Mr. Alligator
Explorer Addict
- Joined
- November 30, 2014
- Messages
- 1,297
- Reaction score
- 1,029
- City, State
- Tampa, Florida
- Year, Model & Trim Level
- 1997 XLT Explorer
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:
REPAIRS AFTER 2013 DEER STRIKE
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!
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:
- Body pinstripes
- Auto head lamps feature (after two replacement units fail)
- CD player and OEM stereo
- All automatic door and ignition chimes
- Cargo door badges
- Roof top cargo rack
REPAIRS AFTER 2013 DEER STRIKE
- Replace grill and grill Ford badge
- Replace front headlight and turn signal assemblies
- Replace brush guard
- 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!