1994 ExCab 4.0 "Grimace"

[jballard81]

Good looking truck. Nice to see another 94 being brought back to use!

For you auto to manual swap, did you source just the manual transmission or did you source a parts truck?

I ask bc I've heard that the parts truck is the way to go bc of the odds and ends needed for the manual swap.

 

[eaglescout94]

Thanks, it has very minimal rust so I’m gonna do what I can to fix the existing and coat it so I slow down any future.
As far as the conversion parts, it ended up being a bit of both. I have a 95 I was able to get the transmission and transfer case from, a 1 piece driveshaft from a 01 I bought for the frame, some parts from a auto yard and some parts I bought online. It would have been easier to have a complete parts truck but for whatever reason around me 4.0 trucks in general are hard to find for sale

 

[jballard81]

Thanks, it has very minimal rust so I’m gonna do what I can to fix the existing and coat it so I slow down any future.
As far as the conversion parts, it ended up being a bit of both. I have a 95 I was able to get the transmission and transfer case from, a 1 piece driveshaft from a 01 I bought for the frame, some parts from a auto yard and some parts I bought online. It would have been easier to have a complete parts truck but for whatever reason around me 4.0 trucks in general are hard to find for sale

Not just in your area , other than explorers and 97+ rangers I hardly ever see any early 90s 4.0s.

Following with interest. Good luck!

 

[eaglescout94]

Started on the front suspension since I didn’t feel like swapping out the brake/ clutch pedal assembly. Started on it anyways since I didn’t have a socket for the suspension bolt, or so I thought. Guess it’s a good thing I’d bought a new set of coils. Hoping with the all new suspension I don’t have much of a lean, otherwise I’ll have to shim the drivers side a little to even out

 

[rumblecloud]

Looking really good in that shot.
Both my front springs looked exacltly like yours when I pulled 'em.

 

[Ab_Reed]

Started on the front suspension since I didn’t feel like swapping out the brake/ clutch pedal assembly. Started on it anyways since I didn’t have a socket for the suspension bolt, or so I thought. Guess it’s a good thing I’d bought a new set of coils. Hoping with the all new suspension I don’t have much of a lean, otherwise I’ll have to shim the drivers side a little to even out

What size wrench did you need for the lower spring nut? Im assuming my 96 is the same size. Im lowering my 2wd truck and need to pull the springs.

 

[scotts90ranger]

What size wrench did you need for the lower spring nut? Im assuming my 96 is the same size. Im lowering my 2wd truck and need to pull the springs.

It'll be 1 1/8" for the radius arm nuts and coil spring nuts.

 

[eaglescout94]

Yep, 1 1/8” wrench and deep socket.
The pic of the truck is where I’m hoping it’ll sit if the new coils give me the 1.5” lift/ level they claim. It it comes close I’ll be plenty happy with it. I still might get the Chevy shackle for the rear but I’m undecided yet. I will for sure be removing the fenders on the flatbed, even if it means lowering the bump stops a little

 

[alwaysFlOoReD]

Way back, I removed that nut. It took a lot of force. After, I saw signs of locktight, so some heat might help when removing that nut.

 

[eaglescout94]

Mine was about the opposite, didn’t really take a ton of force with my 2’ ratchet but they do look like nyloc nuts. But now I’ve got more work ahead of me, the passenger coil bucket and frame behind it are rusted out and looks like the passenger radius arm hole is wallowed too. Debating pulling both coil buckets and patching/ plating the frame behind each. Then I guess a new arm mount as well

 

[eaglescout94]

Got the passenger side bucket off and the rust cut out. Should be able to get the filler pieces welded in within the next couple evenings and get my new buckets installed when they get here. Is there any reason I couldn’t drill a hole or cut the bottom of the dish out where stuff can sit and rot the frame?
I’m getting excited being as close as I am to being able to drive Grimace.

 

[eaglescout94]

Making little progress as i get the time. Its sitting on its own again and I've been working on mounting the flatbed so its level with the body lines. Then get to weld on the taillight panel and redo all the rear wiring to clean it up. Im waiting to hear back about another ranger for parts, most importantly the passenger steering knuckle since mine doesnt hold the inner brake pad anymore. Id love to find a 95-97 to get the knuckles from but just trying to get the truck on the road right now.

Revisited the Perfection clutch youtube video to get my clutch working. I spent 3 days fighting it and making pretty much zero progress. Follwed their tech section video to mimic a call in diagnosis and had it working flawlessly, atleast sitting there, in less than an hour.

Started swapping the seat tracks over from the factory seats to the 01 seats I have but hit a roadblock. The back is attached to the track, or I have to drill out other rivets. I wouldnt worry alot about it but the 01 tracks are really rusty. Once it stays warmer I plan to bedline the inside floor of the cab before putting the cleaned carpet in it.

 

[eaglescout94]

Grimace goes in tomorrow for a front end alignment finally. Pretty much rebuilt the entire front end with updated brake components, all new suspension. I’m planning to finish up welding the rear hitch tonight, I moved the receiver portion so it’s tucked up and under the rear of the bed instead of hanging down.
Still plan to install an isolated deep cycle battery, aftermarket switches and plenty of lights once I decide where I want them. I’ll also be on the look out for an explorer rear end to set up with 4.10s and make sure the disk brakes are all freshened up. Then gear swap the front to match.