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.

 

[mj1989gt]

Its painted!! I like the color for now but we will see when its all done. It almost looks pink in this picture but its not. Must just be my phone's camera.

 

[wood1]

Looks some purty!

 

[mj1989gt]

Still looks pink in these pics. I need to use a decent camera. I like the way the paint turned out. Now that i finally got it home it's time to finish it up.

 

[mj1989gt]

Started to build the shock hoop for the rear. It's not completely done yet i still need to add some more metal for bracing. I also found a good deal on a m5od r1 on craigslist. He said he got it from a junkyard for a project and never ended up using it. I opened it up and it looks ok inside. I'll add that to the list of things that need to be done.

 

[mj1989gt]

I have done a lot of searching on the internet for threads on using the 4cyl m5od gears in a 4.0 m5od. I would like to do this swap for the lower first gear ratio. Has anyone done this to there explorer. I can only find rangers that have done this swap and was just looking for anyone with an explorer that has tried. I know its the same trans but would like to know how the ratios work with a heavier explorer.

 

[jd4242]

I have done a lot of searching on the internet for threads on using the 4cyl m5od gears in a 4.0 m5od. I would like to do this swap for the lower first gear ratio. Has anyone done this to there explorer. I can only find rangers that have done this swap and was just looking for anyone with an explorer that has tried. I know its the same trans but would like to know how the ratios work with a heavier explorer.

Just get a whole tranny from the 2.9 its a direct bolt up.the lower first gear works great.many people on here use it.i was going to but think ill be doing a 5r and obd2 piggy back instead.

 

[mj1989gt]

I forgot about the 2.9 m5od! Thanks

 

[mj1989gt]

My front shocks came in so i got those mounted. Ended up using fox 10 inch emulsions. I also got the pitman arm replaced with a fa400. Used the reamer to ream out the pitman arm and steering knuckles for the chevy TRE's. The reamer was a real challange but i think i got the holes about right. Next up i need to figure out the steering linkage. I'm going to be trying to build a stone crusher type steering. We'll have to see how it turns out.

 

[mj1989gt]

I am still waiting for my offset TRE's to arrive for the steering so I've started on the bumpers. I picked up a sheet of 3/16 steel and am kinda building it as i go based off alot of bumper ideas i got off this site. I have the rear started. Its just tacked up for now and i may still make a few changes.

 

[crazyflights]

really liking your rear bumper! project is looking great!!

 

[mj1989gt]

I got a little more work done on the bumper side supports

 

[wood1]

Looks great dude, nice fab skills.

 

[mj1989gt]

Got the clevis mounts and hitch reviever cut into the bumper

 

[Trckmagik]

Looks Great.

 

[mj1989gt]

Got the bumper welded up and ready to clean and paint. Steering is done. Only thing that i am waiting for to drive this thing is my driveshafts

 

[mj1989gt]

Finally got the steering finished as well. Took a lot of time and rethinking to get it right but it works great. I need to put some more miles on it to make sure its good to go but as of right now I'm happy.

 

[mj1989gt]

Took the explorer out for the first camping trip this weekend. It worked great the whole tiome and did not give me any problems. I still have a long way to go with this thing but at least its on the road. These are a few pics from anza-borrego state park

 

[cmhaah06]

Nice build. Similar to mine. I love the deaver springs. They flex well and ride smooth. Any more pics on the steering setup? Maybe some close ups or different angles? Oh. If you dont have one, throw a locker in the front. I have gone places with my explorer that people told me I should not have been and its because of the locker.

 

[mj1989gt]

I have seen your truck also and stole some ideas from it -so thanks! I wasn't sure about the deaver springs but I am glad i went with them. I have a steering write up in the modified 91-94 section with more pics. http://www.explorerforum.com/forums/showthread.php?t=346315

I will get a locker in the front eventually. I have a large list of things that need to be done befor the locker.

 

[FROADER]

I was supposed to do Lower Coyote Canyon last weekend, but something came up.

The rig looks good! I like the color and that rear bumper is perfect. Looking forward to seeing the front done.