2006 FX4 Daily / Offroad Build

[Corey H]

Was able to get some work done over the weekend since the weather finally wasn't has hot with the storm passing through. Got all the interior swapped expect for the dash because I wasn't ready to take it on and the passenger door panel since i didn't get it from the junkyard.

Didn't end up doing insulation and sound deadening but that is cause my dad came into town and wanted to help out but also cause i didn't order it from Amazon Also my dad isn't into modifying vehicles and when i explained what and why i wanted it, he said i didn't need it and was making it more difficult then i needed to . Probably has a point though lol

Anyway I'll follow up with some pictures tomorrow after its cleaned up.

 

[MaicoDoug]

Sometimes making a mod and or a repair of your own does a whole lot for your own personal "street cred", haha I said street cred. Job done right.

 

[Corey H]

Well I wanted to get some more stuff done but it is currently on hold, my wife's car was parked and got backed into by an electrician on a hit and run, ended up denting the quarter panel, bumper and liftgate. Luckily some one saw it happened and we were able to track down the driver. Because it was an 08 Lexus RX350, it would have been totaled if we went through insurance so we opted for a cash deal.

I checked to see what was in the junkyard inventory and I guess again this is a lucky junkyard lol but it had the same model in the same color sitting in the yard. Ended up getting everything expect for the quarter panel since it is welded and the entire length of the SUV and walked out for only $300. Just will have to get the quarter panel repaired and painted along with the bumper and will be good as new!

 

[MaicoDoug]

"Lucky junkyard"? Sounds like a bar outside of Tehachapi...(over the hill from Bakersfield). Glad that you found that stuff, must of made the wife & the Lexus very happy! Just need to purchase some new tools. Now get busy........ Don't forget about the wax job.

 

[Corey H]

Finally coming back and getting back on the forum and also working on the ranger! Hoping to get a lot done the end of spring and summer.

Been carrying around all the random stuff in the bed and ready to get it out of there and on or in the truck!

 

[Corey H]

Here is the most recent items done since the interior swap.

Started on the headliner replacement, added a armrest support, pulled a part the explorer visors, dyed and started painting any grey parts to black.

 

[Corey H]

Well attempted to change the headliner and sprayed the glue over the whole headliner and fabric and messed it all up! It started to get stretched out so much all the give was gone and it was getting wrinkles and foam started to tear away, so to say the least I got humbled haha but ordered a new one and its on its way for round two

Beyond that I also ordered sound deadening and insulation for the truck about 70 sqft all together which I don't expect to cover the whole truck but its a start especially since i don't have the replacement carpet yet.

This weekend the plan is to work on the visors reupholster, dash swap from grey to black and some dying and paint of random trim pieces. Will see how much actually happens though its definitely ambition haha

Thinking attempting a How To on the dash removal since their isn't one out there

 

[Corey H]

The plan was to work on the truck last year and get a lot of progress, unfortunately that didn't happen! But the build is still process behind the scenes slowly! I will post about them on individual post from being too long.

In short I didn't end up driving it for about 6 months and then about a month ago I got the itch to get back into. It also was coming to the realization I can't do everything in sequence or else I won't ever get it done. It's better to have some progress then none!

 

[Corey H]

Here is following work from the last post when the headliner needed to be redone and other related work.

First was the two layers of sound deadening. First layer was Siless Max 120mil and second layer Siless Hybrid 200 mil. Followed by black foil tape on all seams, borders and openings. Still have a lot to do, need floor, doors and dash

 

[Corey H]

Headliner redone in Ebony Knit. Went with Ebony to match the interior swap because it FX4 Level II came in "Ebony". Got it from Fabric Empire on Amazon and really happy with it. Gives a lot more updated look and feel because of the foam backing and knit. Still not a 100% happy with the install but a lot better then the first attempt.

The other issue was because I added two layers of sound deadening the ridge foam backing of the physical headliner had to be shaved down. Isn't an exact science on the amount needed to be removed just install, uninstall, remove foam and repeat.

Started on the visors but need to paint all the mirror casing, trim and random parts that were tan. Need to figure out how to paint/dye rubber for the Homelink buttons .

 

[Corey H]

After the headliner, started working on the visors. As mentioned before the visor needed to be pulled apart in order to replace the fabric, more on that here. This has been very slow moving on the visors with the mirrors, lights and homelink. I want to look as OEM as possible and that is making it harder on myself. Which has had me go through three sets of visors currently.

The smaller cardboard is no issue and is ready to be glued back together.

I have had issues with removing the sticker on the mirror, deciding how to get all the trim to be black and the matching the new fabric to the old to allow all the trim and hardware to be reinstalled. Have experimented with dye and different paints. While I am still working on getting the sticker removed, I did decide the best option is to paint it. I will be using SEM Color Coat in Landau Black. From what I have researched it is the best match to factory ebony/black and is a highly recommended product for changing color on interior pieces.

 

[Corey H]

As I worked on the visors I started the interior swap from the standard grey to the black Level II. The biggest to overcome is the dash. When I pulled the black from the junkyard I learned a bunch and also that the skin of the dash could be removed and swapped to my dash. This helped a lot because it made it so i didn't have to worry about any wiring issues or difference of truck years.

Since there isn't a how to remove the dash, I do want to write one up but here is a quick overview of what to do and how I did it with a few pictures

• Remove negative battery cable
• Depending what center console you have remove it if attaches to the dash
• Remove and unplug radio and ac controls
• Remove glove box
• Remove airbag
  • Two bolts on the bottom
  • Not needed it to be removed but didn't want to worry about any airbag issues
• Unplug all connectors at the kick panel
• Remove grounds by passenger kick panel
• Remove OBD, hood release and parking break release
• Remove dash knee plastic trim and metal
• Remove steering wheel and column
  • Isn't required but highly recommended if by yourself because of the weight
  • Remove airbag two screws, one on each side of the steering wheel
  • Unplug the airbag
  • Remove the steering wheel with a torx bit
    • I was able to get it off with just pulling on it multiple times
  • Look under steering column and start unplugging any connector attached to the column
  • Unbolt the steering shaft
    • It is a single bolt about 6 inches from the firewall
  • Unbolt the 4 bolts holding the column to the dash
  • Remove the entire column
• Remove and unplug headlight and dimmer
• Remove instrument cluster trim
• Remove instrument cluster
• Remove black trim piece along the windshield
• Remove two bolts on the driver side
• Remove one bolt on the passenger side
• Remove four bolts along the windshield
  • Will need a 12" extension
  • Leave one bolt in so it doesn't fall
• Remove the dash

Next was painting and swapping the black dash skin!

 

[Corey H]

After getting the dash out I started working on separating the dash skin and support/frame. It isn't difficult because it is just about 15 or so screws on the back side and some wiring and ducting needed to be removed. But it is possible and makes it so I don't have to worry about any wiring changes from whatever year the Level II was in the junkyard to my 06.

Even though the Level II dash was black from the factory it did have a lot of color fading and needed to be painted. I did the research for prep and materials needed to use the SEM Color Coat I would be using on the plastic trim, luckily the SEM Color Coat works on vinyl!

Along with the dash I will painted all the other dash plastic piece at the same time. This was the kick panels, vents, glove box, airbag, fuse covers and knee pieces.

Prep included scotch pad, SEM soap, Vinyl or Plastic & Leather Prep, and sand free adhesion promotor or XXX adhesion promotor.

Nothing better then a make shift paint area out of canopy!

 

[Corey H]

Overall the paint when well! The paint is really impressive is the color match to the existing Ford black is almost if not perfect. I did learn it does need to sit for days or even a week before it is reinstalled. I installed a couple pieces after about 24 hours and then did scratch. After this I talked to customer service and they said the longer the better before installation. So I waited on the rest of the pieces and now I have zero issues.
A couple of the vents will need to be stripped and redone because I didn't like the end result because they were painted with too much humidity.

I do need to touch of the pieces but that is for another time because the dash looks so good the rest of the Level II interior pieces don't match and you can see all the wear, tear and fading. But that isn't on my top priority.

An idea I am hoping to make happen is the swapping to a different headlight switch that has an auto headlight and fog light option. Not sure if it is possible but we will see! The instrument bezel is from a Sport Trac (since it has the same dash as the Ranger) and the switch is found in Excursions, Expeditions, Super Duty's and Sport Trac

 

[Corey H]

Still working on getting all the updates and showing what has been done!

Next item I worked on was swapping the lock, window and mirror switches and trim pieces from 07+. These are when they redesigned the switches to a more modern look and I think it was also when a lot of other vehicles got these switches because I have seen the style in Super Duty's and F150's at the junk yard.

Overall the swap wasn't to difficult because I did find some information of the wiring on 07+ but still was some trial and error. Only thing that I have to figure out or will just leave how it is but the driver side mirror motor works correctly for all direction but the passenger mirror motor the left and right are swapped. Basically when I want to go right I have to push the button to the left and vice versa. Not the end of the world or used often but still want to get it right at some point.

I will do another post with wiring information later on in case someone wants to do it.

I did an extra step and took apart multiple window switches from other Ranger's at the junkyard and I took the switch cover that says "AUTO" and put it on the passenger switch and then the passenger switch on the driver side. So now all the window switches say "AUTO". Technically they aren't auto windows but they will when I complete the auto up and down mod!