Project Green Hornet '01 Sport SAS | Page 8 | Ford Explorer - Ford Ranger Forums - Serious Explorations

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Project Green Hornet '01 Sport SAS

I have been at this for a little while now. I haven't really taken any pictures of the steps leading up until now. I am bad about blogging as I do things, so I will take pictures when I think to and if any of you guys have questions or input I will snap pictures along the way. I fabbed the outriggers from scratch. I used the boomerang shackles to give me more clearance around the body mount and give me a littler better ride. The front cross member was made from a 2"x3" rectangle tubing with hangers from ruffstuffspecialties.com. I then bolted it to the frame in a few places as well as used it as a back mounting support for the winch. I made a dimple die to press the clearance holes and add some more strength and make them look better. I opted to use heims instead of using tie rods. I got the teflon lined 5/8 holes with 3/4" shank both for the tie rod as well as the drag link. I plan to use a pitman arm from either an astro van or a jeep wagoneer. The gear box is from a jeep cherokee which is what I got the Dana 30 from. I bought a crossover steering bracket from bluetorchfab.com made specifically for the jeep dana 30/44 axles. This is a great setup which I will transfer over when I find myself a good dana 44 to swap for the dana 30 I got now. The steering shaft is a hybrid of the stock explorer shaft and cherokee shaft. It had to be shortened by about 13-1/2 inches and reinforced for peace of mind. The gear box will be drilled and tapped later for hydro assist when I find a new 44. I am still in the process of re-plumbing the box, but all my fittings should be here this week. When I do the setup for the hydro-assist I will be adding an adjustable relief valve to upgrade the steering pump pressure that I read about somewhere on this site recently. The pitman arm right now is facing to the back and is looking all kinds of hell, but don't worry I plan to flip it to the front. You can see it's got a little of that explorer detroit lean to the driver side that I will have to address at some point. I'm sure there is more to cover that I haven't covered, so just let me know what you think. Be gentle this is my first major project like this. I’m all for constructive criticism, but don’t be a dick. I will grab a bunch more pictures tomorrow in the daylight, but here is a couple teaser pics.
 

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just1me

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Here are some more pictures.

Curious but how hard is it to remove the front inner fenders? Also really like that front bumper that's awesome.
 



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1-MEAN-X

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Thanks. The inner fenders were pretty easy. I think it was mostly just plastic clips that I had to take out for it to come out. I hung on to them for a while in case I decided to put them back, but it is a lot easier to change spark plugs and access other areas of the engine bay so I chucked them.
 






mynameisaric

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Have you wheeled those military BFG's is some slick mud? I'm looking for a cheap upgrade to the crap goodyears I have now. Was wondering if the BFG's were at all decent.

Even grooved, the goodyear OZ tires are garbage.
 






1-MEAN-X

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Not yet. I'm still putting it back together after putting in the transfer cases and stuff. I would think that they would be better than the OZs though because it doesn't have the center strip running around the center of the tire, but I don't know that for sure. I'll be sure and report back when I do though.
 






1-MEAN-X

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I've been able to get some work done the last few weekends.

Here is the final plumbing of the fuel cell.

IMG_0532_zpscce6b49e.jpg


IMG_0533_zpsd3e9421d.jpg


Here are the shift knobs and levers.

IMG_0597_zps0c0309e7.jpg


Underneath looking at the links.

IMG_0600_zps15e8918f.jpg


Today was a little bitter-sweet. I topped off all the fluids in the transmission and transfer cases and was ready to get this thing out. It fired right up, and that was about as far as I got. The shifters didn't want to shift as smoothly as they had when I was dry fitting everything. At times they were just locked up almost. Also, I need to look into an issue with the transmission shifting. It would shift into gear, but only when I really gave it some gas. It would then stop like something was grabbing. It is the first time since I rebuilt it this summer that I have been able to run it. Any thoughts or suggestions are welcome. I'm also going to look into an easier way to shift into the various 2wd/4wd.
 






Slick Fan

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Also, I need to look into an issue with the transmission shifting. It would shift into gear, but only when I really gave it some gas. It would then stop like something was grabbing. It is the first time since I rebuilt it this summer that I have been able to run it. Any thoughts or suggestions are welcome.

Other than an obvious low fluid level, I have no good ideas. :)
I just read through your whole thread today & gotta give you a big thumbs-up!:thumbsup: This is a cool build, thanks for sharing your progress.
 












1-MEAN-X

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Not too many. I got the transmission shifting worked out. I decided one day to just throw in another quart or two and see what happened since I added the drain plug it wouldn't be hard to take it out if need be, which it didn't. So that was good.

After that I took it around the block, or tried to. There was a pretty rough shake like something was off center or something. I was doing a little more digging and I'm beginning to think there is some truth to the 4wd/2wd engine balance shaft. For the time being, I have parked it until I can get some time to really dig in and figure it out or swap engines.

I have worked on adding a different front stinger bar and off road lights. I will take a couple more pictures in the next few days. It turned out really well and bright as hell.

Day time:

IMG_0731_zpskg5nkji4.jpg


Switches with in cab winch switch:

IMG_0746_zpsbmz1kj2s.jpg


Night time:

IMG_0747_zpsutfszaf2.jpg
 












01STrunner

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And the switch setup.
 












1-MEAN-X

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I got them from Amazon. They are the laser blue rocker switches. They had several different images for whatever you wanted them for. I also bought a Rugged Ridge Rocker Switch Mount which is a 4 piece modular setup so you can mount your switches to a piece of stainless or whatever you want to use to mount them.
 






01STrunner

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Decided to go back and read up on your t-case section and saw you're in Cooke ille. Do you work at ATC by chance?
 












01STrunner

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Thought so haha. Between the machine skills and that's about the only thing around there lol. I work at Robert Bosch in Anderson SC and we go to you guys a good bit. I don't know if you remember the line yall built about 3 years ago to make TCMs for 8spd transmissions but that's the main line I worked with.

Small world
 






1-MEAN-X

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So this project has come to a little bit of a crawl because of this shaking issue. I'm thinking it's because of the balance shaft in the 4wd engines for the time being because I have no other idea what it could be. I'm thinking about adding the balance shaft with a timing chain update but my question is should I spend a little more and get a good rebuild kit and go the extra mile. The engine has 145k and runs good otherwise.

What's your thoughts?
 












monster5685

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Awesome setup i'm currently starting my build. got the rear end SOA last week, IFS all cut out, and a dana 30 prepped to be hung. This forum has helped me immensely! Thanks! You get this thing muddy yet?
 






mynameisaric

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I'm curious how those military tires are working out for you. The 36" goodyears are garbage. I was hoping the 37" BF goodrich ones would be a decent upgrade.
 



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Fish Man

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Sorry, I may have missed it somewhere, but what Rancho leaf springs are your running with your SOA D44?
 






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