Brian1
Elite Explorer
- Joined
- February 2, 2000
- Messages
- 5,387
- Reaction score
- 644
- City, State
- Albuquerque, NM
- Year, Model & Trim Level
- 1991 XLT
- Callsign
- KG5BAQ
This is a how to thread on replacing the stock body mount bushings with the Daystar Kit KF04009 AND reusing the stock hardware without destroying it. I will not be focusing on removing the seats and trim panels to access the body bolts.
For an additional thread that helped me through this process see DeRocha's body bushing thread
Tools and supplies:
Short M12x1.75 bolt
M12x1.75 Tap and Die (optional)
2 18mm open end wrenches
18mm socket
13mm socket
Air Impact Gun
Big Hammer
7/16" diameter punch or equivalent
Penetrating Oil (I highly recommend Kroil)
Hack Saw
Box cutter/Razor
Die grinder with wire wheel
Vice
Grinder
Large Channel Lock pliers or equivalent pair of large gripping tool (pipe wrench, etc)
Small Flat blade screwdriver or small pry bar
Spray Paint (optional)
Copper Coat anti-seize
Floor Jack and a big block of wood
3.5" Diameter pipe, 3.5"-4" long and a piece of scrap 1/4" steel plate to cover the top of the pipe with a 1/2" hole in the middle
There are 5 body mounts per side, the front on the radiator support is position 1 all the way to position 5 just inside the rear cargo area.
Start by removing the front seats, kick panels, trim pieces at the bottom of the door sills, rear trim piece in cargo area and the hinge plate behind the 2nd row fold down seats. Pull back the carpet and pop the rubber boots off to expose the body bolts.
Start removing the bolts, do 1 side at a time. All bolts come out through the inside of the Explorer except the very front mount which the bolt comes out towards the ground. You may need to use a 18mm wrench to hold the top nut on the front mount if it spins. Remove each bottom nut plate along the frame (see each section below) and then place the jack and block of wood under the body just behind the location number 3 mount and jack it up enough to remove the top bushings. Reinstall each new bushing following the numbers in the instructions after prepping the stock hardware (see below posts)
Continued below...
For an additional thread that helped me through this process see DeRocha's body bushing thread
Tools and supplies:
Short M12x1.75 bolt
M12x1.75 Tap and Die (optional)
2 18mm open end wrenches
18mm socket
13mm socket
Air Impact Gun
Big Hammer
7/16" diameter punch or equivalent
Penetrating Oil (I highly recommend Kroil)
Hack Saw
Box cutter/Razor
Die grinder with wire wheel
Vice
Grinder
Large Channel Lock pliers or equivalent pair of large gripping tool (pipe wrench, etc)
Small Flat blade screwdriver or small pry bar
Spray Paint (optional)
Copper Coat anti-seize
Floor Jack and a big block of wood
3.5" Diameter pipe, 3.5"-4" long and a piece of scrap 1/4" steel plate to cover the top of the pipe with a 1/2" hole in the middle
There are 5 body mounts per side, the front on the radiator support is position 1 all the way to position 5 just inside the rear cargo area.
Start by removing the front seats, kick panels, trim pieces at the bottom of the door sills, rear trim piece in cargo area and the hinge plate behind the 2nd row fold down seats. Pull back the carpet and pop the rubber boots off to expose the body bolts.
Start removing the bolts, do 1 side at a time. All bolts come out through the inside of the Explorer except the very front mount which the bolt comes out towards the ground. You may need to use a 18mm wrench to hold the top nut on the front mount if it spins. Remove each bottom nut plate along the frame (see each section below) and then place the jack and block of wood under the body just behind the location number 3 mount and jack it up enough to remove the top bushings. Reinstall each new bushing following the numbers in the instructions after prepping the stock hardware (see below posts)
Continued below...