Good question, I've been trying to decide if I should replace my Explorer or spend the $$ to rebuild it.
I have a 1991 Explorer XLT purchased new in 1990. It has 365,000 kms or I would guess just around 200,000 miles.
Only items I have replaced are,
tires - on third set and averaging 110,000 per set
clutch-currently on second, original replaced at 210,000 kms
front hubs-replaced with Warn Manual locking at 250,000 kms as automatics would lock unexpectedly
front wheel bearings-replaced at this time
main driveshaft ujoints also replaced at this time, only 1 needed but replaced both
starter motor-replaced original at 300,000 kms
parking brake cable-replaced at 300,000 kms as it was rusted solid. Still stiff.
rivet for power door lock mech snapped at 290,000 km. Re riveted
battery-on second but needs replacement.
Things that need to be fixed.
Paint is shot, though it is original and only bad on hood and roof
bad rust holes at seam below rear passenger doors both sides
Top end of motor is very noisey from around 300,000 km point
New intermittant rattling sound from engine unknown cause
sudden backfiring and loss of power under power
anitfreeze loss, about 1/2 pint every tank of gas possibly seeping from around water pump.
Stereo is intermittant, plug on rear is loose. Fixed once but did something dumb when replacing it and bent locking tabs on side so now radio extraction tool will not
I'm wondering whether to replace the motor, and rad (rad is original) with rebuilds. In it's present state I would guess it's trade in value is nil so wonder if I should put several $$$ into it to keep it on the road for another 5-6 years.
But wonder if I am making a mistake as I'm sure there are other items that will be ready to go. Mainly concerned about other possible rust areas, rest of body is actually good including fenders. Main problem area seems to be common on all the Explorers I have seen up here in Canada, salt is a real killer here.
I suppose if trade in is nil and rebuild is uneconomical would parting it out be a better idea instead of a trip to the scrap yard as it is fairly well loaded.
Eg, articulated sport seats (good condition), factory prem snd with amp/subwoofer, fact sunroof, 5sp manual trans etc.
Kevin