Happy owner of '92 Explorer

[Zvony]

Hello,
I'm a new owner of a '92 Explorer Eddie Bauer - automatic. The car is in pretty good shape, but it still needs a little attention on some details that I hope to fix in the next couple of years so it will be ready to become a historic vehicle (2022). Biggest problem so far: 4x4 not engageing.

 

[Zvony]

Here are a few photos of the Explorer that I took today. It's a little beaten up, but I'll try to fix it one small step at a time.

 

[Mike65]

Welcome. Nice looking Explorer.

 

[Zvony]

When today to see my second Explorer (the one for parts) and it is not looking so good. I didn't see it before today and I was hoping it could be rebuild, but it is not: no gas tank, no rear drive shaft, no shock absorbers, missing left headlight, both rear lights and so on.
The good news is that I got the 4x4 shift motor, module and switch and managed to make it work. Also, the windshield washer pump is working (and now fitted on Eddie).
Still no 4x4, but I hope I'll solve it in the next few days.

 

[BrooklynBay]

Welcome to this forum!

 

[Travisfab]

There is a ton of info on the site about the 4x4 not engaging. The stock auto hubs seem to always fail, so that's where I start!

 

[Zvony]

Thanks for the suggestion!
Today I managed to engage 4x4 after testing two motors, but no Low Range. Engine running, NEUTRAL, brakes pressed and Low Range was not engageing.

 

[RangerX]

Check this thread https://www.explorerforum.com/forums/threads/4x4-troubleshooting-guide.202166/

 

[Zvony]

Thanks for the suggestion!
After a lot of testing, there were 2 problems:
1. The bushing in the shift motor.
2. The NSS orthe wire from NSS to Shift Module.
The first one I solved, the second... may in the next few days.
Now I'm trying to install a new radio (closer to the one originally mounted on the Explorer). Hope I'll manage tomorrow.

 

[waggie]

For low range issues, I'd check (from the troubleshooting guide above):
Continuity to the buttons on the dash (make sure you have a good connection on the back of the button panel, I really confused myself when I accidentally pulled out some pins on it whilst swapping instrument cluster lights for LEDs)
Neutral sensing switch continuity
Resistance on the transfer case speed sensors
Motor position sensor

 

[Zvony]

Neutral sensing switch continuity

This guy was the culprit. If I take ground from the body and feed it to the Shift module, it works, so I tested the NSS and has no continuity when in N. Ordered a new one, I'll swap it when it comes.
Now I'm reading about the Air Condioning system conversion to R-134, as I can't find R-12 anymore.

 

[waggie]

This guy was the culprit. If I take ground from the body and feed it to the Shift module, it works, so I tested the NSS and has no continuity when in N. Ordered a new one, I'll swap it when it comes.
Now I'm reading about the Air Condioning system conversion to R-134, as I can't find R-12 anymore.

Glad to hear you get the low-range issue diagnosed! Regarding the conversion to R-134, in my case the previous owner did the conversion so I can't speak to the details. I will say, however, that there is reduced performance when moving to R-134. It's still perfectly reasonable at 90F/35C, I haven't tested it beyond that.

 

[Zvony]

The restauration continues. I managed to take down the LPG system (not a fan of it, also the LPG tank was expired so I cound't get ok to drive the car) and found the parts to rebuild my spare wheel support (it was taken down to make room for the LPG tank).
I finally got the shock absorbers (standard) ant I'll fit them next week, I hope. Also, I'll have to weld the exhaust back as it was taken down. I hope in about 2-3 weeks to have the car registered and able to drive it more than 40m around the block.
I love how the old radio fits! (I know it is not the one that the Explorer came with, but I can't find that one...).

 

[MrQ]

That thing was run on natural gas?? Wow, rare!

 

[Zvony]

It is very common in Europe to make gas engines to use LPG because it is cheaper (~1/2 the price), but I'm not a fan of it and, also, I want the car to become "historic (classic) vehicle" and that means to be as it was made, so no LPG. I'll try sell the system for about 250euro (aprox 280$).
Even the other one that I have for parts was made to use LPG, but does not have the full system now.

 

[MrQ]

Considering how high your gas prices are the cost of converting to LPG must be really worth it.

 

[Zvony]

Guys,
I need a little bit of help. Can anyone help me with some photos from a 1st gen Explorer spare wheel support? Mine had none (to make room for the LPG tank) and now I'm trying to put one together. I don't know if the wheel is held in place only by that cable-wire or if there is another safety or something. Thanks!
PS: some photos under the truck would be great.

 

[kmack]

The only thing holding the tire up is the cable/winch setup that you show in your post #13. That cable/winch setup is mounted to the cross bar that you also show. I'm at work and my Explorer is at home so I can't get any good pics for you, but the cross bar should be fairly easy to get mounted in place. Then just winch up your spare tire.

Make sure that the tire is pulled up tight. Otherwise, you may hear it "bump" when you go over potholes in the road.

Nice looking Explorer. Love that color!

 

[Zvony]

Thanks for the info!
I wasn't sure because on that bar that holds the winch I found a long screw and I was thinking that is supposed to be somekind of safety, but now I think it was some left over from the LPG tank.

I hope that next year I'll be able to give the Explorer a paint job (same color, but fresh) as it has a lot of dents and scratches.

 

[Zvony]

Managed to put the spare wheel in place (and the whinch), but I forgot to take some pictures. Also, I passed all the road tests, but for some reason I had a waiting time for almost 2months until registration (and license plates). Only 2 weeks left right now, I can barery wait to take the Explorer for a first trip.
Meanwhile, in order to have a lower tax for it (~150$/year instead of the more than 2000 $/year) I made it a utility van (no back seats). After registration, I'll take a risk and put the back seats into the car.
I encountered (I think it is) a problem: while shifting fron N to OD (or D), I can feel a powerful shock and the car moves a little like it. If I shift to R it does not do that. Any ideas what could it be? (I don't know what to search for on the forum)