Project "Rupert" '91 Ford Explorer

ExplorerExplorer

Adventurer
Almost... The Ford Ranger has a different crossmember between the 2wd and 4wd versions, which requires pulling the engine, unattaching the crossmember, spreading the frame and fitting the 4wd crossmember in... The Explorer/Bronco II do not... In fact, the Bronco II actually has a 'dummy' t-case in most 2wd models, so a 4wd swap is even easier...

Hey, I guess they fixed my other username, lol... ^That^ was me BTW
 

ExplorerExplorer

Adventurer
You won't need to do the 44 outers if you're only going to run 32s. The D35 will be plenty strong for any trails you go on with 32s. A basic 4" Skyjacker, Superlift or Trailmaster lift will work perfectly for you and would allow you to run 33s if you ever felt the need to bump up a size. You've got the right idea with the Jeep hubs too.

Should be a cool build. If you haven't already, check out explorerforum.com

I was thinkin' about the 44 outers just for better braking ability (I have terrible luck with RBV brakes), and better bearing set-up... I just picked up another (3rd) set of D35 beams, and I'll probably have them cut and turned and a 44 knuckle swap done on them (these are future plans)... I've been to explorerforum alot... What I'd really like to know is what lift set-up is the best? I like JD's set-up because I can get it with extended rad arms and I've heard the cheaper ones have problems with the arms cracking and the older drop plate style have a problem punching holes in the diff... I know either Skyjacker or JD would be the one to go with... I'll no doubt do the Superrunner steering set-up (one of the key modifications to keep a lifted TTB happy, and not chew up your tires)...
 

zjrog

Observer
My mistake. My understanding was the RBVs all had different crossmembers for 4x2 and 4x4. I finally saw a 4x2 B2 with the dummy case a few days ago...
 

Beanmachine7000

New member
Well, I ran across a 96 Disco I, 5-speed... If things work out I'll be building it up instead... I love the Disco, and I know it won't be near as reliable as what I have now, but there's just something about a Rover, right?
 

wanderer-rrorc

Explorer
I also have a 92 explorer...

its nowhere close to stock...

heres some helpfull hints...

A4LD...get dual or tripple coolers on it!! I have had one survive 3yrs of serious abuse...the coolers and changing the fluid every 6mo has kept it alive!
(and cheaper than a rebuild!)

do a SAS...by the time ya mess with the ttb stuff and steering..its actually CHEAPER to do the sas...leafsprung works for a cheap install..anythings better than the twinbeams...

a TTB35 and TTB44 use the SAME size shafts and joints..(except lenght)..the upgrades are only the spicer x570 joint..nobody makes alloy inners for them...

the sas is MUCH simpler than trying to get all the pivot points bolted correctly in place..and the sas works so much better..

get some EB coils (early bronco)...they are a MUCH nicer ride...on a stock setup a 3in coil will add 1.5 lift and drasticaly improve the ride!!

WINCHES..get a good one...xrc8 from 4wheelparts is a great value!!..

under the pass carpet...is the inertia switch...cut it out...splice the wires...and never worry about it again!

electric fans are cool..but not when you forget to turn them on..or they fail...leave the mechanical one on it..

powertank over OBA...its more portable..and easier to deal with...sure its a finite ammount...but its ALOT...and reasonable to carry..(unless already have the oba installed..)
 

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