Pugly

The Good, The Bad, & the Pugly

1994 Purple Explorer XLT 4wd

I decided to have a registry for my "Other" rig so I can post things done and have a reference for it.

Pretty much stock drive train.

4.0 OHV-A4ld-1354e.
D35 front 4:56 Yukon gears, Aussie Locker.
2nd gen disc 8.8 rear 4:56 gears, Spartan Locker.

Front C-Clip eliminator Mod.

Slight lift with 2" Skyjacker coils & rear F-150 hybrid leaf packs.

3" PA body lift
Helpful thread with pics for the front body mounts
Pics of front body lift mounts

Swapped to manual hubs.
Double U-joint XJ steering shaft.

33" x 12.5" x 15" Cooper Discoverer ATX3, mounted on 15"x10" AR Outlaw1 alum wheels - full size matching spare.

Shocks:
Front Rancho 9000xl
Rear Rancho 9000xl
Duff Stabilizer shock.

Sway bar quick disconnects front & rear.
Custom tube sliders w/kickouts

22" LED light bar.
18w amber fog Led pods.
55w rock lights--2 front--1 rear over diff.
8 LED pods for rocker lights.

Full brush guard.
2.5" Fender Flares.

TTB Diff guard & Skid plate.

Custom roof rack with 48" Extreme Hi-Lift jack.

Flipped Tow hitch & front hooks for tow points.

Cobra19 CB & rear hatch mounted firestick antenna.
Rear view HD camera.
JVC DVD/CD/MP3 Head unit with 7" HD Monitor.
Sony 6.5" front speakers.
Rockford Fosgate 5.25" component rear speakers.
8" JL Audio sub in 2001 enclosure with 500w amp mounted on enclosure.

Custom made center console with CB/Rear view color monitor/2-12v outlets/ in-out temp display. D cell Maglite mounted on cargo panel. Truck bed liner on cargo floor.
Custom Cargo storage box with topside spare tire mount.

'99 Eddie Bauer Front Leather buckets.
'94 Limited Rear leather split bench.

 

[gmanpaint]

Guess it couldn't hurt to try it. Pair of used seats from the JY is $110.00

 

[gmanpaint]

After messing with the broken lever, I said heck with it. I went to the JY and got a set of 2nd gen Eddie Bauer leather seats, and installed them today. I had a bit of confusion on the wire harness on these as they has 6 wires and the rig only had 2. I got it sorted and they work just fine.

I also got a nice HD clutch for the fan to install tomorrow, along with a new seal kit for the steering box.

 

[lynchy wa]

Bloody nice mate!

 

[Turdle]

Well, there ya go.

 

[Glen4X4]

The seats looks good Gregg. Nice addition.

 

[Twiztid]

After messing with the broken lever, I said heck with it. I went to the JY and got a set of 2nd gen Eddie Bauer leather seats, and installed them today.

:ttiwwp:I had a bit of confusion on the wire harness on these as they has 6 wires and the rig only had 2. I got it sorted and they work just fine.

I also got a nice HD clutch for the fan to install tomorrow, along with a new seal kit for the steering box.

 

[gmanpaint]

Looks like I spoke too soon

The seat belt catch arms have a smaller size receptacle in them, and the stock belt clips wont fit. WTF!

So...
1st option...Try to swap the catch arms from 1st gen to 2nd gen.
2nd option..Go back to the JY and grab the seat belts from the Eddie Bauer and install them.
3rd option....This is where you guys enter something..LOL!

 

[Turdle]

Yeah I noticed that the 97 mounty seats I installed have a different clip than the 93 seatbelts. I'm going to swap the old clips to the new seats.

edit, they seem to work as is but do not release well. In a panic this would not be good.

 

[gmanpaint]

The 94 clips wont even go into the smaller 99 catch. I guess they changed them to a smaller size in 99.

I just now seen 410fortunes info on this for these seats. I read the thread yesterday, but somehow spaced out and skipped over this part.

According to Jamie, the catch arms are easily swapped and only held on the rails with 2-10mm bolts. I will have em swapped here in a little bit. Just sucks I have to remove them to do this. ACK!

I do have to say, these seats are very comfy in the lumber and seat areas, but they lack the side support (bolster) of the old seats. However...they soak up tons more road jarring then the old ones. Truck feels as if it is newer now.

 

[cybergasm]

Should get 5 point harnesses FTW

 

[gmanpaint]

5 point? Heck, I dislike the 2 point as it is. I wear em, but I don't like em.

 

[blazin8556]

I don't think the 5 points are DOT approved

 

[gmanpaint]

Seat belt problem solved.
Ended up swapping just the receiving arm and not the rails. There is a T-50 bolt holding each one on and they had lots of thread locker on them. A few seconds with the propane torch remedied that. The reason being is that the rails are diff lengths, and are mounted a bit diff to the seat carriage. This took lots more time to get finished than I anticipated, but is def worth the end results.

...On to the HD clutch for the fan.
I managed to scrape myself up once again fighting the tight area removing the fan. (I hate these fans with a passion.) The fan is incredibly loud now & I know it is working. Standing at the side fender, you can feel the massive amount of air blowing out over the wheel.

...On to the Pitman arm seal kit.
This was over before it started. I do not own a big enough wrench/socket to remove the nut on it. Largest I own is a 32mm socket, and a 1-1/4" wrench, it's bigger than either of those. Looks like I either need to borrow a wrench, or purchase a new one.

 

[gmanpaint]

Well, the HD fan clutch had a bad bearing in it.

It decided to let go this morning. It didn't come apart all the way, just enough to make the fan have a bad wobble. It got limped back to the hacienda, and a new Hayden severe duty clutch installed. This thing might be to much for the stock fan, and will most likely have to get a severe duty fan for it.

Always sumptin sumptin.

 

[cybergasm]

I don't think the 5 points are DOT approved

Only illegal if ya get caught

 

[gmanpaint]

Passenger front window motor bushings ( I think) are going out. I have to help it up & down partially because the motor starts spinning and the window just stops going up or down.

The fan kicks major butt tho
A/C cranked, and the temp gauge stays below the "O" in Normal. Woot!

Looks like a better clutch for the fan is going in the 95 Ex as well.

 

[lynchy wa]

In sickness and in health, For richer or poorer, jeez it's good, to own an Explorer!

 

[crazyflights]

Sweet seats man!!! So when you putting the 4.10s in it?? or did i miss that and allready done LOL.

 

[gmanpaint]

Still needing the full 8.8 set up.

I have been chasing my tail just doing maintenance on this thing, haven't been able to do any mods in a while. .......sigh

Seats don't count as a mod as I just lucked out at the JY when searching for a replacement for the busted one.

 

[GRNMACHINE]

In sickness and in health, For richer or poorer, jeez it's good, to own an Explorer!

Love that!!