Thinking about new project / swap

[331stroker]

Hello I am new here and I have found some good information so far. I couldn't find a better form to post this in and I do not actully own an explorer just yet. What i do have is a 96 mustang with a 331 stroker and tremec TKO among many other "mods". Basically the only thing stock is the body. It was built for race and is not very street-able. It is more or less an expensive toy now that sits, so i've come to the point where i need to do something with it or sell it. I have too much time and money in it to sell it, so i've been thinking of a new project. Basically I'm wanting something useful. Something that will handle decent on the highway that i can also take out in a field or through the woods or pull a trailer behind. I don't want to spend much as i've already put a lot of money into the mustang. So i'm thinking a 1st or 2nd gen Explorer (or maybe expedition), 4-door, 4x4 and would like to re-use as much as i can from the mustang. Some of the things i learned so far is that the 2nd gen's had a 5.0L option which is great because my 331 is a late model 5.0L block so the swap should be easy. One thing im not too sure on is the TKO. It sounds like it might be possible, but im not sure. Is there a difference in a "truck" transmission vs a "car" transmission. The TKO has a 31-spline output shaft, which is the factory on some of the expolorer tranny's right? The motor is carburated so no electronics to worry about. I will want to "fix" any weak drivetrain componets as well. So here is want i'm wanting to know right now:

1. For best on-road & off-road handling and suspension/drivetrain durability, which model/year explorer should i buy?
-1st gen ladder-bar rear & TTB front vs 2nd gen IFS
-1st vs 2nd engine/tranny swapability.
-1st vs 2nd suspension/drivetrain durability.

2. How difficult would it be to get my TKO to mate up with a transfer case?
-Also considering the Atlas II

3. I've read the front differentials and transfer cases are kinda weak. My motor has around 400hp/tq (im guessing). I will not be doing any rock climbing, mostly street and small ditches. Maybe climb over down trees in the woods, idk. What kind of drivetrain mods would i need to do to prevent breakage?


I will have more questions but this should be a good start for now. Thanks for the help in advance.

 

[331stroker]

ttt.

 

[4x4junkie]

The 1st-gen TTB front differential is actually quite strong (the whole axle is really, aside from the locking hubs which can be swapped out for the stronger Warn 'Jeep' hubs). Same goes for the 1st-gen transfer cases, though if you're planning on an Atlas, then this wouldn't be as important.
For something to take offroad at all, the 1st-gens are the ones to look at.

About the best thing a 2nd gen has IMO is the disc brake rear axle, though it's stupid easy to swap it into a 1st-gen... Just bolt it in. Pretty sure the master cyl is compatible with the disc rear (my BII's MC was), though it's not hard to swap that part too if it needs it.

What size tires are you planning to put on this project?

 

[331stroker]

I will probably run the biggest tire i can fit under it with oem ride height. It looks like I can fit 31x10.50 based on this thread.

Are the drivetrains the same for V6 vs V8 on 1st gen? So far here is what im looking for:

91-94 V6 or V8 4x4 4-door explorer

Also it looks like the expeditions were not made until 97, how do they compare to the explorers, do they have the IFS?


EDIT: It looks like the 1st gen only came with a V6. Will my 302 block still bolt up with ease?

 

[331stroker]

Basically, what im worried about is since these came with v6's, i dont want my engine to break the drivetrain. I'm more familiar with mustangs, and i know the v8 has a stronger drivetrain than the v6 model. Also if there is any possible way to re-use my tko tranny in this that would be great, but im not counting on it so sticking with the stock drivetrain, what would i need to worry about breaking, if anything?