95 Explorer XLT 4x4 Conversion

[ronin2501]

I researched this a few years ago and deemed this to be too expensive of a project to do part by part. The only documented process for this was for a 91-94 rather than a 95 so i didn't know what parts would be needed.

Recently I was able to get a 95 Explorer 4x4 as a donor vehicle for $450. It's been rolled/totaled, and the top has been cut off. The entire engine and drivetrain is still in good condition.

I've had my Explorer for 4 years and I am not new to custom work on cars/trucks. However, I am new when it comes to modifications to the Explorer and just recently getting into modifying her.

Here is what I have and here are my questions. If this is already documented some where, please point me that direction and if possible provide URL's.

My Current Explorer:
1995 Ford Explorer XLT Automatic 4x2 4 Door

Donor Vehicle:
1995 Ford Explorer (Expedition) Automatic 4x4 2 Door

1. Has anyone done this on this year model or same generation before? I hate to re-invent the wheel.

2. Is this a straight forward conversion? Does it require any special metal fabrication? (Just curious, I'm completely comfortable either way)

3. Will the drive shaft from the 4x4 2door be compatible with the 4 door? When I do part searches it shows results for both as if they where interchangeable. I would think that the 2 door would be too short. Is that correct?

4. Is the rear gear ratio in the 4x2 model the same as the 4x4 model? Will I need to swap the axle? (or just the gearset?)

5. This is an electric transfercase engage. Behind my dash the wiring and plug are present, but no switch. Does anyone know if the switch needs to be plugged in? (and the bezel swapped from the donor)

6. Is the plug for the transfer case already present in the 4x2 model and just bundled up into the harness, or do I need to run new wiring to the t-case?

7. Does the TCU for the Automatic Transmission interact with the transfercase at all, or is it independent? (I wonder if I need to swap the TCU...)

8. I plan on getting new hubs/Wheel bearings (or whichever the front of the 4x4 model has readily sold), shocks, and bushings for installation prior to this project. Is there anything else I am forgetting?

9. Are there any other modifications or maintenance items I should perform while everything is apart? (other than the rear main seal since the tranny's coming out)

10. Are there any other questions that I should be asking that I didn't?


I really appreciate any time that anyone spends reading this post and responding to it.

 

[ronin2501]

Even though no one replied I guess I'll post my findings from my own research here in case someone else needs it. I suppose I"ll be doing the write up for the 95+ Explorer 4x4 Conversion. So far it looks pretty straight forward. Luckily I have a donor vehicle so if I forgot anything it's available.

I did quite a bit of reading over the last few days on this forum, thanks to everyone who took the time to write it up. It took quite a bit of searching but I was able to answer some of my own questions.

 

[96eb96]

Even though no one replied I guess I'll post my findings from my own research here in case someone else needs it. I suppose I"ll be doing the write up for the 95+ Explorer 4x4 Conversion. So far it looks pretty straight forward. Luckily I have a donor vehicle so if I forgot anything it's available.

I did quite a bit of reading over the last few days on this forum, thanks to everyone who took the time to write it up. It took quite a bit of searching but I was able to answer some of my own questions.

I think the ABS system has additional components in the 4X4 flavor. Think about 4X4, if your drivetrain is locked and one wheel is on ice it is possible to lock up all wheels. Then the ABS thinks you aren't moving!

There is a component called the "G-spot" I believe. It is on the drivers side of the truck, around the center and I believe on the frame rail. Make sure you have a service manual to verify.

 

[ronin2501]

I think the ABS system has additional components in the 4X4 flavor. Think about 4X4, if your drivetrain is locked and one wheel is on ice it is possible to lock up all wheels. Then the ABS thinks you aren't moving!

There is a component called the "G-spot" I believe. It is on the drivers side of the truck, around the center and I believe on the frame rail. Make sure you have a service manual to verify.

The front left and front right ABS sensors are different. Hopefully the sensors on the donor vehicle are good...they aren't cheap. $200 each...??

The only other differences I can see (based on part types only) are between the 2 door and 4 door models such as the ABS control Modules.
ABS Control Modules:
F57a-2c219cc
F57a-2c219cd
F57a-2c219ce

I guess I will see when I get to that point. If I have to I'll disable ABS until I figure that out.

On the topic of Service Manuals..are you getting these from the Chiltons CD or directly from Ford?

Thanks,
Ty

 

[gijoecam]

There is a bunch of stuff (and IMHO, it's not worth the effort), but to each his own.

Obviously, there is all the suspension stuff you'll need to transfer over... front knuckles, brakes, hubs (ABS sensors will be with the hubs), calipers, rotors, possibly hoses.

Then there's the drivetrain: Halfshafts, front axle (which may or may not bolt right in... I think it will), front driveshaft, transfer case, transmission.

Then there's all the electrical and electronics: Transfer case wiring may or may not be present on your 4-door, wiring from the t-case back up to the GEM, transfer case shift relays, torque on demand relay, and all that stuff may or may not be connected to the apropriate power supplies and fuse panels... they may or may not have the wires present for the relays and modules. Once it's all said and done, the GEM will likely need to be either replaced with one from a 4x4, or yours will need to be re-flashed to enable the 4wd control system and its associated programming. It may or may not require a different GEM, ECU programming (to control the shift maps with the transfer case in low range) etc....

It's not going to be a simple bolt on plug-n-play setup...

-Joe

 

[ronin2501]

There is a bunch of stuff (and IMHO, it's not worth the effort), but to each his own.

Obviously, there is all the suspension stuff you'll need to transfer over... front knuckles, brakes, hubs (ABS sensors will be with the hubs), calipers, rotors, possibly hoses.

Then there's the drivetrain: Halfshafts, front axle (which may or may not bolt right in... I think it will), front driveshaft, transfer case, transmission.

Then there's all the electrical and electronics: Transfer case wiring may or may not be present on your 4-door, wiring from the t-case back up to the GEM, transfer case shift relays, torque on demand relay, and all that stuff may or may not be connected to the apropriate power supplies and fuse panels... they may or may not have the wires present for the relays and modules. Once it's all said and done, the GEM will likely need to be either replaced with one from a 4x4, or yours will need to be re-flashed to enable the 4wd control system and its associated programming. It may or may not require a different GEM, ECU programming (to control the shift maps with the transfer case in low range) etc....

It's not going to be a simple bolt on plug-n-play setup...

-Joe

All good things to check...I'm glad you brought it up. I have the GEM from the donor vehicle and I suppose if I absolutey had to, the wiring harness could come over. The only wiring that I was able to confirm so far was that the 2WD/4HI/LO switch wiring is already in my 2WD explorer. Hopefully that's an indication that they used a standard wiring harness between the 4x2 and 4x4 models and just tied off the unused ends...

I'll definitely check the Relay and Fuse boxes and compare them.

The ECU thing may be an issue, they made so damn many of them it's hard to tell which one has what functionality.I really need a wiring diagram from Ford....

Thanks for the input, I'll check each of those things out.