Questions/advice about my build?

[NickEx623]

Hi all! Bought a 92 Explorer 4wd a month ago to wrench on. Plans are to make it a fun/reliable truck for light off roading/getting groceries. I have some questions/seeking advice before starting the build, here it is!

1. Plan on putting an 8.8 rear axle from an later year Ex and jamming in 4.88 gears and reap the benefits of disc brakes since will be doing a 4" lift and run 35's. I assume the rear should be a simple bolt on replacement, correct? Stock 92 Ex driveshaft?

2. How much work will I have to do to the exisiting brake lines/system to accomodate the disc brake calipers or is it just a matter of swapping/fitting hoses? Also, I plan on doing the front brakes upgrade with Ranger knuckle/caliper for bigger calipers, will my stock booster/master cylinder be fine with the ranger calipers and the rear calipers on the 8.8?

3. Considering the amount of work I plan on doing on the truck, I figure I may as well rebuild the engine while I'm at it. Where can I find a parts list/guide to rebuilding the OHV and giving it a bit more power? Would like to stick in 410 or 422 cam and probably port it but not sure what else I should do.

4. Any dudes on this forum who can build a bada** tubular front/rear bumper? Don't want to pay $1250 each, which is what some companies are asking

 

[BKennedy]

How To: 8.8 Drums to Disc swap the hard way

Disclaimer ...Before modifying your vehicle, you should seek Professional help..:crazy:..Seriously ____________________________________________________________ Two different ways to do a Drum to Disc swap - "Hard" or "Easy" ...The "Easy" way would be to swap in a whole axle from a 95-01...

www.explorerforum.com

Please search for topics before posting. There are numerous threads already on drum to disc swaps, but I think the link above is the best. I based my swap on T-Bars thread.

Bumpers

Show us your custom bumpers!!

show us your custom bumpers!!(i need ideas for mine i am going to make)

www.explorerforum.com

Also lots of threads on engine rebuilds here.

 

[RangerX]

Welcome to the forum!
You don’t mention regearing the front axle, are you not planning to do that, to go along with the rear 4.88s?

 

[410Fortune]

1. Yes the later 95+ disc brake rear axle is same as your 31 spline 8.8 under the 92, Except 95+ have disc brakes. You can easily convert your 92 over to discs if you wanted to just build your 92 axle housing

2. Brett Grooms did a rear axle disc brake conversion thread on this forum many many years ago.
96-97 Ranger dana 35 TTB outers are what you want, you will need the knuckles and brake rotors. You will want to replace the calipers and pads. 96-97 Rangers use dual piston calipers with slide bolts instead of the old style slide pins, a very nice upgrade.
You will want a new master cylinder for the rear disc brakes and larger front calipers. A 1995 Explorer master cylinder for a truck with no cruise control is what I run in my BII. It has the correct proportioning for the rear discs and enough volume to handle the larger front brakes.

3. 410 cam is street able, 422 is not, well not really.
Rebuilding a OHV 4.0 can get pretty expensive! This engine was in production until 2000, maybe consider finding a later model ohv and start with its long block. After 95 the heads were much better. Can find these engines on Ebay.

4. There are lots of Ranger and Jeep front bumpers can be adapted to the explorer. We recently put a Ebay ranger bumper on a 2002 sport trac, I just had to modify the ranger bumper mounts to move it up 2", pretty easy really.

 

[NickEx623]

How To: 8.8 Drums to Disc swap the hard way

Disclaimer ...Before modifying your vehicle, you should seek Professional help..:crazy:..Seriously ____________________________________________________________ Two different ways to do a Drum to Disc swap - "Hard" or "Easy" ...The "Easy" way would be to swap in a whole axle from a 95-01...

www.explorerforum.com

Please search for topics before posting. There are numerous threads already on drum to disc swaps, but I think the link above is the best. I based my swap on T-Bars thread.

Bumpers

Show us your custom bumpers!!

show us your custom bumpers!!(i need ideas for mine i am going to make)

www.explorerforum.com

Also lots of threads on engine rebuilds here.

That disc swap is exactly what I was looking for, thanks! Sounds like it's easier to get an later Ex rear axle and bolt it on mine/do the gear swap.

Welcome to the forum!
You don’t mention regearing the front axle, are you not planning to do that, to go along with the rear 4.88s?

I need to do some more research on what gearing for the front axle would work with a 4.88 in the rear, or is 4.88 a good choice as well for the front? I've seen some 4.88 front gears for the Dana 35 but all of the part mentions they are for the Jeeps, I assume it will be just fine for the Ex since it's still a Dana 35?

1. Yes the later 95+ disc brake rear axle is same as your 31 spline 8.8 under the 92, Except 95+ have disc brakes. You can easily convert your 92 over to discs if you wanted to just build your 92 axle housing

2. Brett Grooms did a rear axle disc brake conversion thread on this forum many many years ago.
96-97 Ranger dana 35 TTB outers are what you want, you will need the knuckles and brake rotors. You will want to replace the calipers and pads. 96-97 Rangers use dual piston calipers with slide bolts instead of the old style slide pins, a very nice upgrade.
You will want a new master cylinder for the rear disc brakes and larger front calipers. A 1995 Explorer master cylinder for a truck with no cruise control is what I run in my BII. It has the correct proportioning for the rear discs and enough volume to handle the larger front brakes.

3. 410 cam is street able, 422 is not, well not really.
Rebuilding a OHV 4.0 can get pretty expensive! This engine was in production until 2000, maybe consider finding a later model ohv and start with its long block. After 95 the heads were much better. Can find these engines on Ebay.

4. There are lots of Ranger and Jeep front bumpers can be adapted to the explorer. We recently put a Ebay ranger bumper on a 2002 sport trac, I just had to modify the ranger bumper mounts to move it up 2", pretty easy really.

Thank you, I will look into brake fluid flow rates but I think it makes sense that a master cylinder from a later model Ex would be perfect. I will have to put more consideration into options for the engine and possibly look into swaps. I figure a lot of bumpers would be adaptable but I don't weld, so I figure it'll be easier to have someone on here build one for me but that's not a priority. Thanks again!

 

[BKennedy]

Master cylinder from a 1999 Explorer, no cruise control, no proportioning valve. You can add a in-line adjustable proportioning valve for the rear brakes if necessary. I did and it worked very well.

 

[1sicbronconut]

James Duff makes a nice front tube bumper. Ft Pre-runner Bumper 1989-90 BII, 89-92 Ranger & 91-94 Explorer | dufftuff.com

 

[RangerX]

I need to do some more research on what gearing for the front axle would work with a 4.88 in the rear, or is 4.88 a good choice as well for the front? I've seen some 4.88 front gears for the Dana 35 but all of the part mentions they are for the Jeeps, I assume it will be just fine for the Ex since it's still a Dana 35?

You NEED to have the same ratio front and back. I don’t think 4.88 is available from our front D 35. It is NOT the same gears as a Jeep D35, even if a website or salesman tells you it is.
I suggest 4.56.
Have you looked into what all is involved with changing the front gears?

 

[Travisfab]

I ran 4.88’s in my old truck with a Dana 44 front. It’s a pretty aggressive gear set. How much highway driving will the truck see?

 

[410Fortune]

4.88 is available for our front diff
The TTB front diff is a reverse rotation dana 35 carrier
4.88 came out a few years back
3.73, 4.10, 4.56, 4.88 and 5.13 are your choices

4.56 is great with a manual and 34-35" tires consider 4.88 if the truck is full time trail rig or you plan to go larger then 35's (not likely with a ttb and Ranger as 37's will start to hit the HVAC box and firewall......plus 37's are big for a dana 35 ttb

95-01 brake master cylinders are all the same, so a 95 or a 99 master with no cruise is a good choice for a ttb rig with 96-97 Ranger outer's and rear discs (exactly how my BII is setup)

 

[NickEx623]

Master cylinder from a 1999 Explorer, no cruise control, no proportioning valve. You can add a in-line adjustable proportioning valve for the rear brakes if necessary. I did and it worked very well.

Thank you, seems like that's the consensus here so I will go with that.

James Duff makes a nice front tube bumper. Ft Pre-runner Bumper 1989-90 BII, 89-92 Ranger & 91-94 Explorer | dufftuff.com

Dude, that's perfect, right price point for me too. Thank you!!!

You NEED to have the same ratio front and back. I don’t think 4.88 is available from our front D 35. It is NOT the same gears as a Jeep D35, even if a website or salesman tells you it is.
I suggest 4.56.
Have you looked into what all is involved with changing the front gears?

Thank you, I'll keep that in mind, to make sure the gears is for an Ex. I honestly didn't know the fronts would have to be changed too, but that makes sense, so I will have to some more research into that. I probably will do mostly highway/city driving with some offroading on sand and dirt, perhaps a 4.10 would be better?

I ran 4.88’s in my old truck with a Dana 44 front. It’s a pretty aggressive gear set. How much highway driving will the truck see?

Definitely will be mostly highway/city driving, perhaps 4.10 or 4.56 would be better.

4.88 is available for our front diff
The TTB front diff is a reverse rotation dana 35 carrier
4.88 came out a few years back
3.73, 4.10, 4.56, 4.88 and 5.13 are your choices

4.56 is great with a manual and 34-35" tires consider 4.88 if the truck is full time trail rig or you plan to go larger then 35's (not likely with a ttb and Ranger as 37's will start to hit the HVAC box and firewall......plus 37's are big for a dana 35 ttb

95-01 brake master cylinders are all the same, so a 95 or a 99 master with no cruise is a good choice for a ttb rig with 96-97 Ranger outer's and rear discs (exactly how my BII is setup)

As mentioned above, I will probably be mostly doing city/highway driving, what would your input be on gearing? Perhaps a 4.10 or even 4.56 would be better? My Ex is an auto and I doubt I will ever go up to 37's. Thank you re. the brake MC, will go with that

 

[RangerX]

I run 4.56 and 35s for ten years now and think it’s a great combo. Previous to this, I ran 37s for 12 years with the same gears and was fine with that combo, too. You will be happy with 4.56.

 

[BKennedy]

I just realized you want to run 35" tires. A 4" lift will not clear those tires. I had 32's on mine with a 4" lift and had to trim the back edge of the front fenders. With the 35's and a 5.5" life, I had to trim them some more.

 

[410Fortune]

stick with 4.56 gears
Stuff some 33-34" tires and you will be happy happy
With 4-5" of lift plan on trimming

ALL 4x4 MUST HAVE SAME GEARS IN BOTH DIFFS

 

[NickEx623]

Solved - Lifts and Max tire sizes

Lift and tire size info for explorers Lifts and max tire and wheel sizes for explorers This is a quick reference guide I have put together based on information gathered from the Explorer Forum. Remember this is just a guide. You may have to do some fender trimming to fit these tires on your...

www.explorerforum.com

So this thread is inaccurate about being able to fit 35" tires? I was going to do a 4" bulge fiberglass front fenders to make it work.

If it isn't going to be possible/practical, I may have to just go with 33's which would suck b/c I was planning to put the 35's that I already have on my F150 on my Ex when it's ready to save money.

 

[Travisfab]

The VAST majority of people do not take the time to cycle their suspension and really see what fits and what doesnt. The reality is that a 35 would fit on a stock truck if you did enough trmming/relocating, limited your bump travel, and trimmed or ran fenders. Here are some real world photos for you to see why it's tough to make a 35 work with any size lift. These photos are with 31's & the owner does plan on running 35's down the road. I told him that I am not going to sacrifice any more bump travel, and we will need to do some trimming when that day comes.

 

[NickEx623]

Thanks for that visual, 35's definitely woud be tight if it fits. Going to stick with the Rough Country recommended 33x12.5's

 

[BKennedy]

With fiberglass fenders 35" tires might fit with a 4" lift. Ask the fender manufacture when you order them and they should be able to tell you if they will clear.

That tire size to lift thread also states you will need a 2" body lift along with the 4-6" suspension lift to clear 35" tires.

 

[410Fortune]

35" tires come in different sizes (from like 33.5 -35" actual rolling diameter) and different wheels will place them in different locations in relation to the spindle/hub
So not all trucks are the same when it comes down to it, what fits on one might come close to fitting on another.
35's will fit, how much trimming is needed is up to your setup
37's start to get into the firewall a little bit on these 91-01 explorers and 98-11 rangers

My BII has a 3/8" body drop and a 5" suspension lift and I clear 35's by using fiberglass, I also pushed my beams forward 1" on each side
I could clear 37's but Im not running 37's on a daily driver with dana 35 outers

 

[NickEx623]

Got the truck running today! Just needed a fuel pump after all.

Now I need to put back the driveshaft before I can start test driving it. My driveshaft has a boot on it, separating the two pieces, does the side that is closer to the boot goes to the rear axle or transfer case?