My First Explorer, 2000 EB

[traveler]

The brush guard could have been much worse. It was a steep incline down an embankment, into a creek with unseen rocks in it. The grill guard did the it's job and caught the big impact. If I hadn't changed the mounts to be bolted directly to the frame rather than a simple clamps who knows how much damage it could have done. And yea I was warned about the tail light guards but I like em. And I wanted to get new tail lights anyway.
The bumper... Well now that it's torn up anyway I can comfortably cut it up for more clearance, and mount lights in a safer location using the factory foglight wiring. So... It's all good. And the body lift will go on as scheduled.
The antenna... Yea... A killer tree reached out and... But it's just the aeriel, a cheap easy fix.

 

[gmanpaint]

Might source an older set of steel bumpers off a 95, 96. Without all the Tupperware, they are half the size of yours height wise, and can take some abuse. Just an idea.

 

[traveler]

Hmm.. I was unaware there was a difference between 94-95 and 99-00 bumpers. I'll look into it.

 

[CDW6212R]

In 1998 they began having different bumper types. There were two Limited front bumpers, both with the same outer plastic cover. One inner bumper was aluminum, and the other sheet metal with Styrofoam in it. I saw one of the AL types and didn't get back to buy it, mine has the light sheet metal one, slightly bent.

So you can get steel bumpers from 95-98 models.

 

[traveler]

Well, the Explorer is throwing tantrums. I think its mad I bought the Expedition LOL.
It wouldn't start once I got to work. (Had to drive the Explorer, as my wife drove the Expedition because her Mercedes had a dead battery) Anyway, I had to load the Explorer on a dolly to get it home. Then had to figure out how to get it off the dolly since it wouldn't start, then had to figure out how to get it in the driveway. Anyway, I got it all done.
Now its in the carport. I tested the battery and starter with a multimeter. Its got 12.9 Volts at the batter, 12.24 volts at the starter. but it only clicks when the key is turned. thoughts?

 

[CDW6212R]

Hold old are the battery cables, and when were the terminals last off and cleaned? Are the terminals still the great OEM type, or the cheap horrible bolt down type? The factory cables are excellent, but after 20 years there can be corrosion build up inside the wires, and then they have to be replaced.

I went through all of that ten years ago with my 91 Lincoln, and my last 98 Explorer had the terminals cut off and used the bolt down type. I replaced those with much better ends, which used soldered lugs.

Here's a picture of Explorer battery cables installed on my 91 Lincoln, I had a spare take off set back then. Now the cables are obsolete, I'd love to buy about four new sets of them.

 

[Turdle]

Mike, the clicking is a symptom of battery cable clamps becoming dirty. These trucks are real picky about what is on the battery posts. Clean the clamps and posts real good and see if it helps. Might also be a weak battery if it is over 3 years old.

 

[traveler]

Battery is 2 years old. The battery is fully charged. The connections are clean and tight. The multi-meter says I've got 12.25 volts at the battery, in the cables, and at the starter.
I pulled the starter off the block, cleaned all the mounting surfaces, and bolted it back in place. Still nothing. I decided to pull the starter completely off and have it tested. While pulled my the wires, the smaller post broke off in the wrench. So looks like I'll be buying a starter anyway, unless it's possible to just buy the solenoid.

 

[CDW6212R]

Ouch, those little SOB's are fragile. It sounds like you had to R&R the starter anyway to fix the problem.

You can have the starter rebuilt, everything is replaceable. I had three done a few years back, they replaced everything but the armatures and cases.

Bolting the starter in, be sure the small terminal doesn't rotate and touch the big one or the other cable.

 

[traveler]

Just wondering, do most folks attach the wires and then bolt on the starter? Or vice versa? From the way it's oriented I'd say it's impossible to attach the wires after it's bolted in. But with the wires attached you risk pulling on them and...

I am taking the starter in to Oreillys tomorrow to have it tested just so I'll know. Then install a rebuilt starter.

 

[CDW6212R]

The starter has to go on first, then the wires. You have to twist the starter a bit to snake it up in there, I doubt it would go with the wires attached.

All of the small starters made for these 302's are very good, so you don't have to be picky about brands like with some older Fords. Ending up with a spare is a good idea, so it's smart to have the old one rebuilt when you can.

 

[traveler]

Well Oreillys confirmed a bad starter. I'll pick one up tomorrow (the Oreillys that tested it didn't have one in stock) and get it installed. I'll look into a rebuild.

 

[traveler]

Hmmm...
New starter on Amazon for 1/3 what they cost at Oreillys, just gotta wait til Saturday. Can I leave the explorer in the carport all week.....

 

[traveler]

New starter went in easier than the old one came out and it started right up. One problem solved. Now to fix the damages caused by my last outing.

 

[Turdle]

Glad you got it fixed.

 

[traveler]

Well.. had to make the big cuts... But there is a little more clearance. It'll do till I can swing one of rock rangers bumpers.
Also got the damage around the tail lights fixed.

 

[traveler]

New light mounts arrived. Can't wait to mount them. Suggestions for lights. These go on the fenders near the firewall.

 

[timtimtimajim]

I’ve got a set of KC Rally 400 lights on the same brackets. For halogens they put out quite a bit of light. Any small LED cube would work good too!

 

[traveler]

Went with some 140 watt LED lights from Amazon, can't remember the brand right now. They are very light and thin. Haven't wired them yet, ran out of daylight. Not sure I really like them yet, we'll see. Don't know why the side angles shots came out so dark, took all pics within a minute.

I bought some yellow fog lights to replace the factory fogs that I lost when I cut the bumper. They'll be mounted to tabs that will be welded to the grill guard. I've got the tabs cut out but haven't welded them on yet.

 

[gmanpaint]

Cool beans. Update after wired up please.

Might be too late, but....

Lowes sells 1/4" thick L brackets for unistrut. Only a few bucks, and work perfect for mounting to the sides of that bull bar vertical plate. Holes are 1/2" in them. Find them in the electrical pipe isle.