1992 explorer gets a solid axle and v8 5 speed

[410Fortune]

Here she is! My next victim

This sweet, well used, and well setup family rig has come to my shop to get some upgrades

The plan is simple
Delete the ttb and install a high pinion Dana 44 solid axle
V8 power plant with m5od-r2 manual, 4406
Manual transfer case

Rebuild and upgrade the 8.8 rear axle

Dual arb lockers
Lots of new along the way

So join me as I dismantle the existing and build up the new

Parts have been coming in for a while
Truck has been in my possession since last October?
Scored a eb d44 from a friend of mine that was slated for another build that never happened

Here we go, tomorrow is day one
Inventory parts, clean and then drain fluids
Start dismantle

 

[1sicbronconut]

Doing the C clip eliminator kit to the 8.8 to get a 5x5.5" bolt pattern, been tempted to do the SAS at times since I have a spare EB Dana 44 in my parts horde.

 

[bnbader]

Subscribed

 

[Josh P]

351W?

 

[WormsExplorer]

Want to see this one.

 

[donalds]

yes new builds

 

[410Fortune]

This is happening as we speak! Hang tight updates coming, I’m still playing catch up from being down basically all of February with the flu virus b , bird flu, pneumonia side effect it was rough! I’m still gaining my voice back and having coughing fits… but manageable. Home shop has been deep cleaned and organized in prep for bringing this beast into bay 1. That happens tomorrow/ Friday March 07. The tear down will happen very quickly and the buildup is very straight forward… here we go!

 

[Josh P]

Details on the motor going in?

 

[410Fortune]

Gt40p 5.0l 302 from a 2000 explorer currently has 147k miles on it (don’t quote me on that it’s still outside under some snow) thing runs like a top.. the kid I got it from paid his buddy to do a waterpump only to find out the timing cover is the leak… lots of new tune up parts trying to get it running just to give up on it after that repair. When I say it runs good I mean it is one of the best running 5.0 I have seen in a long time. I drove it a few blocks to get on my trailer and will run it some more (with video) before the teardown

The rest of the truck is a total disaster been wrecked, missing glass, ripped up interior, etc etc . I Will be doing lots of pics and videos on this build.

The engine will get a refresh performance camshaft and tune up bits.. real
Typical 410 build…we are sticking with stock manifolds for now. The goal here is reliability with a side of reliability

Sorry Josh, no 5.8 in this one… lol

 

[bnbader]

This is happening as we speak! Hang tight updates coming, I’m still playing catch up from being down basically all of February with the flu virus b , bird flu, pneumonia side effect it was rough! I’m still gaining my voice back and having coughing fits… but manageable. Home shop has been deep cleaned and organized in prep for bringing this beast into bay 1. That happens tomorrow/ Friday March 07. The tear down will happen very quickly and the buildup is very straight forward… here we go!

Can't wait to see it happen. Thanks again Jamie for taking on this build I know you've had a tough couple of months. Can hardly contain myself! If anyone has any questions about the original rig/build and the new build feel free to ask away. Also, can track along for the ride on mine and Jaime's youtube channels.

410Customs

Off Grid / Off Road, Private Customs Shop in North Idaho. Specializing in Ford Ranger based trucks (RBV), Toyota, atv, utv, and sleds. I customize entire vehicles from bumper to bumper. Drivetrain conversion and wiring specialist, suspension fabrication, electrics and custom interiors. I have...

www.youtube.com

and

Overtime 4X4

Overtime 4x4 is a lifestyle 4x4 offroading channel based in the Pacific Northwest (PNW) of the USA. Created by childhood friends Nick and Ben, Overtime 4x4 exposes our audience to the amazing scenery, camaraderie, great food and best offroading/overlanding locations in the PNW. Offroading is a...

www.youtube.com

 

[bnbader]

Throwback Thread - Then to Now. Jamie called it in comment #3, 5 years ago...

New Member: 1991 Ford Explorer XL 4X4 ("The Papa's Truck")

Hi All, I have been utilizing the forum as a resource for years now but haven't posted anything to this point. I first of all want to say how much of a help and a resource this forum has been and I feel like I should at least contribute something to the forum after years of using it! In any...

www.explorerforum.com

 

[410Fortune]

Hahahahaha cool!!!

 

[410Fortune]

Score
M5od-r2
Bw4406m
And all the trimmings in hand
Trans was rebuilt a few years ago
They both shift very smoothly
Story is the 4.2l v6 seized up then the guy / shop parted his f150
Super score for us because I didn’t have the pull these and these are getting harder to find especially in excellent working condition
Thank you Internet!

The shop os spring cleaned, the fluids are drained and the stock drivetrain is coming out
I have about 100 boxes to open and parts laid out all over the place. Taking inventory
This project is now front and center

Our road is now super nasty with mud so I decided to take this project on at the city shop…
This is going to be one sick gen 1

Been spending some time with the truck. For a 92 it runs sooo smoothly. The old 4.0 and trans will be given a good home (b2)
I like the manual windows and locks, cloth interior and non broken door handles. This thing has been well cared for to say the least.
Video and pic coming

I thought this was cool.. aux switch box hung like a cb radio … nicely done

Taking her apart I discovered she is a 1992 lol not a 94
So I changed the title of the thread
I got to the wiring distribution box and I’m like that’s not a 93-94 box… sure enough door tag says 92

 

[410Fortune]

Couple of hours later
It has been a while since I messed with a gen one
92 power box

All work under the hood done
Now for the underneath
Engine trans t case will be out shortly
I’m gonna keep her rolling for another day so I can power wash the engine bay and undercarriage

 

[410Fortune]

Working underneath
Got her way in the air more room to work

We can see this truck has a full 6”
Trailmaster suspension under it. Once nice thing about the trail disaster lift is the eccentric cams on the beam pivots and radius arms. This kit will find its way into a bii project I have planned

The rock rail on passenger side was welded directly to trans cross member so I had to cut it. I will cut it off the frame and then slug it and weld it all back when we are done

Also note the fancy exhaust, the big oval was closed with some flat plate and a 2.5” single tube was inserted. I cut the exhaust instead of messing with these old bolts
The v8 will get a new setup with a flowmaster dual in single out muffler

My blade broke so I need to run get another torch Blade for my sawzall
I’m soaking the starter and front d shaft bolts right now… they are very tight. I already broke the lower starter bolt… will extract that piece later

 

[Josh P]

the trail disaster lift

410 approved!

 

[bnbader]

Haha it's what my early 20s self could afford.. my friends and I put that lift in there originally. Had a few issues and breakages along the way where some of the metal plating around the drop bracket had to be welded up after it cracked along the welds but with the new welds in its held up perfectly since then. I hope the James Duff parts are higher quality off the gate but this particular lift kit with the extended radius arms will give you the lift you need to fit 33's on a budget. As always, you get what you pay for. The exhaust was another slap job i did, not proud of it but made it work. Mandrel bent stainless exhaust going in with Jamie's help.

 

[dvdswan]

Excited to see this one...

 

[410Fortune]

Tuff country lol not trailmaster


The James duff parts are super strong
My bii has been Rocking James duff pivot brackets for dang near 30 years now

Tuff country is decent stuff, not the strongest but works good for most people the drop brackets have always been known to crack on the trailmaster or tiff country lifts… nothing a welder and some plate can’t fix

 

[BKennedy]

My Duff radius arms have held up very well over the last 12 years. I almost went with the Duff solid axle swap kit for Rangers and Explorers, but I wanted to push the axle 2" forward so 35-37's would clear the firewall.