• Register Today It's free! This box and some ads will disappear once registered!

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.
 

Attachments

  • before.jpg
    before.jpg
    99.3 KB · Views: 1,826
  • springs.jpg
    springs.jpg
    90.6 KB · Views: 1,663
  • frame cut.jpg
    frame cut.jpg
    99 KB · Views: 1,657
  • dr frame plate.jpg
    dr frame plate.jpg
    98.7 KB · Views: 1,699


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.






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
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.
 

Attachments

  • on trailer 4.jpg
    on trailer 4.jpg
    101.1 KB · Views: 871
  • on trailer 3.jpg
    on trailer 3.jpg
    100.7 KB · Views: 858
  • on trailer 2.jpg
    on trailer 2.jpg
    90.5 KB · Views: 856
  • on trailer 1.jpg
    on trailer 1.jpg
    101.1 KB · Views: 871




mj1989gt

Elite Explorer
Joined
September 7, 2011
Messages
109
Reaction score
5
City, State
Yucaipa Ca
Year, Model & Trim Level
1991 explorer
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.
 

Attachments

  • 2012-02-02 13.12.37.jpg
    2012-02-02 13.12.37.jpg
    98.5 KB · Views: 851
  • 2012-02-02 21.39.24.jpg
    2012-02-02 21.39.24.jpg
    99.5 KB · Views: 828
  • 2012-02-02 21.39.36.jpg
    2012-02-02 21.39.36.jpg
    97.7 KB · Views: 818




mj1989gt

Elite Explorer
Joined
September 7, 2011
Messages
109
Reaction score
5
City, State
Yucaipa Ca
Year, Model & Trim Level
1991 explorer
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

Explorer Addict
Joined
October 15, 2008
Messages
10,789
Reaction score
286
City, State
va beach
Year, Model & Trim Level
92explorer&94 ranger
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

Elite Explorer
Joined
September 7, 2011
Messages
109
Reaction score
5
City, State
Yucaipa Ca
Year, Model & Trim Level
1991 explorer
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.
 

Attachments

  • 2012-02-08 22.15.56.jpg
    2012-02-08 22.15.56.jpg
    47.6 KB · Views: 725
  • 2012-02-08 21.43.20.jpg
    2012-02-08 21.43.20.jpg
    93.8 KB · Views: 746
  • 2012-02-08 21.42.42.jpg
    2012-02-08 21.42.42.jpg
    93 KB · Views: 751
  • 2012-02-08 21.28.36.jpg
    2012-02-08 21.28.36.jpg
    100.2 KB · Views: 754




mj1989gt

Elite Explorer
Joined
September 7, 2011
Messages
109
Reaction score
5
City, State
Yucaipa Ca
Year, Model & Trim Level
1991 explorer
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.
 

Attachments

  • rear bumper 1.jpg
    rear bumper 1.jpg
    91.1 KB · Views: 735
  • rear bumper 2.jpg
    rear bumper 2.jpg
    45.3 KB · Views: 687
  • plasma cut.jpg
    plasma cut.jpg
    98 KB · Views: 714




crazyflights

Explorer Addict
Joined
August 31, 2008
Messages
2,528
Reaction score
20
City, State
St. Joseph, MO
Year, Model & Trim Level
97 1 ton Jeep
really liking your rear bumper! project is looking great!!
 








wood1

Explorer Addict
Joined
May 3, 2007
Messages
2,921
Reaction score
4
City, State
North of Edmonton
Year, Model & Trim Level
'93 XLT, Cayman Green RIP
Looks great dude, nice fab skills.
 








Trckmagik

Ole Bag
Moderator Emeritus
Joined
August 22, 1999
Messages
4,771
Reaction score
1
City, State
Celina, Texas
Year, Model & Trim Level
1996
Looks Great.
 




mj1989gt

Elite Explorer
Joined
September 7, 2011
Messages
109
Reaction score
5
City, State
Yucaipa Ca
Year, Model & Trim Level
1991 explorer
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
 

Attachments

  • 2012-03-15 21.47.03.jpg
    2012-03-15 21.47.03.jpg
    100.4 KB · Views: 648
  • 2012-03-19 18.52.38.jpg
    2012-03-19 18.52.38.jpg
    87.6 KB · Views: 614
  • 2012-03-19 18.52.08.jpg
    2012-03-19 18.52.08.jpg
    71.3 KB · Views: 501
  • 2012-03-19 18.52.19.jpg
    2012-03-19 18.52.19.jpg
    76.1 KB · Views: 550




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 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.
 

Attachments

  • 2012-03-19 20.42.50.jpg
    2012-03-19 20.42.50.jpg
    94.7 KB · Views: 668




mj1989gt

Elite Explorer
Joined
September 7, 2011
Messages
109
Reaction score
5
City, State
Yucaipa Ca
Year, Model & Trim Level
1991 explorer
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
 

Attachments

  • 2012-03-23 09.50.11 (1).jpg
    2012-03-23 09.50.11 (1).jpg
    100.4 KB · Views: 621
  • 2012-03-23 13.05.36.jpg
    2012-03-23 13.05.36.jpg
    96.9 KB · Views: 622
  • 2012-03-24 18.20.58.jpg
    2012-03-24 18.20.58.jpg
    87.3 KB · Views: 639




cmhaah06

Elite Explorer
Joined
March 30, 2007
Messages
633
Reaction score
1
City, State
CLOVIS, CA
Year, Model & Trim Level
91 XLT
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

Elite Explorer
Joined
September 7, 2011
Messages
109
Reaction score
5
City, State
Yucaipa Ca
Year, Model & Trim Level
1991 explorer
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.
 


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.




FROADER

Staff member
Moderator
Elite Explorer
Joined
January 28, 2000
Messages
19,976
Reaction score
182
City, State
Huntington Beach, CA
Year, Model & Trim Level
1991 Eddie
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.
 




Top