where to start

[91nut]

I have a bone stock 91 xlt. What is the first thing I start with to make it trail ready. SOA. Lift, lockers, transfer case, change IFS to solid (change to what). Budget of $5000. It was either make my explorer trail ready or buy a cj. Any helpful answers?

 

[Sandy]

If it was me, I would start with a lift, 4 inches or more, re-gear the axles and look for mud tires to fit the budget based on teh new gearing.
An free flow air cleaner and exhaust will help as well as a computer chip change.

If you ever get more money , try a transfer case change and a V-8, of course these will run well over $5000 by themselves.

If you break the axles then consider upgrading to a D44/
D60 front end and later to a beefier rear like a D60.

Believe me everything cost a lot of money these days, good luck on your choices.

 

[91nut]

what kind of transfer cases are available for the 91 xlt. ? Or do I just change the gearing in the existing one. I thought about the lift, but what about the add-a-leaf suspension. I want to do the SOA conversion too.

 

[CoryL]

Options for t-case...

Swap to an Atlas 2. They come in 3.0, 3.8, and 4.3 ratio low ranges. Stock is appx. ~2.6. If you are interested, I can hook you up on one for a decent price. The 4.3 retails for $2640 + shipping.

Anything else requires a motor swap to get a different tranny to run a different t-case, unless you get a C5 bellhousing and bolt a C4 tranny with D20 t-case to that bellhousing.

Currently no one makes a new planetary gear set for the BW1350 or BW1354 t-cases. I am trying to work something out, but it looks doubtful.

With the SOA in the rear, you shouldn't need an add-a-leaf.

 

[91nut]

SOA in the rear with stock springs? How much flex can I get with them? As for the front end how durable is the IFS. Will it survive with mild rock crawling. Dana 44 is in the works but not till later.

 

[asp84]

V8 First!!!!!!!!!

 

[RFR2212]

Originally posted by 91nut
SOA in the rear with stock springs? How much flex can I get with them? As for the front end how durable is the IFS. Will it survive with mild rock crawling. Dana 44 is in the works but not till later.

Do it right the first time... dont dump money in the TTB if yer gonna be doin a SAS...

 

[yob_yeknom]

In the beginning. Sorry, couldnt' resist.

With $5k, I'd start with around a 4" suspesion lift. Then get the biggest tires you can fit. New gears front and rear to compensate for the larger tires and a locker in the rear. You'd have a capable rig, and money left over for some little things.

 

[91nut]

IFS

Does the front end handle off camber angles and stress. Is it worth to swap out to a Dana in the begining or is it strong enough to hold onto for a couple of years.