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Explorer for Overlanding


crazybronco

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It has been a while since my last post here, I sold my Ranger a little while back and have been looking for a new project.
I have been into Motorcycles and Adventure riding, basically mild off road forest service, fire roads and that kind of thing. However my wife just does not want to go with me on the bike and she does not ride. So, I have been thinking about creating a SUV for mild off road stuff.
We want to explore FS roads, fire roads, Ghost towns and the like. I think an Explorer would be the perfect vehicle for this kind of thing. I want to find one with the V8, as I love the 5.0l engine. So, I think this puts me in the 95-2001 range. I saw the post about the 95 lift kit issues, so no 95. I do not plan to go big on the lift, just 2-3in just to fit some good aggressive tires. Also thinking a drop in locker, Aussie or something like that in the rear only. A winch to get out of trouble, etc.
I want to camp inside, or go with a roof top tent. I will be adding a rear tire carrier and fuel can rack. On-board-air and I have a Hi-Lift jack already. I also have some nice big lights for night driving.
So, the question I have is, what should I look for? Is there a transfer case that I should look for and one to avoid? How would I identify the right case easily?
I see us using it mostly in the USA, Canada and maybe Mexico, so a Ford Explorer is a good choice. If I was using it abroad I would go for a Toyota or something else easy to get parts for. I figure here in North America parts will not be an issue.
Please give any other suggestions you have, links I need to read, what ever.
Thanks
 


Shran

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It has been a while since my last post here, I sold my Ranger a little while back and have been looking for a new project.
I have been into Motorcycles and Adventure riding, basically mild off road forest service, fire roads and that kind of thing. However my wife just does not want to go with me on the bike and she does not ride. So, I have been thinking about creating a SUV for mild off road stuff.
We want to explore FS roads, fire roads, Ghost towns and the like. I think an Explorer would be the perfect vehicle for this kind of thing. I want to find one with the V8, as I love the 5.0l engine. So, I think this puts me in the 95-2001 range. I saw the post about the 95 lift kit issues, so no 95. I do not plan to go big on the lift, just 2-3in just to fit some good aggressive tires. Also thinking a drop in locker, Aussie or something like that in the rear only. A winch to get out of trouble, etc.
I want to camp inside, or go with a roof top tent. I will be adding a rear tire carrier and fuel can rack. On-board-air and I have a Hi-Lift jack already. I also have some nice big lights for night driving.
So, the question I have is, what should I look for? Is there a transfer case that I should look for and one to avoid? How would I identify the right case easily?
I see us using it mostly in the USA, Canada and maybe Mexico, so a Ford Explorer is a good choice. If I was using it abroad I would go for a Toyota or something else easy to get parts for. I figure here in North America parts will not be an issue.
Please give any other suggestions you have, links I need to read, what ever.
Thanks
I am not terribly familiar with 95 up Explorers, however, a couple things come to mind:

Some (all?) V8 Explorers that are AWD (not 4wd) have only high range transfer cases. No low range at all. I don't know how big of a deal that would be to you. I have done some light wheeling on really washed out, nasty dirt roads in a similar vehicle...the automatic transmission made up for the lack of low range somewhat, but the vehicle was literally maxed out at that point. It limits you to easier trails.

I would also be tempted to find one with an OHV 4.0 V6 instead of the SOHC 4.0 V6, if you ended up going with a V6 instead. I feel like the OHV engines are easier to work on and a lot less complicated, although they do not make as much power.

Probably the main thing is finding one in good shape I guess. Most of the junked ones I have dealt with have suffered from blown head gaskets or burned up auto transmissions, usually between 170-200k miles.
 

alaskan155

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you can crank the torsion bars on a explorer and add longer shackles in the rear to gain 2" of lift, then add a body lift and that gives you 5" total(what i have on my ranger), allow for you to clear 33s pretty easy.

the front diff is a low pinion, aluminum housing with no lockers available to my knowledge, so you are going to need a skid plate to protect it.(i already broke mine after flat towing once and 1 season of wheeling)
make sure you carry spare cv shafts

the torsion bars have no flex offroad.....

the transfer case is easy in the v8 (uses the same bolt pattern as a fullsize, and since the frame rails are wide on a explorer i think alot of people use expedition cases or bronco cases(i have a spare from my old 88 that i saved because it had fixed yokes front and rear)


imo i would look for a 91-94....
the ttb is stronger and flexes better. will have a better ride offroad.
same 4.0 ohv basically as the 95-01. the SOHC can easily be swapped in if you need more horsepower but the ohv is more reliable.
easy to solid axle later down the road, james duff basically makes a bolt on kit, and dana 30 swaps are easier since its already ready for coils and has a steering box.

downfall is the A4ld, its a week automatic.


sorry i have a 2000 ranger with the same front suspension as the 95-01 explorers
 

crazybronco

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Thanks for the info. I think to begin with, I will be doing more light off road stuff and should be able to get by with 31in tires. I would rather swap a transfer case than to have to swap an entire engine. It is a lot more work to put a V8 where a V6 was than to swap a T-Case on the end of a trans.
I am aware of the issues with IFS. I have wheeled an IFS, a TTB and a few solid axle Jeeps. I know the IFS is limiting, but for my use it should be OK. I figure I can just lock the rear and mount a winch. Good judgment and experience should help me avoid the need for more.
Now for a big question, I know these are small SUV's, but can 2 people sleep in the back? And, is the 02-10 any wider or longer? Is first gen the same as 2nd gen?
I may need to go with a roof top tent.
As far as what I can fix, I have built several wheeling rigs, SASed a B2, ground up on a Cherokee, several 73-87 Chevs and worked as a mechanic for 25+ years. I can tackle about anything. :icon_welder:
 

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'02-'05 is wider/longer than '91-'01. '06-'10 is slightly wider (and I think longer) still. '02-'10 is IFS and IRS, not sure if that is an issue for you (and also the V8 is the 4.6, not a 5.0).
Yes, all V8 Explorers came with a single-speed AWD t-case that can be swapped for a two-speed F-150 case.

Plenty of lockers available for both axles (D30 & 8.8") on '02-'10 Explorers (may have to machine the side gears slightly for the IRS axle circlips depending on the locker), but there is still also the Powertrax No-Slip that will fit the '95-'01 D35 IFS too.

Pull the swaybars and the IFS flexes pretty decent within it's range of travel, but yes it does max out pretty quickly (I'd suggest disco's for it because the handling without them gets pretty sloppy on IFS trucks compared to TTB trucks).

I would think two could fit no problem in a pre-'02 truck if you don't mind a little coziness.
 

crazybronco

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'02-'05 is wider/longer than '91-'01. '06-'10 is slightly wider (and I think longer) still. '02-'10 is IFS and IRS, not sure if that is an issue for you (and also the V8 is the 4.6, not a 5.0).
Yes, all V8 Explorers came with a single-speed AWD t-case that can be swapped for a two-speed F-150 case.

Plenty of lockers available for both axles (D30 & 8.8") on '02-'10 Explorers (may have to machine the side gears slightly for the IRS axle circlips depending on the locker), but there is still also the Powertrax No-Slip that will fit the '95-'01 D35 IFS too.

Pull the swaybars and the IFS flexes pretty decent within it's range of travel, but yes it does max out pretty quickly (I'd suggest disco's for it because the handling without them gets pretty sloppy on IFS trucks compared to TTB trucks).

I would think two could fit no problem in a pre-'02 truck if you don't mind a little coziness.

Thanks, I have been looking and I really like the 95-01 V8 Explorer/Mountaineers. I think that is the way I am going to go. The T-case swap would be much easier than the engine swap. I think it will just work best.
Disco's is not problem, made some for my XJ.
 

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