Pugly

[gmanpaint]

Thanks guys!
The silicone tape fix is working real well right now. Kurt and I scoured a couple salvage yards looking for a replacement seal. These yards had everything BUT a first gen Explorer.
We looked at rangers of all years, Bronco II's, and probably every year of a 2nd gen. None of them have the sleeve seal stock. We can only surmise that only the 91-94 Explorers used them. We found a 95 4.0 OHV, and it didn't have it.

Don, if you have the 1st gen sleeve in good condition, I would gladly pay you for it, if you would part with it. That would be awesome.

Brian, I had electrical tape on the other end as that seal went south last year. lol

Jon, Thank you for the suggestion sir! Thing is the intake tube end is much bigger OD then the TB intake OD, and the intake tube just fits length wise over the intake tube as is. The silicone tape is holding with the clamp tight for now.

 

[Turdle]

How difficult would it be to build an intake tube? If ya can't get factory, make it more better

 

[Turdle]

These things adapt to diff size tube and allow for flexibility.

 

[gmanpaint]

How difficult would it be to build an intake tube? If ya can't get factory, make it more better

If I can't find a replacement sleeve, that would be the next option. I dislike cold air intake kits, and prefer stock over anything, but if push comes to shove, so be it.
Pugly might be getting retired soon anyways. I need a lower milage work truck, and have been looking at F-250's. The next person can deal with it. LOL

 

[410Fortune]

I would use a 96-2000 ranger air box and intake tube

I had my floor Matt mash the throttle down in my old 96; I went right through a red light! The brakes in my old 96 were powerless at the time to stop her, I had the e303 cam and. It enough vacuum at the old booster to stop me. I was able to get across the road and turn the ignition off pulled over safely.. it could have been so much worse.
Couple of years ago I was hauling a load of red bricks with my big truck (97 f350) and the trailer brakes went out… on a mountain pass going downhill. I was barely able to shut her off and stop at a pullout. Front brakes were on fire! I was able to put the brake pads out with my breath like
Blowing out a birthday candle I got lucky. Next step would have been the extinguisher for sure. I needed a rotor and new pads, new fuse for the trailer brakes…these fords are tough!! Now if we can stop them from trying to kill us!!

 

[gmanpaint]

I will look at those air boxes and see if they will fit similar to the 1st gen setup. Batteries and fluid tanks are opposite last I checked. So I know there has to be some difference in how they mount up, sit.

Thanks Jamie.

No wobble at all, and new rotors seemed to take the abuse. Thank goodness as those aren't cheap.

 

[410Fortune]

I moved my battery and fluid tanks I wanted to get fresh air for the air filter
In 88 the airbox was on top of pass tire?? Much better behind pass headlight

Now my battery is in the back left lots of room under hood

 

[BKennedy]

I have a 99 intake tube and air box, it is in the passenger front corner. The coil over and mounts needed to be space where the OEM box resided. The only potential issue with this is the intake tube rests on the upper radiator hose flange and is slightly compressed by the hood. The 99 radiator has the upper hose flange lower. I ended up installing a all aluminum radiator so it really doesn't matter is there is a little pressure on that hose flange.

I navigated 1to this thread because I'm almost done with the PS swap and wanted to compare notes.

 

[gmanpaint]

Hmm... Pugly has a 3" body lift and the radiator is dropped. If it is a direct replacement, I'm all for it. Thanks for that heads up!

 

[BKennedy]

If you get the intake and box at a junk yard, get the box mounting plate and all the rubber mounts. You line up the box and drill 2 holes in the inner fender so the rubber mounts fit snugly. You can mount the plate under the box to your inner fender. I didn't bother because there is very little movement without it. The front of the box is mostly open because the 99 had a intake snout that goes there. I didn't bother with that because I had to modify the box to keep the pre-heater due to California SMOG, so there is a fairly large intake on the bottom too. I plugged the vacuum lines going to the pre-heater so it's always open because it's a unnecessary part, but again California. If I register my rig in Arizona, I will take all that out and probably go with a generic cone type filter. The 94 throttle body bolts right up to the 99 parts.

Hardest part is relocating the battery and getting the old battery box out. They did a very good job attaching the box to the inner fender.

 

[gmanpaint]

Ahh, dang. I was thinking the air box was where the 1st gens are. I'm not going to relocate the battery. Too much work. Lol
I Could have sworn I seen a 2nd gen with a flat filter box that might work in the same location. Might be a different model, or maybe a sohc setup?

 

[BKennedy]

Don't know about that. It is a lot of work to relocate the battery if unnecessary. Mines a flat filter box, but its square with a deep box, nothing like the 91-94 boxes. I already had a auxiliary battery on the driver side, but it was still a pain extending the power wiring from the starter solenoid. The ground wire mounts the same way. There is a threaded hole in the driver side frame and on the engine block, same location as the passenger side.

Auxiliary battery is now where the spare tire was, with my air compressor and tank.

 

[gmanpaint]

Yeah, if this was the play rig, I would be up to all that, but it's not. It's just a once in a while trail rig, and get thru any bad winter weather work rig.

I have so much work to do on the other rig still. Over worked and bad weather has kept me from it, and $$ already spent on parts collecting dust is depressing to look at.

 

[CDW6212R]

I was thinking of that hose today, my 93 engine is under my shelving along a wall in my garage. I have to step around my big mower to get to it, but I shouldn't have trouble taking the hose off when I get there.

 

[gmanpaint]

Thanks Don! Only need the rubber seal ends that slide on/off. My tube is still perfect. Send me a PM if you would please.

 

[CDW6212R]

Done, PM sent.

 

[gmanpaint]

Pugly got the Flowmaster Jesus Muffler, replaced with a stock muffler.

Between this and the new steering pump, all I can hear is the severe duty fan when it engages. It's so quiet, that the starter is in jeopardy from me, not knowing when to release it.

The skinny pedal can now be mashed without waking the neighborhood.

 

[Kirby N.]

I just ordered the saginaw conversion parts. Thanks for the writeup.

 

[gmanpaint]

I have been storing a set of 6 barely used Cooper Discover AT3 for awhile in the garage, and they just need a good home. They can't live here anymore. They owe me rent money!
4 have less than 5k on them, and one has a 10mm plug patch between the 21/32 tread pattern.
1 was the spare, but has a few hundred miles on it from a weeks worth of use.
1 is brand new, never mounted still has stickers on it. I bought this as a replacement for the tire with a patch.

If your in the Central Midwest (MO), and can pick them up, Do some research, & make me an offer via DM. They look as good as they do in these pics.

33" x 12.5" x 15"

 

[gmanpaint]

Hi all, been a while!! Thought to check in here and post a little.

First off, these 1st gens are just amazing & Pugly has been a complete champ closing in on 300k Miles with a stock engine. Yes, it has it's little quirks I deal with but overall, it's been one heck of a work rig. Never thought it would still be in use after 17 years of putting it thru it's paces on & off road.

With that said, after spending a couple hundred at the grocery store, Pugly had a slight hiccup today. She didn't want to start, and almost left me stranded.... almost.

Battery was good with over 12v. Cables was tight, tried a jump anyways. Started didn't even engage with a turn of the key. Big man, big sad.

With all the perishables inside, I decided to call an Uber to get all that home to refrigerator safety, and come back to mess with it, or tow it home.
Uber said 4 mins. Cool.
10 mins later, and Uber said 9 mins.
5 more mins , and Uber still said 9 mins. WTF?
I got 4 big Ribeyes, and 5 lbs of lean ground beef in the back seat for heavens sake!! Panic set in....

OK, time to do something or lose everything I just bought. I had a hammer, but it was a 32 oz waffle head framing hammer with a big Hickory handle. Thanks to the lift, I was able to go over the front tire, over the frame rail, and get the hammer's head a couple inches from the starter, and tap it with a good poke. Crossed my fingers and turned the key. That OHV fired right up!! I didn't even get dirty.

Canceled the Uber that still said 9 mins out. Then it tells me..... Are you sure? The driver is on their way and is only 9 mins out. If I could have sent a flip off emoji I would have. They still charged me for it. Richards.... I have been adding to the Bank of Karma as much as I can, and in this situation, I think it helped. It could have been a lot more costly.

Moral of the story is to always carry a hammer, as a jump pack doesn't always solve things, when you're all you got.

No idea what I'm going to do first here. Starter isn't too old, and I replaced all the main cables when I did it. It has biblically rained here for 12 days. Water did leak inside at the top of the windshield, and Pugly sat for over a week. Going to wait it out a bit and keep trying to test start it a few times a day to see if it was just a fluke and needs dry time before I start yanking it apart again.

Thanks for letting me post about my day EF! How was your day guys?