600,000 miles! Made it.

[Mr. Alligator]

Ford Explorer Repairs and Modifications


General Repairs and maintenance … Ford Tough, but this is 600,000 miles across 26 years. Certainly this is not a complete list, and many of these projects were done more than once. Did most of the maintenance myself, with lots of help from the Explorer Forum, and the local salvage yard.


[*]Replace upper control arms and upper ball joints
[*]Replace lower control arms and lower ball joints
[*]Replace outer tie rod ends
[*]Replace inner tie rod ends
[*]Replace front sway bar linkage
[*]Replace sway bar bushings
[*]Replace front shock absorbers
[*]Replace rear shock absorbers
[*]Replace fifth shock absorber
[*]Replace radiator
[*]Replace transmission cooler lines
[*]Replace thermostat and thermostat housing
[*]Replace upper and lower radiator hoses
[*]Replace radiator overflow tank
[*]Replace purge valve solenoid
[*]Replace battery cables and terminals
[*]Replace starter solenoid
[*]Replace battery
[*]Replace serpentine belt
[*]Replace idler pulley
[*]Replace serpentine belt tensioner
[*]Replace EGR valve
[*]Replace EGR tube
[*]Replace DPFE
[*]Replace DPFE hoses
[*]Replace SOHC manifold cover
[*]Replace alternator
[*]Replace steering rag joint
[*]Replace rack and pinion system
[*]Replace all relays in under hood power distribution box
[*]Replace all relays in relay box below air filter
[*]Remove intake extension from air filter box
[*]Replace air filter with K&N filter
[*]Replace and extend front and rear differential breather lines
[*]Replace air conditioner clutch
[*]Replace fuel pressure regulator and braided line
[*]Replace windshield wiper cowlings
[*]Replace front brake calipers and pads
[*]Replace master cylinder
[*]Replace front hubs/bearings
[*]Replace hood struts
[*]Replace cargo glass struts
[*]Replace entire cargo hatch (rust on upper hinge)
[*]Replace all ground straps (rust)
[*]Replace all rims and tires
[*]Replace front windshield washer motor
[*]Replace all windshield washer hoses
[*]Replace both horns (rust)
[*]Replace steering knuckles
[*]Replace battery tie down hardware (rust)
[*]Replace OEM radio
[*]Repair cigarette lighter by adding o-ring to console attachment
[*]Replace EGR vacuum solenoid
[*]Replace all vacuum lines under hood
[*]Replace radio antennae
[*]Replace blower resistor
[*]Replace blower fan unit
[*]Replace intake manifold o-rings
[*]Replace upper and lower oil pan gaskets
[*]Replace oil pressure sensor
[*]Replace transmission dipstick tube (rust)
[*]Replace oil dipstick o-ring
[*]Replace hood release cable
[*]Replace hood release latch
[*]Repair blend door
[*]Replace timing chain tensioners
[*]Replace water pump
[*]Replace crank position sensors
[*]Replace throttle position sensors and connector
[*]Replace idle air control
[*]Replace mass airflow sensor
[*]Replace oxygen sensors
[*]Replace vacuum reservoir ball
[*]Replace spark plugs and spark plug wires
[*]Replace inner fender liners
[*]Replace front bumper (rusty brackets)
[*]Replace power control module
[*]Replace radiator fan (cracks)
[*]Replace primary timing chain springs
[*]Replace radiator cooling line male fittings
[*]Replace heater control valve
[*]Replace heater hoses
[*]Replace PCV valve
[*]Replace rear shock absorber perches (rust)
[*]Replace almost all interior plastic panels
[*]Replace rear cargo window gaskets
[*]Replace shifter bushings
[*]Replace speedometer unit
[*]Replace odometer cylinders/gears
[*]Replace voltage meter
[*]Replace rear leaf springs
[*]Replace oil pressure “gauge”and sender
[*]Replace console vents
[*]Replace light bulbs in dash console: 4x4, fog lights, rear wiper switches
[*]Replace dash cluster bulbs with LED bulbs
[*]Replace glove box lid
[*]Replace console lid cover
[*]Replace entire long console, and replace console rear fan
[*]Replace driver and passenger seats with Mountaineer leather seats
[*]Replace all interior door handles
[*]Replace all exterior door handles
[*]Add springs to driver and passenger rear door locks
[*]Replace driver’s side door keypad
[*]Replace all door weatherstripping
[*]Replace all window motor bushings
[*]Replace front drivers door hinge
[*]Replace all door hinge detente bushings
[*]Replace driver’s door rear view mirror
[*]Replace driver’s side rear view mirror control switch
[*]Replace radio bezel
[*]Replace head liner with camo pattern
[*]Replace rear overhead lighting units
[*]Replace door striker bushings
[*]Replace door latch springs and clips as needed
[*]Replace ignition cylinder lock
[*]Replace door cylinder locks
[*]Tighten shifter linkage hardware
[*]Replace cruise control switches
[*]Replace front seat belts and drivers side latch
[*]Replace door puddle light assemblies and fasteners
[*]Replace window belt trim
[*]Replace door ajar sensor(s)
[*]Replace rear glass hinges
[*]Replace third brake light with LED lighting
[*]Multiple fuel pumps
[*]Fuel filters and fuel socks
[*]Replace spare tire lug wrench (broke in extreme cold weather)
[*]Replace bottle jack (rust)
[*]Replace rear hatch door and glass struts
[*]Replace rear hatch struts
[*]Replace rear glass wiper unit
[*]Replace rear glass wiper arm
[*]Replace reverse lighting assemblies
[*]Replace rear bumper (rust)
[*]Replace cargo door wiring harness and latches
[*]Replace tow package wiring harness
[*]Replace cargo area carpet
[*]Replace overhead console
[*]Replace heater control unit
[*]Replace speed sensors for transfer case
[*]Replace drivers seat power motor
[*]Replace passenger seat frame with manual unit
[*]Replace charcoal canister O-rings
[*]Replace charcoal canister and canister bracket (rust)
[*]Replace rear brake drums and pads
[*]Replace parking brake pads
[*]Replace rear brake light assembly
[*]Replace turn signal module for LED lights
[*]Replace turn signal light bulb sockets (heat)
[*]Replace rear passenger door inner window seal
[*]Repair rear cargo storage net
[*]Replace spare tire winch (rust)
[*]Repair rear quarter panels (rust)
[*]Replace rear pinion seal
[*]Replace steering rag joint
[*]Replace steering rack and pinion
[*]Replace u-joints
[*]Rebuild transfer case motor
[*]Replace transfer case sensors
[*]Replace cargo hatch release latch
[*]Repair cargo hatch lock cylinder
[*]Replace fuel tank filler tube (rust)
[*]Replace fuel tank filler hose
[*]Replace fuel tank filler vent hose
[*]Replace fuel tank door rubber bumpers
[*]Replace rear differential speed sensor
[*]Replace spare tire rim (rust)
[*]Replace PCM
[*]Replace crankshaft position sensor


ADDED:


[*]Functional hood scoop
[*]Four LED fog lights hooked to factory fog light switch
[*]Two flood lights hooked to high beams
[*]Brush guard
[*]Two tone paint, and then flames over the hood, fenders, and doors
[*]Front wheel alignment cams
[*]Large supplemental transmission cooler
[*]Leather steering wheel cover
[*]Rain deflectors for front doors
[*]Custom JVC stereo
[*]Fuel pump access panel
[*]Black out Explorer badges on front doors
[*]Cut and trim front fenders for 32x10.5” tires
[*]Class 2 receiver hitch
[*]K & N air filter
[*]Replaced rusty shackles with extended shackles for rear lift
[*]Torsion twist for front end lift
[*]Replace OEM rims to fit larger and wider tires
[*]Camo headliner
[/LIST]


DELETE:

1. Body pinstripes
2. Auto head lamps feature (after two replacement units fail)
3. CD player and OEM stereo
4. All automatic door and ignition chimes
5. Cargo door badges
6. Roof top cargo rack

REPAIRS AFTER 2013 DEER STRIKE

1. Replace grill and grill Ford badge
2. Replace front headlight and turn signal assemblies
3. Replace brush guard
4. Replace headlight and turn signal assemblies

REPLACE AFTER 2015 VALET PARKING DAMAGE


[*] passenger front and rear doors


REPAIRS AFTER 2020 CHEVY SUBURBAN STRIKE


[*]Replace left and right front fenders
[*]Replace left and right inner fenders
[*]Replace hood
[*]Replace header panel
[*]Replace radiator core support bolts and bushings
[*]Replace hood hinges
[*]Replace/repair fender brackets
[*]Replace hood hinges



REPAIRS DONE BY PROFESSIONAL SHOPS: * the only work I did NOT do myself… lacked the tools, the location, and/or the skills.


[*]Replace windshields
[*]Install rebuilt engine
[*]Rebuild transmission
[*]Replace rocker panels with welded metal 2x4’s.
[*]Muffler, with turn-down pipe after rear axle
[*]Replace transmission neutral safety switch
[*]Rebuild transfer case
[*]Re-upholster seats and upper door panels with “alligator” material



OEM PARTS NOT REPLACED… Happy Days, but not the longest list.


[*]Fuel injectors
[*]Front and rear differentials
[*]Almost all wiring harnesses
[*]Airbag
[*]Power steering pump
[*]A/C compressor and most components
[*]Heater core

Opinion: these trucks are tough, but at this age would be annoying and expensive if you do not do your own repair work.



THANK YOU to everyone on Explorer Forum!

 

[Mbrooks420]

Wild mileage.

 

[donalds]

@Mr. Alligator
You are sticking around here on the forums?
Sounds like ur signing off lol

 

[Mr. Alligator]

@Mr. Alligator
You are sticking around here on the forums?
Sounds like ur signing off lol

Still sticking around, still getting good information here, and still driving the Ford cross country.

Thanks for your help, @donalds .

 

[Josh P]

I'm thinking you could get a 1 in front of that number

 

[Mr. Alligator]

I'm thinking you could get a 1 in front of that number

Roll it to one million, then claim it has never been used,

My other plan is to trade it back to Ford for a puppy…

 

[Josh P]

Y

Roll it one million, then claim it has never been used,

My other plan is to trade it back to Ford for a puppy…

You hit a million miles, the car maybe in a commercial

 

[Turdle]

What a testimonial!!?

I think you'll get a million outta it.

 

[BTR]

Wow! Huge cred for that! Now I have something to shoot for (currently at 24 years and 152,000 miles on 4.0 SOHC)!

 

[Floridacatfan2020]

Take that Toyota for—runner fans - built in Louisville Ky

 

[Floridacatfan2020]

This is a very useful list for things to look at to prolong a 4.0 sohc ex - noted still running the original starter and timing chain guides-?

 

[Mr. Alligator]

This is a very useful list for things to look at to prolong a 4.0 sohc ex - noted still running the original starter and timing chain guides-?

No, the starter has been replaced several times. Several years ago I had to replace three or four in a three or four month window. Never thought I would get a good starter.

The timing chain guides were replaced when a rebuilt engine was installed. I did replace the tensioners and the Jack shaft spring tensioner, but the rest is way over my ability level.

Take care and be safe.

 

[C420sailor]

Awesome! Hoping to be there one day…

 

[CDW6212R]

Congrats on that new milestone.

I haven't driven that far with my several Explorers since my first in 1998. But my last four are 2nd gen's and the mileages are all getting up there. My Mountaineer I went from 98k to 227k, my 99 Explorer went from 77,450 to 152k, my black 98 went from 158k to 228k, and my white 98 went from 171k to 232k now. So 335k miles is a lot for me in 25 years, not counting my cars along the way.

 

[BTR]

The timing chain guides were replaced when a rebuilt engine was installed.

@Mr. Alligator - Regarding your rebuilt engine: Is it from a vendor that sells rebuilt engines... or was it rebuilt by your mechanic... or some other method? I'm asking because sooner or later I (might) want to get mine "rebuilt." Thus, I'm starting to vet which option to pursue. Please advise. Many thanks.

 

[Mr. Alligator]

@BTR I had a rebuilt “Powertrain” engine installed by a mechanic.

My logic was this: First, the timing chain guides were getting worn and noisy, and if they completely failed, I could be stranded with a ruined engine, The decision to go use the “Powertrain” engine was based on the complexities of the 4.0 SOHC engine. I figured that if a mechanic did not sort of specialize in rebuilding these engines, there could be problems. And apparently there are expensive tools needed (or strongly suggested) for the rebuild of these engines.

Thus, deciding that the rebuild had to be done, and lacking the tools and ability to do the work myself, I decided that the Powertrain rebuilt was the best option. The mechanic I was using thought that the “Jasper” engines overrated. Everyone’s opinion might be different here.

 

[BTR]

Roger that... and thanks for replying.

 

[donalds]

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Both are great choices