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1991 explorer build

1991 explorer 4x4 build

Hi my name is Mike and I have been watching this site for a while and now that I have started my explorer project I figured I would post it here.

I started out with a stock 91 explorer 4.0 auto 4x4. I picked it up in good running condition for $1000. Since this is not my DD I am taking my time making it a little more offroad worthy.

My plans for this explorer are to use it as a weekend camping vehicle that will see mostly desert trails and mountain roads. With that in mind I am more focused on durability than rock crawl capability. I already have a large amount of parts sitting in the garage and am starting to build this thing. Any ideas or problems you see with what I am doing let me know.I am going to work at putting pictures up and parts list.

Parts list for now

Front suspension
-skyjacker drop brackets for beams
-deaver superflex coils from f150 #csh57
-extended radius arms using stock arm and 2"x1/4" dom tube. bushings not hiems
-extended brake lines
-d35 with 4.56
- upgraded u-joints and c-clip eliminator
-manual hubs
-Fox 2.0x10" shocks
-upgraded swaybar
-Dual piston calipers from 96 ranger

Rear Suspension
-l/s 8.8 with 4.56
-stock leaf springs with SOA
-Fox 2.0x12" shocks
-disk brakes from 97 explorer

Engine
-stock and will probably stay that way

Trans
-M5OD
-manual transfer case with home built shifter and linkage

Wheels/tires
-5 d window steel wheels
- 4 new bfg km2 33/10.50/r15
- 1 used bfg at 33/10.50/r15

Steering
-stonecrusher style steering with chevy tre's



First picture is when i pulled it into the garage. We stripped the front suspension off. since im using coils from an early F150 (deaver superflex 4 in lift) i cut the coil buckets off as well. I have skyjacker drop brackets, have built my own radius arms using the stock arms, I am working on mounting coil buckets from an early bronco.
 

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Ageman

Well-Known Member
Joined
June 25, 2010
Messages
143
Reaction score
0
City, State
Buena Park, Orange County CA.
Year, Model & Trim Level
'92 5 speed 4x4 Explorer
Where is SoCal, and post some pictures if you can
 








mj1989gt

Elite Explorer
Joined
September 7, 2011
Messages
109
Reaction score
5
City, State
Yucaipa Ca
Year, Model & Trim Level
1991 explorer
Does anyone have a good suggestion for the rear. I would like 4inches of lift. I want to put deavers in but dont have the $700+ to buy them. Are skyjacker leafs good for around $450? or maybe F150 leaf mod with longer shackles?
 




mj1989gt

Elite Explorer
Joined
September 7, 2011
Messages
109
Reaction score
5
City, State
Yucaipa Ca
Year, Model & Trim Level
1991 explorer
Got my tires already. BFG KM2 33/10.50/15 . am waiting for my other 3 wheels to show up. I am using these coil buckets from Duff along with there lower coil plates to give my springs a solid mount
 

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mj1989gt

Elite Explorer
Joined
September 7, 2011
Messages
109
Reaction score
5
City, State
Yucaipa Ca
Year, Model & Trim Level
1991 explorer
Finally got the explorer back on the ground. No axles or anything installed just figuring out where to place the coil buckets to get the right amount of lift i want. Now i have everything back apart so i can finish welding and drilling mounting holes
 

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  • coil bucket mockup.jpg
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Sams01XplrSprt

Southern Cali Explorer
Joined
November 14, 2004
Messages
14,224
Reaction score
2
City, State
Newport Beach California & Bay Area California
Year, Model & Trim Level
2001 Sport (sold)
looking good where in so cali u at im in newport beach
 
















mj1989gt

Elite Explorer
Joined
September 7, 2011
Messages
109
Reaction score
5
City, State
Yucaipa Ca
Year, Model & Trim Level
1991 explorer
I need to have the explorer out of the garage for the next two weeks so i had to get the front back on the ground. Got everything bolted in. Upper shock mounts built using hacked up f250 towers. I still need to build the lower mounts on the radius arms. I finally put the axle shafts and diff in. Looks great with the rear suspension and tires stock- i think i'll leave it;). Those deaver front springs are very soft. I am going to need the sway bar for sure.
 

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mj1989gt

Elite Explorer
Joined
September 7, 2011
Messages
109
Reaction score
5
City, State
Yucaipa Ca
Year, Model & Trim Level
1991 explorer
Grabbed the disc brake 8.8 from the junk yard. Took it apart today and am now getting it back together with 4.56 gears and new bearings. I'm leaving the l/s for now until i can get a good locker. I am hoping to have this axle in the truck thius week.
 

Attachments

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mj1989gt

Elite Explorer
Joined
September 7, 2011
Messages
109
Reaction score
5
City, State
Yucaipa Ca
Year, Model & Trim Level
1991 explorer
Got the axle in last night and did a spring over conversion. ended up with around 5inches of lift. I still need to build shock mounts and finish up the brake lines.
 

Attachments

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mj1989gt

Elite Explorer
Joined
September 7, 2011
Messages
109
Reaction score
5
City, State
Yucaipa Ca
Year, Model & Trim Level
1991 explorer
Got the brake lines finished and bled the brakes. I put the old wheels and tires back on while it gets painted. I did a side job for the painter at my work so i get a free paint job. I been polling all my friends about what color to paint it and i think I'm going with desert tan. I even got the explorer fired up again and ran it for a while.

the last picture is of my buddies 03 ranger 4x4 with a dana 44ttb in front. He has a real nice truck and just needs the suspension tuned to make it fly in the desert.
 

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mj1989gt

Elite Explorer
Joined
September 7, 2011
Messages
109
Reaction score
5
City, State
Yucaipa Ca
Year, Model & Trim Level
1991 explorer
I got the explorer down to my work and the body guy has already gotten the body repair done. The body was really in good shape and only needed a little work in a few spots. Hopefully the painter can get to it in the next week or so. I havn't been able to work on this thing for a while and am ready to get it finished.
 

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jd4242

Explorer Addict
Joined
October 15, 2008
Messages
10,789
Reaction score
286
City, State
va beach
Year, Model & Trim Level
92explorer&94 ranger
you have to use one from a 95 with no abs,no cruise and no proportioning valve.
 










Join the Elite Explorers for $20 per year. Gets rid of the ads! New $5 per month "try out" option.

Explorer Forum has probably saved you that much already, and will continue to save you money as you learn how to diagnose fix problems yourself and learn which modifications work without having to experiment on your own. Elite Explorer members see no advertisements, no banner ads, no double underlined links, can add their own profile photo, upload photo attachments in all forums, and Media Gallery, create and save more private Conversations, and more. Join Today. Your support is greatly appreciated.




mj1989gt

Elite Explorer
Joined
September 7, 2011
Messages
109
Reaction score
5
City, State
Yucaipa Ca
Year, Model & Trim Level
1991 explorer
The painter has been slowly getting the explorer preped for paint. He has the whole thing sanded down and ready. Now we are just waiting for some time in the spray booth. Should have paint in the next day or two.
 

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