Returning...

[dubbio]

Hello! again. my name is steve, im from ohio. i'm back on the forum again after a few years without an explorer, sad boring years.

this time around i managed to find an '02 XLS with a manual trans, its only RWD but has the D4 axle code (3.55 LS?). it was a steal for $400. only kicker so far seems to be the clutch is fried, as a bonus it turns out no one ever made replacement parts, or very few. The 4 door featured the m5odr1-hd, but with a 26 spline 1 1/8" input shaft, and its a dual mass flywheel setup so the clutch disc is unsprung.

ill likely be asking a ton of questions regarding clutches from 4.0l motors, measurements and the like. probly my biggest question is can i use a 23 spline input shaft? if thats a go then im likely to convert to the readily available clutch setup and be on the road for another $300 which gets me all-in under $1k

 

[BrooklynBay]

Welcome to this forum! Check the threads in the transmission section for more information.

 

[96firephoenix]

Please keep me in the loop on what you find for clutches. the Dual-mass FW and 26 spline combo seems to only be on early build explorers, from what this thread says, but no sources cited

If all else fails, a 4.0 M5OD from a Ranger should do the trick.

Also, what part of OH are you in?

 

[dubbio]

im between dayton and cincy.

ive found a few places to get the 23 spline input shaft but im skeptical as to whether or not i can just swap it out. idealy id like to convert over to readily available parts, but very worst case scenario i send my oem parts to be refurbished.

i did find a clutch disc that will fit the input shaft from a 5.0 fox body, but the disc is the single mass type with the sprung hub and is 10 3/8in vs 10 1/8" and it wont fit inside the DMF. if i could make up the difference in the O.D. by trimming a bit off the disc and opening the dmf's pocket slightly, id try it for $40. wont help the pressure plate being grooved, but im not a racer so itd likely hold up for me.

 

[dubbio]

im thinking its also viable to get the 23 spline disc and drill the rivets holding the friction media to each disc out, then just build the one i need. but still, not helping the pressure plate. plus the riveting tool is like a minimum $200 setup. theres options to explore, ill let you know what i figure out. with pictures! with the holidays right here and now you'll need to be patient tho.

 

[Mike65]

Welcome back.

 

[tonytheexplorer]

Welcome back! Cheers from the Sin City!

 

[beepinX]

Sounds a good score, congrats! Looking forward with your build thread

 

[96firephoenix]

im between dayton and cincy.

I'm in Indy, but I work in Batesville, IN. I'd be down to come out that way to take a look/give a hand (I need to run to the IKEA in West Chester, anyway).

 

[dubbio]

cool, thanks! i'll let you know when the fun gets going

 

[dubbio]

my bad, 3.73LS, apparently i cant read