Ranger one - my son’s first Ford. 98 stepside build by 410customs

[410Fortune]

I could have drilled a hole in this one too!! Knowledge is power

Mortar mixing trays are like $12! Best drain pan ever

This is the 5r55e silly 2004 Mazda b4000 4wd

 

[410Fortune]

So e ranger got some era correct side steps!
They look awesome

Had to drill 4 holes per side, made a cardboard template and it worked out awesome

Now I’m taking the valve Body out of the trans and installing new gaskets, a trans go shift kit (fix known issues) also replacing the epc and shift solenoid 2 while in there

She still has a rough 1-2 shift and the infamous 2-3 flare after a forced downshift. Leaks in the epc circuit very likely
Probably caused by my dumb ass having the wrong filter in there during testing… the trans was cavitation / starving for fluid and then that’s when the 5r55e valve
Body started to have issues, basically self torture! Par for the course

Battle on!

Oh and I removed and cleaned the ac orifice tube and vacuumed the system, it held vacuum overnite so the system is good to go and will get a full charge

Tube was cleaned w carb cleaner and air, installed back in line

 

[410Fortune]

Time for some fun!
Trans still has a couple of harsh shifts, they occur after I do a forced downshift

This is typically a pressure issue in the epc circuit, a failed or weak epc solenoid, the solenoid for 2 shift also suspect as well as a possible stuck valve

So the valve body is coming out

Look ma! No epc screen!
So now we know a tsb was performed
By ford on this unit… good

This vented end cap was part of the tsb

So with the bonded separator plate getting the gaskets off os next to impossible without a ton of scraping and sanding
Unless you know this trick!
Boil the plate in water
Water destroys trans gaskets in short order
Now the gaskets peel off much easier

 

[410Fortune]

Time to install some updates
The transgo shift kit!
I am replacing the gaskets, ss2 and epc
Solenoid as well as adding the transgo
Shift improver kit to fix many known issues with the 4ld, 4r and 5r55e autos

There is plenty of info out there about shift improver kits from transgo, superior and sonnax. Sonnax is the best and the only one Brett recommends… however I had access to the transgo easily (in town) so that’s what I’m using. I also have access to a spare 2005 transmission if I need another valve body after this (it has a cracked case and pours out fluid in an otherwise working transmission, thanks to my stepson for access to this part if needed)

Rivet is installed here to plug this hole

Hole is drilled through the case here as a pressure relief

Two springs are replaced in the forward modulator and forward control valves /
Circuits

A new pressure relief cap in installed here…
Likely I didn’t need to do this mod since the tsb was performed but since it’s on a different valve I didn’t realize they both have similar functions until later (even though they are installed on different valves? Wild)

Solenoids getting replaced, epc and ss2, epc is a pricey little sucker

This hole in the separator plate,
We actually make it smaller by putting two stainless check balls on it and smack with a hammer until it’s smaller…
(Closes in on itself)


Valve body was cleaned a lot, separator plate also lightly scuffed w scotch brite and cleaned. New gaskets aligned and one more mod to make… transgo has you plug a hole using a strange wire situation… it worked out ok but was very tight fit going through the plate

All buttoned up
Lower gasket and separator
Plate installed. You can see the little wire poking up.. that is the final step to the transfo kit
Now to install and then road test

Fingers crossed!
Brett has a valve body ready to send me if I screwed this up hahahah and I have a known good 2005 one if needed… Brett’s valve body would be the best choice as he does this all the time and is a master at the sonnax updates
Brett does not recommend the trans go kit because they have you drill two holes in the case


Hard to see here but this pressure relief hole was drilled through the bottom of the valve body… part of the trans go kit

 

[410Fortune]

Well the shift kit did not fix it

Gets warmed up starts shifting really hard from 1-2, 2-3 and 3-4-? Not sure I count 3 harsh shifts from a dead stop
So thinking it must be in the valve body I re visited this pan 3 times. I took the vb out again and checked all it over… still same
Issue. Then I went and robbed a known good valve body from a 05 ranger my stepson has with a cracked trans case…. Same result with thay valve body. So i did what any sane ranger Builder would do
I swapped the 5r with another one

Long story short this truck actually
Came with a decent looking 5r… very dirty outside but when I dismantled the truck I noticed it’s a later model 5r and it had a new converter. Now knowing the history of the trans I never put it up for sale and just held onto it … now it’s been re installed into this truck hahaha only this time behind a sohc

This am is the test drive fingers crossed

If it still has shifting issues after this then I’m putting stick in this ***** lmao

 

[410Fortune]

The donor trans was filthy.. they used this truck for coyote hunting as testing mud holes
The trans is clean as can be inside, new converter, new filter, new fluid. It came from a junk yard obviously. Also the second 0ss was never plugged in so we know this trans came from a later truck.
I cleaned it up really good, knocked all the loose dirt off

Truck went on the lift and a few hours later she has a different 5r !!! Fingers crossed

If it still shifts harsh it’s either the custom pcm Or some weird speed sensor issue… I doubt it. The trans I pulled it gushing clutch material… in just a few short drives it smelled like burnt clutch and the fluid was turning dark.. plenty of black dust on the magnet

Back together!

Little trick for getting the upper starter bolt on a 4.0

Bye bye 2005 trans w low miles? What happened? Something broke in the wreck? Maybe I killed it being in a converted truck? I’m going to send this unit to Brett as a “builder”
Maybe he can see what went wrong inside. Expensive pos!! Cost me a ton of time and headaches
Welcome to the game!

New unit in place

Still dirty even though I knocked 90% of the loose dirt off this sucker…

 

[Josh P]

If it still has shifting issues after this then I’m putting stick in this ***** lmao

The 5 stars says it's a good idea.

 

[410Fortune]

Finally she is shifting properly
Engine runs so smoothly I can hardly tell it’s running at a stop light. All my other rigs are cammed v8 or diesels so there is never a time when you don’t know it’s at idle hahaha this sohc runs smoothly
I have put about 200 miles on this sucker now since built, most of them testing the stupid transmission. Good time for an oil change and I plan to install manual timing chain tensioners. Lucky for me the 2005 style intake plenum allows direct access to the drivers tensioner
The engine has cheapo oil in it right now, I will swap over to Mobil one high miles 10-30 for summer and a motorcraft 820s filter. Anytime I have an engine on the stand I like to run it a couple hundred miles and then change the oil and filter. Any bits of gasket or carbon that were left behind hopefully get swallowed up

Swapping the transmission fixed all shifting issues.. what a pain. But this is the game, I am used to it… when you build custom
Trucks using used parts this stuff happens
Funny thing is the “unknown” junk yard mud covered transmission is cleaner inside then the 05 Mazda unit from the low mile donor? Lucky me!

The truck needs a front end alignment (I’ve replaced everything and adjusted ride height a lot)
Next I need to install front d shaft
A few small things like adding the a pillar grab handles and finding a good 98 dome light cover and she will be ready for a paint job later this year, we are going with green Monstaliner

 

[410Fortune]

Well isn’t that nice! I thought it was fixed

Nope

Different transmission, same thing. Starts off perfectly smooth… the more you drive it, hit or miss, the worse the shifting got
That fact that it shifts great for a while and then progressively got worse… all shifts were firm. So we know it is a line pressure issue, meaning this sucker is increase epc pressure for some reason until it’s basically banging in and out of gear.

So this lead me to finally realize that the pcm was the source of the issues

Yes that’s right 3 visits to the valve body
Swapped to a different trans and converter
Same result
Bad pcm
This pcm is a 2005 Mazda pcm that was flashed to have the pats removed. Basically it is now a patsless 04 pcm. And it’s bad

So I was in a tough spot, have another pcm flashed? $$$ and time
Forget that! I know we can run a sohc engine on a ohv pcm… and I just happened to have a 98 explorer ohv auto for parts. So I ripped the pcm, pats module, key and tumbler out of the 98 explorer and installed into this ranger.
Was not terribly difficult, but the result was not good. It ran, and it shifted smooth! But it was gutless and running rich. 98 ohv pcm not compatible with 05 sohc drivetrain.
So i didn’t smart thing
I went looking for a 97 sohc pcm. Before pats. I could also use a 98-01 pcm as long as I can get the pats module and keys too. Off to the junk yards.
I found several sohc auto trucks that would have worked… none of them had the key!!!
Finally the last truck I checked… 97 sport sohc auto, build date of 12-96
PCM was $35
Perfect

So now to install… here is where it got really entertaining

First during all this messing with shifting and what not… I had a vss code during the self test (key on engine off) so I decided to service the rear axle and have a look at the speed sensor and its drive wheel

All checks out
The nasty rear differential fluid was changed,’cover rebuilt

Speed sensor was fine as was the drive gear and diff… 4.1 limited slip!!

98 ohv pcm, pats module, halo key and tumbler installed for testing

Also the now “bad” pcm that is the source of all this crazyness

Welcome to the world of hot rod drivetrain conversions

 

[410Fortune]

So now if you have been following along
This truck was a 99 ohv auto
I converted it to a 05 sohc drivetrain
I used a 05 Mazda pcm flashed to remove pats
I had some issues, like two speed sensors fighting each other… only for a couple of test drives. Fixed that… worked out all wiring and bugs.. running awesome! But shifting was no right
So converted to a 98 ohv pcm… reworked the wiring at the pcm to match 98 explorer v6… added a halo, pats module and keys from 98 explorer donor. Test drive. Find out it shifts great! But barely runs.. note to self… Gen 1 ohv pcm will run a sohc, Gen ii ohv pcm not happy with cam sensor and timing.
Go find 97 sohc pcm… I found one, got lucky

Now to install
I went wire by wire at the PCM all 104 pins to make sure this truck thinks it’s a 97

Junk yard pcm.. heck yes! I walked the whole dang yard the last ditch truck was on the non ford side just sitting there I couldn’t believe it… the one I needed! Happy

Ouch! I work with these traffic corp dudes, I fix and modify rangers for him. Saw one of his trucks at the yard. Hit a dump truck doing 40,’driver got a broken nose that’s it

Now
I built some maps on paper. The actual truck vs 97 sohc pcm

Many wires were moved
Here’s the run down
97 sohc has a variable intake valve, there is one wire that controls it. I simply ignored that wire
97 sohc has an input shaft speed sensor and a oss sensor on the trans, ignore the 01+ iss/tss sensor on the trans
97 sohc has 4ea 02 sensors, my truck has 3…. Even through the pcm harness and engine are wired for 4!!!
Some wires moved locations so very carefully, pin by pin, the pcm wiring was changed to match 97

 

[410Fortune]

How much sleep can one truck cause you to lose?

The answer is ALOT!!!

So now with the 97 sohc pcm in place, she doesn’t want to idle… not at first. Probably due to the fact this is a completely different intake lol
Once she runs for a minute or two she realizes she needs to catch the idle… and then we are good for the rest of the day! Runs fine. Starts right up, idles good… more importantly… shifting correctly!!!!



Of course I get a check engine light eventually… for the missing 4th 02 sensor. I can easily add one to the exhaust

So far so good! Only a few short test runs but it runs like a different truck, the trans is good and it’s learning.

Now because I installed an explorer pcm I had to re wire the ac
The ranger and explorer control
The ac way differently
Some changes required to the ac wiring at the pcm, low pressure switch, compressor clutch and ac relay

Here is the goal to making your ranger work with an 96-01 explorer PCM

Access underside of
Pjb and ac relay.

The ground side of the ac compressor is changed from its original
Source to a new spot. Basically the ground side of the compressor
Clutch is now fed from passenger inner fender ground, through the low pressure switch then to the high pressure switch then over to the ac relay ground. The positive wire is triggered by the relay. The relay is controlled through the dash .
More on this later… now I have a running shifting truck and working ac

I can finally test drive the crap out of this thing before finally handing it over to my son… this has been a 8-10
Week battle! This is all happening in my spare time! Between scheduled work and other projects. I am very happy to finally be winning

This is the goal at the ac relay. Make it happen captain

Son and his buddy in his Ranger.. was
Hoping to hand him the keys… turns out it was still shifting crappy so back to the shop

Did get some pics of the cool lights. The front turn signals are sequential!! Cool

Test driving now, will get some good exterior shots and video

 

[GRNMACHINE]

Insane amount of work and knowledge and ability!!! Out of all you have done I can confidently say the only thing I would be fully capable of doing is the Rear Axle Cover Rebuild... Seriously, impressive work and determination!!!

 

[Josh P]

Still needs a M5OD transmission

 

[410Fortune]

Or a v8

 

[Josh P]

Or a v8

Yes, either a 302 or a 351W. Then then transmission choices are unlimited.

 

[allmyEXes]

I've only scanned your post and when I get to work, I will read it more thoroughly. I have a question about the later style intake electric operated
variable intake runner flapper deal. When the engine is running, is the vacuum created opening it? Or do you physically have it zip tied open or could a low voltage signal having to do with another sensor be wired to it?
I was wondering if it is acting like a manual choke with it defaulting closed. I'm asking because I'm ignorant to this later model set-up with the flapper.

 

[410Fortune]

The flapper went away
The 97-99? intakes had the variable intake runner it is controlled by one wire. It’s not hooked up on my truck, that one wire

No codes for that yet

My 05 intake does not have a flapper lol lol
Basically that old valve changed the length of the intake runners as you drove, maximizing torque? Silly ford

I do have codes… for the mia 02 sensor (bank 2 sensor 2) and a speed sensor circuit code which maybe near impossible to remove while running the 97 computer
In 97 they had a speed sensor that made 8000 ppm,
My truck here the 1998 abs pump is taking the rear axle vss and making the 8000ppm, but the computer wants to see the + and - wires hooked directly to that sensor for feedback or I get a p0500 circuit issue. I’ve dealt with this before. I think the only way to get rid of the code would be to actually wire in a vss…it doesn’t have to actually generate the 8000ppm, it just has to be on the end of the vss + and - wires

I can weld in a bung and add a second downstream sensor…
I have a small coolant leak at the temp sensor on the thermo housing
I lost an alternator yesterday, replaced with another. It was at 12.8-13.2 volts now she’s steady at 14.2 when running

I think the plan of attack now maybe get a 2001 sohc pcm and have you turn the pats off.. or just find one with the key and pats and wire it in… the 01 pcm would be better because it only had 3 02 sensors and it’s more closely matched to my 05 engine
But right now anything is on the table including a 5 speed conversion. And or a v8

New lower ball joints (Dorman hd) upper control arms (Moog), inner and outer tie rods and sway bar links will be here today

Stay tuned I’m
Working through these issue but once again the 92 solid axle v8 5’speed has taken center stage in my shop and will get the bulk of my time. It was to be completed about a month ago… I’m like 6 weeks behind “schedule”

I’m also helping dad with some elevator work (rope less “future” elevator studies, quite interesting! and been working on some projects over at the mountain mafia shop… I get pulled in many directions.
They say if you love what you do it’s not work.. man that is a true statement

We finished this rig

And now we are putting a 94 Camaro efi 350 and 4l60 into this 70 c10

I love my work

I know I know it’s a bow tie! I get xp points

 

[410Fortune]

Insane amount of work and knowledge and ability!!! Out of all you have done I can confidently say the only thing I would be fully capable of doing is the Rear Axle Cover Rebuild... Seriously, impressive work and determination!!!

Thank you very much
You nailed it!
This has been one of the most challenging conversions I have ever done.. because I am a glutton for punishment.

You see I have the entire 05
Mazda donor…

I could have just wired the truck bumper to bumper to be a 05 and had zero of these issues. But an 05 has a different firewall, the 3 large bulkhead connectors on the drivers side under the brake booster do not exist in a 05 and there is a larger
Hole in the passenger side of the firewall for the pass kick panel mounted fuse box. I didn’t want to hack up the 99 firewall or plug big holes in the metal.. so my brain had me instead try to simply “wire in” the 05 computer and its security… that didn’t work. That lead to the custom flashed pcm, some wiring issues, a bad pcm. Many months sorting out the bad pcm by messing with 5r55es and now we have come to this! When wired in the 98 ohv computer from
And explorer I was right back to where I would have been over a year ago if I just kept the 99 ranger pcm! Bwahahahahahahahaha
But where is the fun in that?

This project was called project “spare parts”… now it’s called projects “give me a break”

I spent all these years avoiding the sohc engine and 5r in my fleet… hahahahahaha I stuff v8 in everything. This truck started out was going to be a simple flip… but she grew on me and I decided to keep it for my kid…. I am determined to get him a v6 with 5 speed so he can get decent mpg hahahahahahaha yeah right this thing is faster then a stockish v8.. so this is payback of sorts, the sohc and 5r is mad at me for all the **** I talked about them over the years.

Thanks for the kind words I knew you dudes would get it

 

[donalds]

This project was called project “spare parts”… now it’s called projects “give me a break

Lol

 

[allmyEXes]

Was that an '05 pcm that I flashed to '02 PATS off. Get an '02 pcm and I will flash it with my '02 PATS off program then you can switch a few wires around to 2002.
The variable flapper. It all makes sense now that you said you removed it.
Get and send a 2002 SOHC pcm and send it and the one that you are calling '05. I can re-flash it and you can try it out on a same year Ranger sometime to see if it is damaged or not. I think that I mentioned the hardware codes are apparently different for a reason, because of the number of O2 sensors to name one.