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Foxracin's 1991 Exploder

Real Name: Trevor
Year : 1991
Model: Explorer
State: North Carolina
City: Mount Holly

Just picked up this Exploder last week. Its not in the best of shape but overall its decent. The motor runs great and the body has very few dents and dings.

When I got it the trans was out like every other a4ld. I am a 5 speed guy myself and was planning to convert to 5 speed anyway.

First thing and did is check the fluid in the trans. Nice and red, full, and doesnt smell burnt. Pulled one of the lines at the radiator and fired it up and no fliud. Nothing at all. Pulled the pressure plug in the side of the trans and fired it up to make sure the lines were not stopped up somewhere and still nothing so I knew something wasnt right with the pump.

Got it home and put it on some jack stands and started tearing out the trans.


Got the trans out and pulled the torque converter out and found some scaring on the snout. Thats not supposed to be like that. lol

Pulled the bellhousing off then the pump from the bellhousing and theres the problem. One of the pump gears cracked and spread the teeth apart and locked up and spun on the torque converter.


Oh well time to throw it in the scrap pile. Dont want to spend the money on it again not even know if the rest of the trans is good and for it to just break again. I figured I could swap in a 5 speed for not much more then fixing the a4ld.

Figured I would mess with the inside a little while I try to find a trans.

Put in a Sony headunit. Ran new speaker wires and used the internal amp after 2 stock amps were not right. Soldered all the connections and ran new speaker wire and its good as new.

Put it in a Midland CB I had laying around.

Overall shot of the interior.

Then I figured I would ride over the the Pull-A-Part to see if I could run across anything. Sure enough ran across a 1992 5 speed Exploder. But somebody already robbed the trans and starter. Figured I would go ahead and get what I could off it. Got the computer, Manual trans wiring harness, pedals, and Master cylinder(when they got the trans they cut the line so it wasnt useable). Still had the flywheel, clutch/pressure plate still on it too but I didnt have the money for it right then.

So I came home and started swapping out some stuff.

Manual trans wiring harness.

Swapped computers and moved it to behind the glove compartment to get it a little higher.

Swapped the pedals. I left the pedal assembly in and just changed out the brake pedal and put the clutch pedal on. It was aggravating but definitely beats pulling the dash out to change the entire assembly.

Went back the next day to Pull-A-Part to get the clutch and flywheel and all that good stuff crawled under it and somebody done took the clutch and pressure plate. So I missed out on that. Went ahead and pulled the flywheel off though. It looked fairly new.

Pile of junk parts I have pulled off so far. lol It keeps getting bigger.

Thats where I am at so far. Need to scrounge up some money to get me a trans and a few other pieces and I should be set.

For now I will probably just do a body lift and coil spacers and shackles for now with some 33's or 34's after I get it on the road.

Then save up for the d44 SAS down the road.

Ill keep this thread updated as I get some more work done.

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Is the ass end still lower than the front? How do you plan on fixing it?
cough 63 chebbies cough

The rear sits about a inch or so lower since I put the shackles back one. The front will settle a little over time. Springs are still new.

I have actually been contemplating the 63" chevy springs to get rid of the shackles and maybe they will last longer. Havent ever seen anybody do it on a explorer though.

I haven't either, but I've been trying and get an idea of the ways you could do it without relocating too much stuff back there. Got a few ideas I could run by you when I stop by since you likely have the skills and resources to turn them into reality.

Well messed with the doubler a little bit this past weekend. Its tight without a body lift and you not able to clock the rear case up any without cutting a big hole in the floor.




Test fit


Had to trim the body crossmember a little bit and grind a piece off the t-case.



Started making the shifters

2 hi

4 low

4 double low

Going to try to get some more done on it this weekend.

I like the shifter setup. Pretty ingenious. :thumbsup:

have you measured the front wheel travel yet just wondering how much you get with those arms and springs thx

thanks for the parts man. Lookin forward to wheeling together soon.

This is a very nice ride in person.

Doubler is in. I officaly have a mall crawler now. It will definitely crawl and it temporarily 2wd until I get to build the trans crossmember.

Got it all in today and make the shift handles. Double low is badass. Cant wait to get it out and do some wheeling.

Had to get the bfh out on the floorboard.

Got room for it now.

Shifters and double boot. Still got to cut the shifters to length and thread them for some knobs so dont mind them yet.

2 high

4 double low





Going to run to Napa tomorrow and see about getting a new longerspeedometer cable so the speedo will work again.

Wow. That is so frickin cool. I'm so diggin the shifter set up. I know that took some trial & error, and I know plenty of cuss words were spoken during the installation of all that. Those little things are almost always the most PITA things to deal with.

Congrats on all that hard work man, can't wait to see what you do with this thing on the trails. :thumbsup:

This is gonna be pretty sweet!! Looking good!

The duff arms are aweome I had a set and they are stout!!! had my whole explorer rest on one on a nig rock lol, just lost a bit of powder coating LOL

cant beleive i never read this one before. Nice build!

Well was about to order a set of chromo shafts for the front the other day and ran across this for a deal. ARB for the d44. Got it from bronco2guy. Going to save up a little more cash and get some chromo axles next.

Came in the mail today.

Also got a new speedo cable from Napa today. Stock one was too short with the doubler. Its for a 91 Aeroster and has the same ends and is about 8" longer. Works prefect.

Shows how much longer the stock.

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Had a crossmember fabbed up today. Not a lot of room to work with under there with the driveshaft and exhaust in the way and wanting to keep it tucked up in the frame. lol

Pics suck.