UPDATE: Kirby N’s 1991 Ford Ranger STX 4×4 was voted as the March 2024 Truck of The Month and then in December voted as the 2024 Truck of The Year.
Forum member ‘Kirby N.’ always wanted to build a 1989-1992 Ford Ranger and spent considerable time trying to find one with a 4.0L V6, M5OD manual transmission, and manual transfer case. His goal was to build a reliable vehicle that can be used for work, exploring, and off-road. Kirby needs the Ranger to be able to haul dirt bikes, plywood, and sheetrock.
Kirby ditched the Dana 35 TTB front axle and suspension and replaced it with a Dana 44 out of a 1979 Ford F-150. Suspension consists of 6-inch BC Bronco coils, 1979 Ford Bronco upper coil buckets, James Duff extended radius arms, and a custom track bar and mount.
The Dana 44 features Yukon 5.13 gears, an ARB air locker, and is protected by a Ruffstuff Specialties heavy duty differential cover. Kirby relocated the axle mounts inward 2-7/16″ with 2-degrees more caster built in to match the Rangers frame and lift.
The upper track bar bracket is from Ballistic Fabrication, and uses a 2.63-inch Ballistic poly joint. The lower is a Ruffstuffs offset bracket that uses a 2-inch Ballistic flex joint. The steering linkage is made up using Chevy 1-ton tie rod ends from Ruffstuff Specialties.
The rear axle was replaced with a full-width Ford 8.8-inch 31-spline axle from a 1994 Ford F-150. The axle was upgraded with disc brakes from a 8.8-inch axle out of a Ford Explorer. The axle also received Moser axle shafts, Yukon 5.13 gears, an ARB air locker and is protected by a Ruffstuff Specialties heavy duty differential cover. The axle housing was recently beefed up with an Artec axle truss.
The rear axle is suspended by Chevy 64-inch leaf springs on Ruffstuff Specialties spring perches, 7-inch USDR shackles that are 3/8-inches thick, and the factory lift blocks.
The Ranger rides on a set of 35-Inch BFGoodrich tires mounted on 15×8 aluminum F-150 rims. McNeil Racing Fiberglass fenders and bedsides help cover the wider track width created by the fullsize axles. The front fenders are 3-inches wider than stock, and the rear are 4-inches wider than stock. The inside of the cab, bottom of the doors, and the bed was coated with a Rhino spray on bed liner.
Other Features:
- ARB air compressor
- Front mounted winch
- Hi-Lift Jack mounted inside of the cab
- Fox shocks
- Rear shock hoop
- Saginaw steering pump conversion with PSC under drive pulley
- ARB Simpson III roof top tent
- Behemoth Drivetrain Shorty Strongbox
Link:
Check out Kirby’s build thread: Kirbys 1991 Ranger Build Up and Solid Axle Swap
More Photos:
Click the photos to enlarge:
About The Author
Jim Oaks is the founder of TheRangerStation.com, the longest-running Ford Ranger resource online since 1999. With over 25 years of hands-on experience building and modifying Ford Rangers — including magazine-featured builds like Project Transformer — Jim has become one of the most trusted authorities in the Ford Ranger off-road and enthusiast space.
Since launching TheRangerStation.com, Jim has documented thousands of real-world Ranger builds, technical repairs, drivetrain swaps, suspension modifications, and off-road adventures contributed by owners worldwide. TheRangerStation.com has been referenced in print, video and online by enthusiasts, mechanics, and off-road builders looking for practical, and experience-based information.
