Explorer upgrades

[Evan]

I have been focusing most of my attention during the past 8 months on the new job, but after settling in a bit I figure it's time to start working on the Explorer again. For a while I was unsure of the route I wanted to take, but I've finally decided.

Ford 8.8 rear with discs, 5.13s, No-Slip locker
Double cardian rear shaft
New rear bumper
5.13s front with lunchbox locker
Double core radiator, performance e-fan with auto thermostat
Front winch
Jeep hubs
35x12.5s on steel wheels
New clutch, starter, flywheel

I'll be documenting progress and providing pics as I go along.

Got a D35 front today with 5.13s set up and a locker. The 5.13s will bring my final crawl up to 117.

I'll be setting up the 8.8 gears myself. It'll be my first time setting up gears and I'll try to document it from a newb perspective.

http://photos-a.ak.facebook.com/photos-ak-sf2p/v169/131/19/6601727/n6601727_31146120_7253.jpg

[compleckz]

:drool:

gonna be even more beastly after.. whats the front locker? richmond lockright?

[CheapThrillB2]

cool, hopefully we'll get some wheelin pics, i miss my old sport. Atleast i'll get to see you tearing it up with yours

[Evan]

:drool:

gonna be even more beastly after.. whats the front locker? richmond lockright?

Yes, it will be more beastly, but Punisher will still be able to drive right over me in 2WD. :)

Don't know what brand/model the locker is. I bought the assembly from JohnnyU.

[JohnnyU]

It's a LockRight. :icon_thumby:

[compleckz]

what were you running before, welded front?

since my lockrighted d35 and 4.56s, i cant seem to make 1 trip without breaking a shaft or at least popping a cap (gangsta)... i've caught it twice and shut it down real quick when i heard the noise, preventing a larger failure.. i've got new shafts to go in once i get the caps tacked on (both sets of shafts have 760x's, the bad set has full circles, the new set has stock clips)..

what are u running for axle 'mods'/u-joints?

[Evan]

what were you running before, welded front?

since my lockrighted d35 and 4.56s, i cant seem to make 1 trip without breaking a shaft or at least popping a cap (gangsta)... i've caught it twice and shut it down real quick when i heard the noise, preventing a larger failure.. i've got new shafts to go in once i get the caps tacked on (both sets of shafts have 760x's, the bad set has full circles, the new set has stock clips)..

what are u running for axle 'mods'/u-joints?


Right now I'm running both a welded front and rear. My shafts have Spicer 760s all around, with full-circle retainers and welded caps. I have broken 2 joints in my 2 years of offroading, and both occured because I cut the wheel too far and bound the joint.

The 760s make a huge difference over the 297s. Also, it is better to weld the caps in. Using full retainers alone causes the caps to spin in the yoke, which becomes egged out and ruined.

[Evan]

Just picked up a set of 5.13s for an 8.8 on Ebay.

http://i13.ebayimg.com/06/i/08/3c/30/50_1.JPG

On Thursday I'm heading to the yard to pick up a 31-spline 8.8 with discs.

[compleckz]

On Thursday I'm heading to the yard to pick up a 31-spline 8.8 with discs.

when i swapped the 31spl 8.8 into my truck i used two right side rubber lines (i put a right side on the left side), that allowed me to run the hard brake lines on the axle similar to the rear drum setup, and that way i could use my existing extended rear flexible line (the one from the frame hardline to the top middle of the diff).. the disc brake rears have a weird left side brake line..

so you might want to grab an extra pass side rubber line :icon_thumby:

[Evan]

when i swapped the 31spl 8.8 into my truck i used two right side rubber lines (i put a right side on the left side), that allowed me to run the hard brake lines on the axle similar to the rear drum setup, and that way i could use my existing extended rear flexible line (the one from the frame hardline to the top middle of the diff).. the disc brake rears have a weird left side brake line..

so you might want to grab an extra pass side rubber line :icon_thumby:

I don't have any lines at all right now running to the rear.

[Evan]

Picked up an 8.8 yesterday. 31 spline disc off of a low mileage 95 Ex. It's in great shape. Paid $200. I got it mostly torn down last night. Tomorrow I'm going to relocate the perches.

Was surprised at how beefy the stock discs are on that axle.

Gears and install kit are coming Tuesday next week.

[Evan]

A few updates:

I'll post some pics soon. Got the 8.8 all torn down, and one of the spring perches chopped off and relocated for the SOA. Was able to reuse the perch. I plan on moving the other perch tomorrow.

I got my 5.13s for the rear today and damn....that's a tiny pinion!

[compleckz]

sounds like good progress, my 31-spl sat in my garage for a year before i finally put it into my truck.
but it was quite pretty when i put it in:
http://photos-c.ak.facebook.com/photos-ak-sf2p/v143/207/104/513533454/n513533454_399046_5753.jpg

are you going to be doing the gear install yourself? its the only thing i've had someone else do to my truck (but i removed the diffs and took them in)..

just curious, is there any advantage to running full circle clips, if you're going to weld the caps anyways?

[Evan]

http://photos-d.ak.facebook.com/photos-ak-sctm/v185/131/19/6601727/n6601727_31161739_8496.jpg

http://photos-a.ak.facebook.com/photos-ak-sctm/v185/131/19/6601727/n6601727_31161740_8850.jpg

http://photos-b.ak.facebook.com/photos-ak-sctm/v185/131/19/6601727/n6601727_31161741_9178.jpg

http://photos-c.ak.facebook.com/photos-ak-sctm/v185/131/19/6601727/n6601727_31161742_9520.jpg

[Evan]

This weekend with Todd's help I got the perches welded on and the 5.13s set up. Got a pretty good hands-on understanding of how to set up gears. I also got new seals in, and ran some paint over the axle. Should be ready to go in any day.

I also have a pic below of a 302 block that may one day find it's way into the Ex.

http://photos-a.ak.facebook.com/photos-ak-sf2p/v195/131/19/6601727/n6601727_31176540_6160.jpg

http://photos-b.ak.facebook.com/photos-ak-sf2p/v195/131/19/6601727/n6601727_31176541_6451.jpg

http://photos-c.ak.facebook.com/photos-ak-sf2p/v195/131/19/6601727/n6601727_31176542_6722.jpg

http://photos-d.ak.facebook.com/photos-ak-sf2p/v195/131/19/6601727/n6601727_31176543_6992.jpg

http://photos-a.ak.facebook.com/photos-ak-sf2p/v195/131/19/6601727/n6601727_31176544_7266.jpg

[Evan]

I got the rear axle installed. The 117 final crawl is off the wall. The on-road gearing is nice now too, feels like I just turbo-charged the engine. I need to run brake lines to the back, and install the 3rd member up front.

I've got 35s coming, as well as a dual core radiator with a hi-performance e-fan and thermostat. I'm also going to fab up some linkage to shift my t-case from the cab.

http://photos-c.ak.facebook.com/photos-ak-sctm/v185/131/19/6601727/n6601727_31179110_328.jpg

http://photos-d.ak.facebook.com/photos-ak-sctm/v185/131/19/6601727/n6601727_31179111_633.jpg

http://photos-a.ak.facebook.com/photos-ak-sctm/v185/131/19/6601727/n6601727_31179112_928.jpg

http://photos-b.ak.facebook.com/photos-ak-sctm/v185/131/19/6601727/n6601727_31179113_1238.jpg

http://photos-c.ak.facebook.com/photos-ak-sctm/v185/131/19/6601727/n6601727_31179114_1542.jpg

[Todd]

You just have to show me up dont ya. I went 111:1 now you are at 117:1.

Good to hear you got it in. Get that bitch up here for alumni run!!!!!!!!!

[Evan]

You just have to show me up dont ya. I went 111:1 now you are at 117:1.

Good to hear you got it in. Get that bitch up here for alumni run!!!!!!!!!


That's the plan.

It's damn nice not to have to burn the clutch to start out in high range. I'd actually prefer 4.88s or 4.56s. The 5.13s are too deep for driving on the road. Last night when I tested it out I was going about 45 and the RPMs were already over 2000 in 5th. I only got 5.13s because I got an awesome deal on the front.

And don't worry, it'll only be a matter of time before you go to a tripler or 305/NP435/NP203/NP205 and leave me in the dust. :)

EDIT: I mean, I'll leave you in the dust.

[danger88ranger]

That's the plan.

It's damn nice not to have to burn the clutch to start out in high range. I'd actually prefer 4.88s or 4.56s. The 5.13s are too deep for driving on the road. Last night when I tested it out I was going about 45 and the RPMs were already over 2000 in 5th. I only got 5.13s because I got an awesome deal on the front.

And don't worry, it'll only be a matter of time before you go to a tripler or 305/NP435/NP203/NP205 and leave me in the dust. :)

EDIT: I mean, I'll leave you in the dust.

EDIT(again) leave todd in the rocks, or mud

[milje]

I'd actually prefer 4.88s or 4.56s. The 5.13s are too deep for driving on the road. Last night when I tested it out I was going about 45 and the RPMs were already over 2000 in 5th. I only got 5.13s because I got an awesome deal on the front.


Sounds like 35's aren't gonna be big enough, time for 38's :icon_rofl:

[Evan]

Got a lot done this weekend. I replaced the bad pinion input bearing on the D35 5.13 lockrite case. I used the bearing from my old case. When I was removing the pinion nut on the old case I had the carrier blocked with a socket so the gears didn't turn. All of the sudden...CRACK! I looked and the D35 housing had split down the middle, in true aluminum fashion. Glad I didn't try that on the new one. Got the bearing in, and got the front back together, so now I'm running 5.13s with a Lockrite in the front.

Next I went to run lines to the back and connect the rear discs. That turned into a real can of worms. Tons of rusted fittings, etc. Ran a new line to the rear, replaced the master cylinder, new driver side front line and hose, new passenger side caliper (due to a stripped out bleeder hole), and I already had new rotors in the rear.

So now I'm running 5.13s and a Lockrite front, with 4-wheel discs. Next on the list is a radiator upgrade, No-slip in the rear, and the new tires.

[Evan]

Just got a Lockrite for the rear. I decided to go with a Lockrite rather than a No-slip as the Explorer isn't my main DD and I don't mind a little racheting. If I could DD a welded rear for over a year I think I can handle a Lockrite. :)

Putting the 35s on is on hold right now until I find out if they're legal in WI.

http://www.rocky-road.com/media/lockrightlocker.JPG

[Evan]

I have ordered a set of 4.5" Jeep coils for the front. I'll be replacing the F-150 coils with those. I'll be adding a swaybar as the Jeep coils should be much softer. Of course, I'll rig up a quick disconnect so I can disconnect the bar on the trail. Still waiting on the rear locker.

Today I swapped in a new 2-core aluminum radiator, along with new hoses. I got rid of my e-fan and went to a new mechanical fan. My cooling problems should be over.

I also gave the Ex some love, with some standard maintenance. This included new platinum plugs, cleaned IAC and MAF, and a new air filter. And man, my old filter was dirty after just 2 years of wheelin.

I have a question. I have about 1.5" between the radiator and fan. Do I need a shroud? If so I can probably pick one up at the yard...

[CheapThrillB2]

ldeal cooling you need a shroud (will also keep the splash down when mud/water hits the fan). Idealy if you look from the side at the fan you want half the thickness of the fan blade showing and the other half inside the shroud

[mkpecor]

nice,i just picked my 8.8/D35 and cant wait untill its in, is the rust on your leafs from the salt on the roads over there?

[Evan]

nice,i just picked my 8.8/D35 and cant wait untill its in, is the rust on your leafs from the salt on the roads over there?


I'm sure it is, but it's only surface rust. ;)

[mkpecor]

ya its no big deal, i live in washington so you dont see that, thats crazy. hope to see the fineshed project.

[Todd]

You got the 35's yet?

[mhughes165]

Just got a Lockrite for the rear. I decided to go with a Lockrite rather than a No-slip as the Explorer isn't my main DD and I don't mind a little racheting. If I could DD a welded rear for over a year I think I can handle a Lockrite. :)

Putting the 35s on is on hold right now until I find out if they're legal in WI.

http://www.rocky-road.com/media/lockrightlocker.JPG


if i can pass state stability tests in NJ, which has by far the strictest lift laws in the country on 35's i see no reason u would have any problems

[Evan]

Don't have the 35s on yet. I'm waiting to swap on the Jeep hubs, and modify my locknut washer so the wheel bearings don't come loose. Want the sway bar mounted before I go to those too. Tonight I'll be fabbing up a radiator shroud and installing the Jeep coils up front. I should have the locker in the rear by the weekend. Also hope to finally fab up some linkage to my t-case as well.

http://photos-b.ak.facebook.com/photos-ak-sctm/v204/131/19/6601727/n6601727_31231969_5409.jpg

[milje]

Do you have Jeep hubs yet? If not, Jim is going to have them on sale on 3-1, I'm not sure how much they are normally.

http://www.therangerstation.com/forums/showthread.php?t=10612


Can't wait to see it when it's done.

[Evan]

Some updates:

Got the locker installed in the rear. Seems to drive pretty smooth on the road. I got frustrated trying to make a shroud for my mechanical rad fan, so I bought a performance electric. I also bought a thermostat that kicks the fan on at 185F. There is an amazing difference between this fan and the junkyard e-fan I had before. This fan really moves a lot of air; it sounds like a jet engine. I also have manual controls in the cab, in addition to the thermostat. All and all I have well over $350 into this radiator setup, but it should pay off.

I have a set of Jeep hubs coming from Jim.

I bought all the stuff I need to fab up some linkage for my transfer case, so I can get going on that while I'm waiting on the Jeep hubs and 35s.

[Evan]

Got tired of waiting for my retreads, so I cancelled the order and bought a set of 35x12.5x15 Pro Comp mud terrains, mounted and balanced on Rock Crawler rims. Should have those in a week or two.

I tore apart the front end an put Moog greasable joints everywhere. Got my speedo hooked up finally too. Have not had that since I put the doubler in. I had to re-route the cable to get it to reach.

The Jeep hubs are here. They're pretty beefy. Just holding them you can tell a big difference in weight from regular warn hubs. All I really need to do now is get a double cardian driveshaft going in the rear, and bolt on my wheels and tires when they get here. I should have a rig that I can drive to the trail at 65 MPH with no shakes or vibration, and then romp on the trail with no breakage and some pretty good performance. Some pics below:

http://photos-d.ak.facebook.com/photos-ak-sctm/v215/131/19/6601727/n6601727_31267227_1781.jpg

http://photos-a.ak.facebook.com/photos-ak-sctm/v215/131/19/6601727/n6601727_31267228_2214.jpg

http://photos-b.ak.facebook.com/photos-ak-sctm/v215/131/19/6601727/n6601727_31267229_2613.jpg

http://photos-c.ak.facebook.com/photos-ak-sctm/v215/131/19/6601727/n6601727_31267230_3036.jpg

http://photos-d.ak.facebook.com/photos-ak-sctm/v215/131/19/6601727/n6601727_31267231_3453.jpg

http://photos-a.ak.facebook.com/photos-ak-sctm/v215/131/19/6601727/n6601727_31267232_3875.jpg

[CheapThrillB2]

Def can't wait to see it back on the ground with the new 35's

[Evan]

This weekend I got the fenders trimmed for the 35s. Got a 1350 double cardian installed in the rear with Spicer joints. With a doubler and a 2 door Explorer, a front RBV shaft is just the right length. Also fabbed up some linkage to shift my t-case. Doesn't look awesome, but it shifts pretty smooth.

http://photos-f.ak.facebook.com/photos-ak-sf2p/v199/131/19/6601727/n6601727_31284837_2209.jpg

http://photos-g.ak.facebook.com/photos-ak-sf2p/v199/131/19/6601727/n6601727_31284838_3154.jpg

http://photos-h.ak.facebook.com/photos-ak-sf2p/v199/131/19/6601727/n6601727_31284839_4176.jpg

http://photos-a.ak.facebook.com/photos-ak-sf2p/v199/131/19/6601727/n6601727_31284840_5126.jpg

http://photos-b.ak.facebook.com/photos-ak-sf2p/v199/131/19/6601727/n6601727_31284841_6085.jpg

[ZMan]

gonna be sweet!

[CheapThrillB2]

coming together nicely, but i think i need more of a panaramic shot of the truck to see the whole thing esc with the 35s on it.

On my old sport i was able to just switch the rear shaft and front shaft (yokes to) with the doubler in......i always figured if i broke the shaft in the doubler on the trails, i could pull the doubler out and switch shafts and yokes and be wheeling again in no time.

Did you get a decent warranty on your jeep hubs? i bought the basic warn hubs for my D35 and busted them 4-5 times in a year and half (using my 36's) and got them warrantied everytime through a local napa. Holshotracer bought the jeep hubs from a 4x4 vendor locally and he bust his in Early Jan. (using 33's) and he still has yet been able to get them warrantied (he broke the hat and does not have the actually lock out part any more, went flying). The vendor won't give him a straight answer and giving him the runaround.

But all in all, def need some whole truck shots

[Evan]

coming together nicely, but i think i need more of a panaramic shot of the truck to see the whole thing esc with the 35s on it.

On my old sport i was able to just switch the rear shaft and front shaft (yokes to) with the doubler in......i always figured if i broke the shaft in the doubler on the trails, i could pull the doubler out and switch shafts and yokes and be wheeling again in no time.

Did you get a decent warranty on your jeep hubs? i bought the basic warn hubs for my D35 and busted them 4-5 times in a year and half (using my 36's) and got them warrantied everytime through a local napa. Holshotracer bought the jeep hubs from a 4x4 vendor locally and he bust his in Early Jan. (using 33's) and he still has yet been able to get them warrantied (he broke the hat and does not have the actually lock out part any more, went flying). The vendor won't give him a straight answer and giving him the runaround.

But all in all, def need some whole truck shots


Still waiting on my 35s. When I get them you can be sure there will be some whole truck pics.

I bought these Jeep hubs from Jim here on TRS. I don't think there is a warrenty, however I don't plan on breaking them. From what I've read, they should be fairly reliable with 35s. I do carry some spare regular Warn manual hubs on board as well, just in case. Holeshot must have been giving his rig some decent gas to break a set of Jeep hubs running 33s. :beer:

[CopyKat]

Looking good Evan.

Time to get rid of those F150 coils and get some softer ones.

[milje]

Time to get rid of those F150 coils and get some softer ones.

I'm wondering what those black coils against the wall towards the top of the page are?

[Evan]

I'm wondering what those black coils against the wall towards the top of the page are?

Those are a set of 4.5" ZJ coils. They will go in the front end eventually, as soon as I can find some TTB drop brackets and extended radius arms. For now I'm going to keep running the F-150 coils, as they seem to do "pretty" well.

Got my new exhaust tonight so I'll be installing that. 35s will be here Friday this week or Monday next week.

[CheapThrillB2]

drop brackets eh.....i vaguely recall a set of drop brackets:buttkick::icon_rofl:

[Todd]

Those are a set of 4.5" ZJ coils. They will go in the front end eventually, as soon as I can find some TTB drop brackets and extended radius arms. For now I'm going to keep running the F-150 coils, as they seem to do "pretty" well.

Got my new exhaust tonight so I'll be installing that. 35s will be here Friday this week or Monday next week.

Evan, you should come up here and we can build you a set of rad arms and mounts like mine. Just get 4' of 2" OD 1/4 wall DOM and some 3/8" plate along with the old arms and we will get ya set.

Oh and got your voice mail, went out to Kurus before you called but the Sploder was under some major snow, so I didnt get the yoke so no worries there as you got one.

drop brackets eh.....i vaguely recall a set of drop brackets:buttkick::icon_rofl:

Ya I wonder whos rig those are on:D