PlumCrazy's Beater DD 4x4 SAS Build

[PlumCrazy]

1997 Ranger XL (330k+ mile RWD chassis)

-Lima 2.3L
-Mazda M5OD-R1 5 speed (Hurst equipped)
-Borg Warner 1354 manual
-SAS YJ Dana 30 w/ CAD (Posi-Lok cable shift)
-Ranger 8.8 w/ 9" drums and Trac-Lok
-4" lift YJ Front leaves (SUA)
-4.5" Explorer Rear lift leaves (SOA)
-4.10 gears
-31x10.5R15 ProComp MT2
-15x7 Fx4 Level II Alcoas
-KC Apollos
-Vacuum actuated cruise (Ford dealer added system)
-Leer cap

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Been a few years since I have posted on TRS regularly, but figured I would try to document this build.

Most of the OGs probably remember this truck:

Then I kind of stopped posting updates when life got busy.
Sold all my Ranger stuff besides the truck itself.....fast forward a few years.

Got back into a 2.3 Ranger as a DD, lowered it, and racked up a few hundred thousand miles before V8 swapping it:

Then snagged an 88 2.3 truck in need of TLC for a beater daily, but decided it was going to a get turbo motor and got back burner'd:

Then ended up with this 97 XL 2.3 truck with over 300K on the Odometer. Threw some Alcoas and fresh rubber on it ASAP.

Been using it as my winter beater and decided I wanted to do a low buck 4x4 conversion with parts out of the stash, a D30, and some leaf springs.

Plan is SAS and keep it as low as possible on 31s. Planning to use for DD activities and the occasional adventure into the woods. Open diffs and 2.3 should keep carnage to a minimum.

 

[PlumCrazy]

So far I have a 4 banger YJ D30, 4" YJ lift springs, and a pile of new brakes, mounts, and hardware for the front. In the rear Ill need to find a cheap 4.10 axle and toss it under with the 4" Explorer lift leaves I snagged.

I started throwing a 4x4 trans together with a 2.3 2wd trans and some spare parts I had....It was supposed to be a quick swap...but the trans I started was smoked. Shift forks heavily worn and synchro welded to the input shaft along with a pocket bearing that nearly welded the shafts together. Pulled a known good gear set out of my stash and plan to build it back up with those when the bearings and seals I ordered show up.

 

[PlumCrazy]

Still waiting on parts to put this trans back together, but I did have a few of these made:

1/2" thick, 55mm with a hole for 1/2" drive. I had an extra made of anyone is interested ($25 shipped).

Should fit all M5OD-R1 main shaft nuts.

 

[scotts90ranger]

And here I thought the front output shaft bearing on the M5OD in my '90 was bad... that pocket bearing is SCREWED

 

[PlumCrazy]

And here I thought the front output shaft bearing on the M5OD in my '90 was bad... that pocket bearing is SCREWED

View attachment 122919View attachment 122920

Pocket bearing is the most common failure I see. Shifter bushings crumble, then get tossed into the oil galley and plug up the slinger that feeds the pocket.

 

[PlumCrazy]

Started digging more parts out.

Got a transfer case located and off the shelf (easier said than done)

Turns out the driveshaft i have been counting on using....has a dent / bend in it....still going to see if it will work for now.

Designed and printed a bushing quick for the shift lever linkage....my memory failed me. I guessed 5/16 on the case shift arm....looks like it's actually 3/8.

 

[Jim Oaks]

Man, I love your creativity and can't wait to see what you build! Honestly, I would love to see you build a budget friendly go anywhere 4x4 Ranger that you can drive every day and wheel on the weekend and give these younger Ranger enthusiasts inspiration to go build an older Ranger.

 

[PlumCrazy]

Man, I love your creativity and can't wait to see what you build! Honestly, I would love to see you build a budget friendly go anywhere 4x4 Ranger that you can drive every day and wheel on the weekend and give these younger Ranger enthusiasts inspiration to go build an older Ranger.

Thanks I'm looking forward to this one too. I can finally put a lot of parts I've been hoarding away use on something.

 

[PlumCrazy]

This weekend was 4 steps forward and 3 steps backwards.

Was planning to put the 4x4 trans in while I had the current 2wd unit out for a slave cylinder job.....but USPS decided to keep my package with seals and bearings for the 4x4 trans out for delivery for a few more days.

Threw the 2wd unit back in and the new hydraulics feel amazing. Also put a crusty old short throw in

Also picked up what was supposed to be a 4.10 8.8 to match the 4.10 D30....but after getting it home and opened up I found that it's a 3.27 axle.

Not huge deal, but I was hoping to just toss in a fresh axle shaft and a bearing and run it....now it looks like I'm gonna have to throw gears in it too.

 

[PlumCrazy]

Torn down and ready to build back up.

Bought the semi float axle bearing puller slide hammer adapters.... should have bought these years ago. Took 30 seconds to yoink both bearings out

Buddy dropped off some 4.10s (pretty sure I gave them to him years ago for another project) Going to use my 28 spline Trac-Lok in this truck since I decided to go 31 spline when I re-gear the V8 truck. Had all of the other bearings, seals, shims, and crush sleeve eliminator stashed away in a shoebox already....just need to backfill that inventory now.

He also made me a deal on an old Ruff Stuff cover since this axle came with a plastic cover

 

[bobbywalter]

just luk clutch stuff?

 

[PlumCrazy]

Forgot to mention the other oopsie I made...

While doing the slave cylinder replacement the other day I was looking at the incomplete 4x4 trans on the floor.... realized not only were the gears and pocket bearing smoked...it wasn't even a 2.3 transmission. It's a 2.9/4.0 pattern. Guy traded me the trans for a good 2.3 short block... I think I got took on that deal.

Good thing I noticed before building it back up with the new gear set and bearings....life goes on...had to pull a spare 2.3 transmission case down from the shelf for the reassembly (if my parts ever frickin show up)

Notice the starter location difference.

 

[PlumCrazy]

just luk clutch stuff?

I run Luk/Centerforce clutches in all my junk...but quickly loosing faith in their hydraulics. Bought an SKP master and CTek slave this round (both cast aluminum no plastic)

 

[bobbywalter]

i looked at a skp ... ended up with a perfection setup...i think it said perfection. the skp was unavailable at the time.

luk is decent. i have broken a few clutches though....so i prefer the luk..side by side the cage was heavier then the house napa.

 

[PlumCrazy]

The pedal feels so nice in this truck now. It's like new truck now that clutch is so solid and releases so early in the stroke.