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Paul's '91 Sport

Three ashtrays, two doors, one cup holder, and zero Air Bags”

I am the second owner of this vehicle, purchasing it in April 1993. It has been a daily driver, crisscrossed the States multiple times, sat for a few years in storage, and now is dedicated to four-wheeling trips, camping excursions, and hauling the motorcycle to various “track days”. It is not a hard-core rig, but is set up well for the types of four-wheeling I enjoy, and has certainly seen its fair share of difficult trails. It has a number of modifications, with more planned for the future, but is by no means “Done”.

As it sits today. . . (2022)
Snow Sport.5 (DEC 21).jpg


As it used to sit: (2016)
Front Oblique (P).jpg
Rear End.jpg


Here is the run-down of the modifications and when they were installed (or re-worked). . .
- Borla Headers and Cat-Back Exhaust (1995)
- James Duff Pre-Runner Front Bumper (1998)
- Bush Whacker Extend-A-Fender Flares (1998/2016)
- ARB Air Lockers, front and rear (1999/2008/2015)
- 4.10 Gears (1999)
- “SupeRancho” Hybrid Lift, approximately 4” of lift, with SOA (1999)
- 33”x 12.50 Tires (currently Toyo Mud Terrains)
- Con Ferr Roof Rack (1999)
- SuperLift SuperRunner Steering (2000)
- Ramsey REP 8000 winch in Duff Bumper (2002), Warn Synthetic Line (2016)
- Rock Sliders (2002)
- Atlas II Transfer Case (2005)
- ViAir On-Board Air Compressor (2009/2014)
- Modified ¾ Doors (2009)
- Early Bronco fabbed Rear Bumper, “extra modded” to fit the Explorer (2009)
- Rear License Plate Frenched (2009)
- Outback Solutions (ARB) Drawers with fabbed pull-out shelves (2012)
- Corbeau Heated Seats (2013)
- Internal Roll Cage (2013)
- Shelf/Box/Switches (2013-2015)
- Lights – Raptor/Fog/Roof Rack/Rear/Squatch/Interior Hatch/Hood (2013-2016)
- Dual Battery installation (2014)

I'll document most of the projects in subsequent posts with pictures and links to various threads. . .

Paul
'91 Sport





Edit: End of the road in April 2020. . . Read on for the wreck and renovation/restoration/gear swap to new 'Sport'. . .
Fork (APR 20).jpeg
 



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Paul

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Year, Model & Trim Level
'94 “Sport”
“I’m pacing myself . . .”

Finally finished the power steering cooler project. Spent a good wrenching day at Kevin’s, he was installing his winch, couple of LED lights, Ham radio antenna and skid plates on his ‘21 Bronco.

D505BA34-17F5-4764-83EE-54A5244F1A9F.jpeg

That’s some PEX waterline doing chafe protection.

Barely noticeable…
3F8373EB-04BC-45F7-8BFB-07132FA25E1B.jpeg


Paul
 



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Paul

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Year, Model & Trim Level
'94 “Sport”
A little bling for the rig - - my Chinesium hook’s gate and spring failed (“You get what you pay for”), so why not upgrade to a quality American component from Factor55?
8A3B4356-32E2-49BA-9732-02274B2B18CB.jpeg


E43A56C9-A0AF-4D9E-83E0-EAEB06019EE4.jpeg


Paul
 






Paul

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Did a little "pre-run" up to Lonesome Lake with Kevin and his Bronco prior to a snow run in a few weeks memorializing Phil Fisk who we lost in 2019. Kevin's made some nice upgrades to the Bronco, so it was good to field test them. . . although we didn't need to, not much snow and all the electronic gizmos makes it a challenge for him to lose traction.

Anyway, couple of pics:
Haller.3 (11-6) (2).jpg

First stop, Haller Pass


Lonesome.1 (11-6) (2).jpg

Next stop: Lonesome Lake


Got to field test the small "Fire Pit"
Ignik (11-6).jpg

Pretty nice piece of gear. . .

Lookout for Mount Rainier, not much visible today
Overlook (11-6).jpg


Haller.1 (11-6).jpg

Anyone around on Saturday the 26th, give me a shout if you want to join us.

Happy Trails,

Paul
 






Paul

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'94 “Sport”
On the outing last weekend, noted one of the Warn fog lights had a burnt-out bulb, so figured it was a simple replacement. Just a common 55w H3 bulb.

Step 1: Realize there is surface rust on the lights. . .


Warn.1 (NOV 22).jpg

Although the rig lives in the garage, these Warn fog lights sat on the old rig that was parked outside of Kevin's shop for 3+ years. Light sanding on the houses, bezels, metal portion, and what the hell, might as well shoot the lens protectors/guards. . .

Back of the light:
Warn.2 (NOV 22).jpg

(painted portion to the right). . .

Swapped both bulbs, figured only a matter of time until the second one burned out.
Warn.3 (NOV 22) (2).jpg

Step 2: Replace Bulb. . .
0974D02F-4FE8-43E1-9B64-5DD83360AFE7.jpeg
 






Paul

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'94 “Sport”
Aaarrgh. . . Tranny woes. . . Not the more common A4LD (assuming "LD" stands for "Light Duty"), but the M5OD (pretty sure the "OD" stands for "Outdated Design"), but either way - - the thing failed right after Thanksgiving when we ran our Memorial Snow Run for Phil Fisk. Have a couple hundred thousand miles on Explorers, so its just part of Explorer lore, or Explorer "chore" . . .

Luckily, I held onto the fairly fresh transmission that I had in the old rig before its demise. . . but since it takes a whole lot of labor to fix any part of the transmission, opted to go "all in" - - new Centerforce clutch, pressure plate, master and slave cylinder, bearings and the housing that had less than 10,000 miles of use.

Gathered the parts and scheduled a weekend at Kevin's (Diff Whack) shop for the effort.

So, after removing way too much stuff - - transfer case skid plate, transmission cross-member, front and rear drive shafts, exhaust "Y" pipe, etc., etc. we finally got to this point:
Old Tranny - Atlas (JAN 23).jpg

Out with the old - - keeping the Atlas, obviously.

Lots of room now. . .
Tranny Hump (JAN 23).jpg

New tranny housing in the bed of the Ranger in the background.

New clutch in place.
New Clutch (JAN 23).jpg


Last part, master cylinder placement - - made easier by removing the inner fender well, Extend-A-Fender fender flare, and wheel. . .
Clutch Master (JAN 23).jpg



In two days went from deconstruction to up-and-running. Still in Kevin's shop as I'm brining the speedo cable to a local speed shop to repair/re-manufacture since it leaks enough to be annoying. . . Rig shifts well, great clutch pressure, will road test once the speedo cable back inserted.

Paul
 
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Kirby N.

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Sweet! I don’t think I have heard of many problems with a m5. You must be talented at destroying them. I am pretty hard on them and they have held together. My current one had 315k on it and I rebuilt just cause it was out and I wanted to add 4 cylinder 1st-3rd gear. Synchros were even working well. Tranny guy who rebuilt it said it looked really good and not even worn out when he rebuilt it.

You tried a center force in my Navajo and it seemed to preform well. I am on my second sohc clutch in my ranger and I really like it. I smoked the first one a couple times and it still stuck in there- just swapped when I rebuilt the tranny and engine because I was there- not because it needed it.
 






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