1996 Explorer Sport 4WD Upgrades

[TexasBear]

Glad to find this forum! I hav zero experience with Explorers, but have considerable experience with other other vehicles.
I purchased this 1996 Explorer Sport, V6, 4WD from an estate. It’s had zero mods an has the 2wd-4hi/4lo with 61k miles on it.
I have a lot of things that I want to do with it, but my initial priorities are moderate lift and larger tires. With the 2-3” plus a 3” body lift (kit for Ranger) I believe that 33” tires will fit well with 2in offsets. I know I need to change gears, but which would be best to maintain drive ability for every day use? Do you have any advice on where to purchase (pert numbers or links would be awesome!) and any other mods available that you can recommend would be greatly appreciated!
Thanks for reading, and in advance for responding

 

[Fix4Dirt]

Glad to find this forum! I hav zero experience with Explorers, but have considerable experience with other other vehicles.
I purchased this 1996 Explorer Sport, V6, 4WD from an estate. It’s had zero mods an has the 2wd-4hi/4lo with 61k miles on it.
I have a lot of things that I want to do with it, but my initial priorities are moderate lift and larger tires. With the 2-3” plus a 3” body lift (kit for Ranger) I believe that 33” tires will fit well with 2in offsets. I know I need to change gears, but which would be best to maintain drive ability for every day use? Do you have any advice on where to purchase (pert numbers or links would be awesome!) and any other mods available that you can recommend would be greatly appreciated!
Thanks for reading, and in advance for responding

View attachment 433794

wow only 60k?!?!? that thing is still a baby! one word is change trans fluid and big cooler, goes a long way

that said yes 33s will fit with a 2" suspension lift and 2-3" BL. howveer i dont think you can do a 3" since to get mild suspension lift the optionsa re something like a superlift which lifts 4" or a TT and shackle which lifts 1"-2". as far as gears imo you can chiose between 410 and 456 456 is for a bit less highway since rpm will be higher thanstock but 410 will be close to havijgba 355 stock iirc? so depends on what you want 410 is certainly more cost effective being that it comes as a factory ratio

aside from that other nice mods are either a nice limited alip or lunchbox locker, some trans VB upgrwdes and thwn maybe a winch bumper? depends on what ya like to do. can check out my rig its called Fix4Dirt '98 XLT iirc if theres anything you ike there feel free to ask.

welcome to EF!

 

[TexasBear]

wow only 60k?!?!? that thing is still a baby! one word is change trans fluid and big cooler, goes a long way

that said yes 33s will fit with a 2" suspension lift and 2-3" BL. howveer i dont think you can do a 3" since to get mild suspension lift the optionsa re something like a superlift which lifts 4" or a TT and shackle which lifts 1"-2". as far as gears imo you can chiose between 410 and 456 456 is for a bit less highway since rpm will be higher thanstock but 410 will be close to havijgba 355 stock iirc? so depends on what you want 410 is certainly more cost effective being that it comes as a factory ratio

aside from that other nice mods are either a nice limited alip or lunchbox locker, some trans VB upgrwdes and thwn maybe a winch bumper? depends on what ya like to do. can check out my rig its called Fix4Dirt '98 XLT iirc if theres anything you ike there feel free to ask.

welcome to EF!

I know, I couldn’t believe no one was interested in it, sitting there all dusty.
I should have mentioned, it has 5 speed standard transmission.
I was thinking the same on gears, I had an F250 years ago that had factory 410’s it was a beast with 35’s and a built 460!
I’m a lot older now, won’t be getting too crazy off-road but want it useable and not just a street driver. This is an entirely different vehicle but I really think it has potential to be quite fun.
Thanks for your input!

 

[TexasBear]

I know, I couldn’t believe no one was interested in it, sitting there all dusty.
I should have mentioned, it has 5 speed standard transmission.
I was thinking the same on gears, I had an F250 years ago that had factory 410’s it was a beast with 35’s and a built 460!
I’m a lot older now, won’t be getting too crazy off-road but want it useable and not just a street driver. This is an entirely different vehicle but I really think it has potential to be quite fun.
Thanks for your input!

The old guy it belonged to drove it to the border once a week, a 25-30 round trip. The oil was spotless when I checked it, and there was a receipt in the console for transmission and differential fluid change 3 months before he died.

 

[TexasBear]

The old guy it belonged to drove it to the border once a week, a 25-30 round trip. The oil was spotless when I checked it, and there was a receipt in the console for transmission and differential fluid change 3 months before he died.

These were the first things I found, but I’m hoping someone knows where I can find a complete kit for the gear swap

 

[Fix4Dirt]

I know, I couldn’t believe no one was interested in it, sitting there all dusty.
I should have mentioned, it has 5 speed standard transmission.
I was thinking the same on gears, I had an F250 years ago that had factory 410’s it was a beast with 35’s and a built 460!
I’m a lot older now, won’t be getting too crazy off-road but want it useable and not just a street driver. This is an entirely different vehicle but I really think it has potential to be quite fun.
Thanks for your input!

great find!

oh if you have the manual then big cooler doesnt paply to you real trucks dont shuft themselves hahahaha (up for debate)

These were the first things I found, but I’m hoping someone knows where I can find a complete kit for the gear swap

View attachment 433795

ahhh ok so on mine i have 1" spacers but 2" will work too might require light teimming? not too sure.

 

[Fix4Dirt]

in theroy you could get 3" out of a TT but 2 things

1. yoi will eat CV jkints and be hard on all the susension conponents
2. it will ride like a hay wagon

the max poeple do for a 2wd is 2.5" usually and for a 4wd its 2"

ob mine i have the RTZ keys and shackles but imo if your tbars arent too sagged like mine just the shackles will work and you can crank the bars. also AAL im on the fence about since they tend to ride bad being the short AAL. imo start off with shackle and a TT by just cranking the bolt and if you want more then get the other kit with AAL keys and longer bolts. jmo

as for geaars i dont know of any bolt on and ho kit for 456 yukon makes good hears though iirc

410s you can find in a JY i see them most commonly on EB and LTD v6 2nd gens

 

[TexasBear]

Thank you very much, exactly the kind of feedback I was hoping for! You guys have hands on experience and know what results, no need for me to “reinvent the wheel”

 

[Rick]

Nice find! Looking forward to watching you modify this beauty.

Welcome to the forum

 

[TexasBear]

From what I have read, I’ll have to use a body lift for a Ranger, although bumper brackets won’t fit. I’m not really worried if that’s the case, I’ll be changing bumpers anyway.
Does this kit fit otherwise?

Nice find! Looking forward to watching you modify this beauty.

Welcome to the forum

Actually, my dad new the executor of the estate, a friend of his for 35+ years who doesn’t live in Texas. He was the reason I got it. He called me and asked me if I wanted a’96 Explorer, I said “nope”. He said “well now wait a minute, let me finish. It’s 4-wheel drive and has 60k miles. I started it and there’s not the slightest tick coming from it. It sounds like a new truck, seriously!”
I said, “ok, I’ll bite, how much?” He said, “well that’s just it, nobody has expressed any interest in it.”
Turns out there were a lot of guns and tools/equipment in the estate, and that attracted a lot of attention, but not one person interested in the ole’96.
He said make them an offer, which I did, $1,000. Next day he said “you need to go pick up your truck” LOL, I had no idea what a find it would turn out to be.
My dad passed away shortly after I got it. I like to think of it as dad’s last gift.
Thanks for the welcome, I will be providing updates once work begins. My time is limited, but I am really wanting to get going on it. Just want to make sure I get input from all of you to avoid mistakes or unnecessary changes.

 

[Fix4Dirt]

From what I have read, I’ll have to use a body lift for a Ranger, although bumper brackets won’t fit. I’m not really worried if that’s the case, I’ll be changing bumpers anyway.
Does this kit fit otherwise?

Actually, my dad new the executor of the estate, a friend of his for 35+ years who doesn’t live in Texas. He was the reason I got it. He called me and asked me if I wanted a’96 Explorer, I said “nope”. He said “well now wait a minute, let me finish. It’s 4-wheel drive and has 60k miles. I started it and there’s not the slightest tick coming from it. It sounds like a new truck, seriously!”
I said, “ok, I’ll bite, how much?” He said, “well that’s just it, nobody has expressed any interest in it.”
Turns out there were a lot of guns and tools/equipment in the estate, and that attracted a lot of attention, but not one person interested in the ole’96.
He said make them an offer, which I did, $1,000. Next day he said “you need to go pick up your truck” LOL, I had no idea what a find it would turn out to be.
My dad passed away shortly after I got it. I like to think of it as dad’s last gift.
Thanks for the welcome, I will be providing updates once work begins. My time is limited, but I am really wanting to get going on it. Just want to make sure I get input from all of you to avoid mistakes or unnecessary changes.

View attachment 433796

yes the kit will fit otherwise afaik. shadowraven had a writeup. also rockranger has a bumper that iirc fits a 3" BL just sayin

 

[Rick]

$1000.00 wow!

Sorry to hear about your dad's passing, but you're right he did hook you up with a great find.

 

[Rick]

also rockranger has a bumper that iirc fits a 3" BL just sayin

@RockRanger do you still have those bumpers available?

 

[RockRanger]

Yes I make a weld together front winch bumper that fits stock height or 3 inch body lift. I also make a rear bumper kit as well for the 4 doors. Not sure how it would fit on a sport however. If you find the cranked t bars ride to rough I make a kit to put coilovers on the front as well.

 

[Blown]

2" TT (you will not likely need new keys), 2" shackle and the 3" body lift is plenty. I have found most add a leaves to be very stiff and result in a terrible ride. The one's you posted are 2/5" or .4" thick! I removed the thick overload leaf to get a better ride, but I added air shocks and am looking at air bags to assist for when I do carry a load. You gain like 1/2"in height, the thickness of the overload leaf. There are high angle CV axles available, but those are not likely needed if you stay at 2" or under. The higher you crank the front the more down travel you loose................................

I haven't compared pricing recently but Randy's has been good and has got kits for ring and pinion: RANDYS Worldwide | One Stop Differential & Drivetrain Shop

 

[CDW6212R]

From what I have read, I’ll have to use a body lift for a Ranger, although bumper brackets won’t fit. I’m not really worried if that’s the case, I’ll be changing bumpers anyway.
Does this kit fit otherwise?

Actually, my dad new the executor of the estate, a friend of his for 35+ years who doesn’t live in Texas. He was the reason I got it. He called me and asked me if I wanted a’96 Explorer, I said “nope”. He said “well now wait a minute, let me finish. It’s 4-wheel drive and has 60k miles. I started it and there’s not the slightest tick coming from it. It sounds like a new truck, seriously!”
I said, “ok, I’ll bite, how much?” He said, “well that’s just it, nobody has expressed any interest in it.”
Turns out there were a lot of guns and tools/equipment in the estate, and that attracted a lot of attention, but not one person interested in the ole’96.
He said make them an offer, which I did, $1,000. Next day he said “you need to go pick up your truck” LOL, I had no idea what a find it would turn out to be.
My dad passed away shortly after I got it. I like to think of it as dad’s last gift.
Thanks for the welcome, I will be providing updates once work begins. My time is limited, but I am really wanting to get going on it. Just want to make sure I get input from all of you to avoid mistakes or unnecessary changes.

View attachment 433796

Welcome, and thanks for sharing that great story with us. I'm sorry that you lost your father, that's a good memory to appreciate how he helped you with that truck. Enjoy working on it and having a blast for many years.

 

[974X4BLACKSPORT]

WOW, 1k for 60k miles, good deal!
Check your door tag and see what equipment it came with, post a pic if you like. I seen alot of the OHV 4wd with the 4.10 LSD disk brakes already from the factory, code: D2 on the door tag, thats what mine has.

 

[TexasBear]

Do you have a link to pics, or can you email pics?

WOW, 1k for 60k miles, good deal!
Check your door tag and see what equipment it came with, post a pic if you like. I seen alot of the OHV 4wd with the 4.10 LSD disk brakes already from the factory, code: D2 on the door tag, thats what mine has.

That’s funny, I was just searching for rear discs when your message hit. I’ll check the door tag today, maybe you guys can tell me what I’ve got.

 

[410Fortune]

Door tag will list something abiove where it says AXLE
D2 or D4 very common in 96 sport with the 5 speed!!!

I would LOVE to have a 96 with a 4.0 and 5 speed with those miles,. this truck is a real gem! They can go on forever
What types of cars did you work on before this? Jeeps Toyotas? Chevys? Im hoping yes, because now you will see what all the talk has been all these years about Fords..........they really are superior!! I should know I spend all my friggin time fixing chevys Jeeps and Toyotas anymore

 

[joney]

The old guy it belonged to drove it to the border once a week, a 25-30 round trip. The oil was spotless when I checked it, and there was a receipt in the console for transmission and differential fluid change 3 months before he died.

Don't know what you paid, but it sure looks nice! I'd even learn to drive stick if I found one with that low mileage, and little/no rust. Assume Texas doesn't have a rusty car issue.