Lots of updates to get to so here are some things I have done the last few months in no particular order-
My Bosch AGM battery died at 2 yrs old. It would show 12v but didn't have the amps to crank the engine over. I warrantied it out for no cost with PepBoys but they don't sell Bosch anymore and instead sell a Champion AGM battery that I exchanged it for which appears to be made by Johnson Controls like many other Parts Store AGM batteries. The parts counter guy was disappointed too that they stopped carrying Bosch batteries and he said the Pepboys owner has a stake in Champion Auto which is why the switch. As far as Bosch customer service, who I also contacted, I give them 2 thumbs down.
I found a great deal on a new 130 Amp Alternator to replace the 95A factory one which I suspected may have some bad diodes that contributed to the battery death. It was a closeout deal for about $65 with no core needed however it was for a 7.3 Powerstroke Application. With a little research I found it would work and all I had to do when I got it was swap to the Explorer pulley. With the Winch, lights, radio and so on the charging system and battery should be a little happier. (I also have one on my other Explorer but it was from a 94 Explorer Limited application)
In addition to the 2, 2.5lb dry chemical fire extinguishers I carry I added another one, an Element E50. It is like a road flare and you strike it off and the chemical reaction puts out a fire with a 50second capacity which is MUCH longer than the small 2.5 extinguishers and in a much smaller package. Plus, it doesn't leave a mess. I fabbed a simple bracket with some clips from McMaster to mount it on the side of my seat for easy reach.
I also got to thinking about adding an aftermarket steering wheel that was a bit smaller to allow for easier entry/exit because it is a non-tilt column and the cage and high bolster seats make it a little more difficult. I found that Grant makes an adapter kit for the 1st Gens and I have used their wheels in the past with good luck. I ordered the Grant Kit 4288 and 414 wheel. Got them in and started the install when bolt-on became a much bigger project because of Grant's fit, finish and quality.
The steering column cover is punched with a worn-out punch because of the large burrs left so I had to sand those down flat. With the wheel tightened down the column cover rubbed the column so hard it made it hard to turn so I had to make a spacer plate. Reassembled that and found the decorative bolts in the wheel protrude out the back too far pushing the cover into the column so I had to remove those and grind them down flush. The reason this happens is that the Explorer cover is purposely offset when the wheel is straight so for a normal application that shouldn't happen. Two of the decorative top bolts were loose and stripped so I welded up the holes and re-drilled and tapped them.
Their horn button design is one of the worst I have ever seen. The cap "threads" over a fiber disc with a spring that when applied pushes two plates to make contact. After 20 tries to get the cap locked on I tested the horn. 1st one worked great, 2nd tap and the horn stuck on so I quickly pulled the fuse. After reading many forums it is clear that the Grant horn should be thrown in the trash. When it fails, the horn fails in the on position. I debated what to do and came up with a plan. I fabricated a small plate with two standoffs for a 10-32 bolt that I would bolt my own cap on. I found a small momentary push button switch at my local electrical parts supply and wired that to the only part of Grant's horn kit that is worth keeping. It turned out pretty good I think but this simple swap was much more involved than it should have been. The steering wheel is smaller by the width of the stock wheel all the way around and does make it a little easier getting out of. So if it isn't obvious, no I would not recommend the Grant kit and their steering wheels aren't what they used to be 20 years ago.
Lots more updates to come eventually...
