91 body swap

[Dylan94EX]

I have a 91 explorer 4x4 manual rear quarter panels are destroyed, I found a 94 explorer with a good body, what is needed to do a body swap, I can’t find many write ups on what to do

 

[410Fortune]

Not much 91-94 body basically the same
It’s physically intense have to remove all body mounts and wiring some plumbing
Then somehow lift the old body off (or cut into pieces)
Pull the frame and drivetrain out, transfer to under the new body
Basically your gonna be doing the labor twice
Will want to get all new body mounts and hardware at the minimum

Expect to be battling many rusty fasteners and brake lines
Expect to find many parts needing refinishing or upgrading

Maybe easier
Just to fix the 94 using parts from 91?

There are few differences between 91 and 94
94 is better in many ways

91 has crappy power distribution box
Single 02 sensor

 

[Dylan94EX]

Not much 91-94 body basically the same
It’s physically intense have to remove all body mounts and wiring some plumbing
Then somehow lift the old body off (or cut into pieces)
Pull the frame and drivetrain out, transfer to under the new body
Basically your gonna be doing the labor twice
Will want to get all new body mounts and hardware at the minimum

Expect to be battling many rusty fasteners and brake lines
Expect to find many parts needing refinishing or upgrading

Maybe easier
Just to fix the 94 using parts from 91?

There are few differences between 91 and 94
94 is better in many ways

91 has crappy power distribution box
Single 02 sensor

The 94 has some title issues might be some work, I just spent a bunch of time registering the 91 before realizing how bad the quarter panels are, 91 is a 4x4 with a manual why I want to keep that one, runs decent still working on that part, I’m pretty mechanically inclined already did motor mounts, new brakes rotors and hubs put a 2” skyjacker lift on, so just trying to be realistic if the bodies can be swapped

 

[410Fortune]

Yes can be done
Helps to have a lift but can be done with jacks and Timbers

Explorer body is a big deal, 4 door heavy suv but I’m not afraid of a project like this can be done in a weeks time if motivated
Make sure that blue body doesn’t have hidden rust that would make this all not worthwhile

Could also fix your 91 body and do a simple paint job? Maybe even truck bed liner coating? I love my
Monstaliner paint jobs…
Under $500, rolls on, still oooks great after 10+ uears

If your gonna do it strip everything off that blue truck now so you can have a look there actual condition of the quarters
Rockers floor pans and hardware getting the carpet and seat out remove fenders doors makes it a lot lighter for the transfer

 

[allmyEXes]

Just use the "parts" truck for its skins. If you need a quarter skin, cut one off of the donor truck. Jamie is correct. A major body swap would involve a well-equipped shop with 2 lifts to really make the process go smooth. The front end out from under the blue one is worth a few dollars.

 

[Dylan94EX]

Yes can be done
Helps to have a lift but can be done with jacks and Timbers

Explorer body is a big deal, 4 door heavy suv but I’m not afraid of a project like this can be done in a weeks time if motivated
Make sure that blue body doesn’t have hidden rust that would make this all not worthwhile

Could also fix your 91 body and do a simple paint job? Maybe even truck bed liner coating? I love my
Monstaliner paint jobs…
Under $500, rolls on, still oooks great after 10+ uears

I appreciate it first post first big job for me by myself, my quarter panels are rough or I for sure would, I was thinking fiberglass but I enjoy the clean straight body so much more it’s super clean body why I’m so motivated for the swap

 

[Dylan94EX]

Just use the "parts" truck for its skins. If you need a quarter skin, cut one off of the donor truck. Jamie is correct. A major body swap would involve a well-equipped shop with 2 lifts to really make the process go smooth. The front end out from under the blue one is worth a few dollars.

It is a big job but how big of one, I’m trying to find a write up on what needs unplugged to see how do able it is I’m more of a mechanic than a body work guy

 

[410Fortune]

Might be able to find posts for a ranger cab swap… would be similar

It’s pretty
Obvious I mean if it’s connected to the frame and body, drivetrain and body, it’s gotta be disconnected..
Just like pulling an engine start around the outside and just keep going till it’s all free

Gantry crane, cherry pickers, tractors, chain fall, all of these things can make life easier heck you can make some slings from a grouping of trees… where there is a will there is a way
I would take the donor apart first,,, then your driver

 

[amj441]

It is a big job but how big of one, I’m trying to find a write up on what needs unplugged to see how do able it is I’m more of a mechanic than a body work guy

For ford cab offs you will need to disconnect the following:

- battery cables and retainers that click into the body
-PCM harness from firewall.
-Engine harness from fuse box
-vacuum lines from engine to accessories
-Master cylinder from brake booster (ABS Module if equipped unsure of 1st gen)
-coolant hoses from heater core
-rad hoses
-radiator
- trans cooler lines
-intermediate steering shaft
-grounding wire from engine block to body
- grounding strap from passenger side frame rail to passenger floorboard
-A/c evaporator box (let the evaporator just sit with the engine)
- evap canistor/lines (if the first gen is like the 2nd with it under the battery.
-fuel filler neck

**If I remember anything else, Ill put it here, but that should be all of the major ticket items.
Ive done a few f350s and an f150. its similar for all ford trucks. (granted with a lift. i highly recommend a lift)