Increasing towing capacity for 98 Explorer 5-speed

[masospaghetti]

Is there any practical way to do this? It's a 98 XLT, 4.0 OHV 4WD, 4-door, 3.55 gears, M5R1 transmission. Based on my research its rated at a paltry 2500 lb towing capacity.

Since the automatic is rated quite a bit higher I assume it's a weakness in the manual transmission? I'm trying to justify having this as an extra vehicle, I need a vehicle that can tow a car to the track (track car is about 2500 lb, trailer is between 1300-2000 lb depending on the type). So total towing capacity needs to be 3800-4500 lb. This would be within the weight limits of an automatic-equipped Explorer with the same engine. Trailer would have brakes.

I'm thinking maybe HD clutch? Is there a heavy duty version of the M5R1?

I have an opportunity to essentially get this vehicle for free. I owned it about 5 years ago and then gave it to my brother so I know it's had a ton of work done to it (rebuilt transmission, rebuilt transfer case, full suspension, timing chain, etc etc). The only catch is that the vehicle is in California and I'm on the east coast and the thing has about 280,000 miles on it so it's not a trivial task to go pick it up. (but seriously, how often do you see a 4-door XLT 4WD 5-speed?)

 

[koda2000]

I believe the Sports only have a single/mono leaf spring in the rear (that's what my '97 Sport has). Adding HD 4-door rear springs would increase towing capability. Also, install a 4:10 diff would give more pulling power. The OHV V6 is low on HP, so some extra grunt will help. I don't know about a particular weakness with the manual trans. Maybe the fact that towing is harder on the clutch is why Ford rates it lower... ?

 

[masospaghetti]

I believe the Sports only have a single/mono leaf spring in the rear (that's what my '97 Sport has). Adding HD 4-door rear springs would increase towing capability. Also, install a 4:10 diff would give more pulling power. The OHV V6 is low on HP, so some extra grunt will help. I don't know about a particular weakness with the manual trans. Maybe the fact that towing is harder on the clutch is why Ford rates it lower... ?

Thanks Koda. This is actually on my 4-door XLT with the multileaf pack. When replacing my suspension I also put those load-leveling shocks in the rear.

I know the OHV isn't exactly a powerhouse but still, if it is rated for it with the automatic, surely that can't be the limiting factor?

 

[CDW6212R]

Yes the clutch is the weakest link, but the manual has better gearing than an auto, so the 3.55 gears aren't too bad. Your final gearing is better than an automatic with 4.10's, but for towing any improvement in gears would help.

I'd defer to experts with that manual transmission, to say what it can handle for towing. I think that's the limiting factor to pull 4500lbs.