5spdman's slow and cheap XLT build

[5spdman]

Well, it happened....................

Ran out here to Tuba City to run a weekend shift (fire department) and figured I'd replace my leaking master cylinder while I had some downtime. Got the old one out, installed it, and started bleeding it. Two hours later, I thought to myself, "gosh, this should be good to go by now" but there was still no pressure on the pedal....I then looked to the front of the vehicle and noticed fluid dripping from the front of the bell housing. Stuck my fingers in the bell housing only to start playing around in brake fluid...........:roll:

I have a new slave cylinder, fluids and tools being brought to me tomorrow night. I'll take this opportunity to reseal the transmission and change fluid in the transfer case while it's all out as well....here's to a long day laying in the dirt on Sunday............:thumbdwn:

 

[Pollarican]

Watch some videos online of how to bleed the clutch setup - it is an incredibly stubborn SOB if you attempt to do it installed in the truck. A better option is to bleed it preassembled on the bench, then install it in the truck.


https://www.youtube.com/watch?v=HgNTDGwcjZc

Found it - you will thank me later!

 

[5spdman]

Well, I'm going to have to take it back out to do all that (I don't know why I didn't do it before I installed the stupid thing... Guess I was just so ready to install it that it slipped my mind, but it will get done!) Thanks for the video link! It's really good info!

 

[unometooo]

Off topic for a moment. I just noticed in your "Ride List" you have a 92 Escort. I use to have a 94 Escort Wagon 5 speed car that was a blast to drive. It was pretty peppy (or so I thought) and fun to drive, I was always looking for a GT motor to put in it at the salvage yard but never came across one. I even bid on a turbo kit for it on Ebay that someone had pieced together but lost interest when the bid hit 500. I miss that little car.

 

[5spdman]

I wish it was a 2 door 5spd, but when a friend sent me a message asking if anyone needed a car for $350, I couldn't pass it up! I originally planned to use it in replacement of the 91 Mercury Tracer I used to tear around the woods in (and rolled,) but it was in such good cosmetic and mechanical shape, I started using it as a daily driver.

I saw a 2 door here on the reservation that hasn't moved since I moved here a year and a half ago. I've seen the car pretty close (owners kids go to the Mission school I work at) and I know for sure it at least needs a new windshield, but if it's a 5spd with just engine problems, I'd love to take it off their hands! (I know the family could use the extra money too, so why not help out!) I'll have to ask...thanks for lighting that spark again haha!

Right now the hatchback is sitting in Ohio with some sort of transmission problem...it will shift from 1st to 2nd just fine, but then it won't shift any higher. There's some sort of pump valve (I think that's what the guys on the FEOA forum were saying......I've been away from it too long) that I think is the culprit, but didn't have the time during the summer or Christmas while I was home to look at it...will have some more time this summer to check it out.

 

[5spdman]

Back to it!

It was extremely windy today (had downed trees and a roof blown off of a house) so working outside was out of the question...we moved a few pieces of plywood into the station, pushed the XLT inside, and I got to work....

The transmission had been leaking for some time from between the tranny housing and extension housing.....cleaned it all up and laid a good bead of Permatex super blue gasket maker down.

Hand-tightened the bolts as per instructions and let the sucker "cure" for an hour (also as per instructions.) I then replaced fluid in the transfer case during the waiting period. After that all was done, I flipped the transmission back over and got to work on the slave. The stupid thing was busted for sure.....I could hear air coming out like a squeak toy when I pushed on the sucker. Also went ahead and pulled the master cylinder back out to bleed the stupid thing properly (thanks for the video link Pollarican!)

By this time, the sealant cured, so I flipped the transmission back over and installed the new slave cylinder for NAPA.

After that, it was time to put the transmission back in.

Everything is back in place and working smoothly! Will just need to re-weld the exhaust when back at the school.

 

[5spdman]

Still waiting for a check to come in from the FD, but in the meantime, I figured I'd stop by the junkyard to pick up a few small detail-type pieces since I was in the area...wheel centers that aren't flaking, door latches for the rear doors, a rear passenger side panel that matched everything else, spindle nuts so I can do my manual hub conversion, a rim to have a matching spare now that anyone behind me can see what it looks like.

I got 1 piece: a gas cap.........I did however find a few deer-track style rims, plenty of rear door latches (just couldn't get the screws out) and 1 manual hub and the spindle nuts for both sides from a 91 sport (didn't have a magnet to get the key out.)

In addition to getting these small pieces for now, I took my camera along and got pictures of ALL of the explorers and rangers (there were no bII's in the yard.) I came across parts for axle swaps...12 limited slip 3.73 axles and 3 limited slip 4.10 rear axles. In all the rangers in the yard they ALL had 3.45 gearing (door tag code 84,) so no 4.10 front pumpkin for me to pull. I decided I would go across the road to the other junkyard to see if they had any rangers with 4.10 up front, and came across a big red sign on the door reading: "As of 3/22, our parts department will no longer be open." $#!+...............

On the plus side, I found 3 sets of F250 shock towers, most of the LS 3.73 axles were from 95+ explorers (disc brakes!), a working sun roof from a 92 sport (might be nice) and what I believe to be lift coils on an 88 ranger. I'll have to double check all of my findings next time after I get my checks and I go in to harvest all these wonderful things!

On a side note, I saw this X in Flagstaff and wondered if anyone knew who it belonged to....it looks good and was curious about it....

 

[Maniak]

and 1 manual hub and the spindle nuts for both sides from a 91 sport (didn't have a magnet to get the key out.)

The inner/outer/washer set for the manual hubs doesn't have a key. The automatic hubs have a single nut and a key..

You just need a set of spindle nuts for a Dana 44 (assuming the stock style, not something like the stage 8 kit).

The spicer p/n (which is cheaper than warn) is 28068X and runs for about $16 a side. Even amazon carries it (well, they fulfill it for BJ's Off-Road)

~Mark

EDIT: Dorman makes a kit too.. It is dorman p/n 05305.. Oreilly sells it for $25 but others are much cheaper.

 

[5spdman]

Found the Dorman kit on Rockauto...I might go that route just so it's one less thing to do in the yard, although it still would be cheaper from the yard....thanks for that info and thanks again for the hubs in the first place!

 

[5spdman]

I got rid of the small single work light on the rear of the luggage rack and got 2 Blazer tractor lights with a flood pattern that match the front Blazer driving lights....

I'll be keeping the stock 55w bulbs in these instead of upgrading to 100w and 130w bulbs like the driving lights and roof lights...

 

[5spdman]

Got some wheeling in last weekend for the first time with this explorer....went to Sedona, camped along the jeep trail off Schnebley Hill road, hit Diamondback Gulch, Dry Creek Basin and Soldiers Pass trails and had an absolute BLAST!!! For sure needing/wanting to go ahead with this lift, but NNFD is way behind in getting me my checks, so no money at the moment...

But as I wait for checks, more mod ideas are running through my head....this is one of them....

Two-tone black and lime green paint, silver pinstripe (optional) clear corner markers, smoke tint on tails and turn lights, an F150 Raptor inspired Explorer graphic under the rear window (also optional) and black rims.......opinions?

 

[mr cribb]

It would be different and unique in a good way. I've seen worse colors from the factory.

 

[Redneckfordf250]

Nice build. I like the ideas you have planned for the truck.
The only thing I would do personally is keep the black handles black and do the green middle. I just think it would flow nicer. It is your truck though. Glad to see an Explorer guy near by here in AZ.
Trav

 

[tylerwiseman1992]

in that picture of your muffler, you can see the front shackle that holds the leaf spring in place. my shackle is the only thing under my ex really rusting away, anyone know where you can get theses new?

 

[mr cribb]

in that picture of your muffler, you can see the front shackle that holds the leaf spring in place. my shackle is the only thing under my ex really rusting away, anyone know where you can get theses new?

I might be starting to part mine out in the next month or so. I have a southern only(NC, TN, OK) 92 model. If I have any rust it's surface only. It all depends if I get my hands on this other explorer I'm eye - balling.

 

[tylerwiseman1992]

I might be starting to part mine out in the next month or so. I have a southern only(NC, TN, OK) 92 model. If I have any rust it's surface only. It all depends if I get my hands on this other explorer I'm eye - balling.

Awesome

 

[5spdman]

Nice build. I like the ideas you have planned for the truck.
The only thing I would do personally is keep the black handles black and do the green middle. I just think it would flow nicer. It is your truck though. Glad to see an Explorer guy near by here in AZ.
Trav

I used photoshop to put the colors on, so some went to places they shouldn't have (aka the front bumper has green on it, the door handle, not all of the roof has black)...bumper will stay chrome and the door handles black lol

 

[5spdman]

in that picture of your muffler, you can see the front shackle that holds the leaf spring in place. my shackle is the only thing under my ex really rusting away, anyone know where you can get theses new?

Don't know about new....on the 93 I had one that rusted in half...a buddy and I just ended fabbing one up and it work end good...looking back I'd change it a bit to bolt it on rather than weld it to the frame lol

 

[Redneckfordf250]

I used photoshop to put the colors on, so some went to places they shouldn't have (aka the front bumper has green on it, the door handle, not all of the roof has black)...bumper will stay chrome and the door handles black lol

even better. I personally like a little black and chrome in their. I think this is going to look nice.
Trav

 

[littlebro294]

Does having a big roof rack like that kill your mpg? I've been looking into them but i would have to add it all, like from the plastic that goes onto the roof to the cage itself. but this is also my daily so im not sure if i want to get it if it will hurt my mpg by anymore than 3mpg as im already only getting like 16 or 17mpg.