EB]

x2 on the leave the sway bar off. I have not had mine in over a year and I noticed no difference.

BTW don't be too hard on the folks for cutting your e brake cables, they are a PITA to disconnect, and they have other stuff to work on. Besides, it gives you a good chance to check out the brakes before you put them on, which you should do anyway. For dealing with those stupid little spring collars that hold the cable in place, a pair of these work really really well.

 

[gmanpaint]

I thought about installing the CB in that spot, but didn't know what was behind it. I ended up installing mine inside the ashtray itself. Used the ashtray bracket and tray holder and screwed the CB to it. I no longer have a cig lighter tho...lol But I did purchase a 12v accessory plug in for it today.

 

[Hitchhikingmike]

When I installed my ham radio. I cut up a piece of license plate and placed it behind the plastic kick panel so that it was not just attached to the plastic panel alone. I then secured the metal plate with some hanging wire to the frame of the dash so that zero weight of the radio was being held on by the plastic kick panel. You have to remember that when you go over bumps or the unexpected pot holes at higher speeds, the radio will increase in mass by several time, so make sure the bracket will stay secure under more than just the weight of the radio.

I would imagine as well that it is pretty routine to just cut the brake lines as well. You would want to take apart and examine and re-adjust all the brake parts anyhow with a foreign axle of unknown condition.

Same on the rear sway bar. I don't think you will notice that much of a difference. But the front sway bar is absolutely essential for city driving. I wouldn't even chance driving without the front sway bar. I would equate no front sway bar to driving with 12psi in your tires on the highway. Good luck with install the axel though. Hopefully it won't take more than a day for you to complete.

By the way, are you able to hit any local repeaters with your radio?

 

[MrQ]

x2 on the leave the sway bar off. I have not had mine in over a year and I noticed no difference.

BTW don't be too hard on the folks for cutting your e brake cables, they are a PITA to disconnect, and they have other stuff to work on. Besides, it gives you a good chance to check out the brakes before you put them on, which you should do anyway. For dealing with those stupid little spring collars that hold the cable in place, a pair of these work really really well.

Thanks for the tip!

I thought about installing the CB in that spot, but didn't know what was behind it. I ended up installing mine inside the ashtray itself. Used the ashtray bracket and tray holder and screwed the CB to it. I no longer have a cig lighter tho...lol But I did purchase a 12v accessory plug in for it today.

Apparently there is a hard plastic behind that area. I really didn't want to lose my ash tray with the 12 outlet. I used some very long machine screws and once I got through the thin layer of foam it held right in place.

When I installed my ham radio. I cut up a piece of license plate and placed it behind the plastic kick panel so that it was not just attached to the plastic panel alone. I then secured the metal plate with some hanging wire to the frame of the dash so that zero weight of the radio was being held on by the plastic kick panel. You have to remember that when you go over bumps or the unexpected pot holes at higher speeds, the radio will increase in mass by several time, so make sure the bracket will stay secure under more than just the weight of the radio.

I would imagine as well that it is pretty routine to just cut the brake lines as well. You would want to take apart and examine and re-adjust all the brake parts anyhow with a foreign axle of unknown condition.

Same on the rear sway bar. I don't think you will notice that much of a difference. But the front sway bar is absolutely essential for city driving. I wouldn't even chance driving without the front sway bar. I would equate no front sway bar to driving with 12psi in your tires on the highway. Good luck with install the axel though. Hopefully it won't take more than a day for you to complete.

By the way, are you able to hit any local repeaters with your radio?

I guess the consensus is to leave the sway bar off. Fine by me. I guess I really didn't want to dig into the drums. I can do it, it'll just take some extra time.

Also if anybody has any leads or any dimensions for the little linkage that attaches to the t-case (not the shifter) I would be very grateful.

Mike, my radio is a cb. Can it hit repeaters?

 

[Hitchhikingmike]

Oh, I was not too familiar with Citizen's Band (CB) radios until I just educated myself about them on wikipedia. I thought the term CB was synonymous with amateur ham radios. I did not realize that they are a completely different classification of radios. CBs are only ad-hoc radios.

I'm interested to know, have you encountered anyone else on the radio bands yet?