Build Thread | 1992 Ford Ranger XLT | 2.9L V6 | 4WD | Manual

[kdenmcfish]

Welcome to my Build Thread!

Over the past year, I have been working to repair a no-start, yes-crank 1992 XLT Ranger 2.9L V6 4WD Manual, which was gifted to me. The truck spent much of it's last years in a driveway, essentially a grocery getter. As far as I can tell based on the VIN Checks I have ran, I acquired it with 198,000 miles all original.

As you may have expected, the list of repairs/maintenance has grown significantly longer than initially expected; but given the truck was free, I figure the first couple thousand were free anyway. Plus, now I have a big red collection of M12 tools and a Harbor Freight ITC membership, so win-win.

I have learned a ton through this process, I'd wager I could complete most of the jobs in half the time now... got to learn somewhere. Mistakes were made and I have felt stupid a lot, but I can bump start a motor now.

I figured I would publish a living database in case any of YOU in the future had questions about a certain repair, as I witnessed firsthand that a lot of the answers you will need for a truck this old are not easy to find. That being said, if I did find a helpful resource, I will link it below so that you can reference it. In general, the Ranger Station website is your gospel, not so much Reddit.

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Specs:​

Engine: 2.9L V6 (Will go to 4.0L if ever makes sense)

Transmission: Mitsubishi FM146 | 5 Speed w/ Overdrive

Transfer Case: Electronic BW1354

Front Axle: Dana 35 TTB

Rear Axle: 7.5" (Will go to 8.8" if ever makes sense)

Body: Standard Cab, Long Bed

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Engine, Ignition & Fuel​

• Spark Plugs
• Spark Plug Wires
• Ignition Coil
• Distributor Cap
• Distributor Rotor
• Fuel Pump
• Fuel Filter
• Fuel Filler Neck
• Fuel Cap
• Upper Intake Manifold Gasket
• Valve Cover Gaskets
  • I used the Blue Felpro Gaskets from Rock Auto, seems to have fixed the infamous leak for now.
• Idle Air Control Valve Gasket
• Engine Air Filter
• PCV Valve
• Breather Filter Element
• PCV Valve + Breather Filter Element Grommets
• Coolant Temperature Sensor
• Oil Pressure Sender Switch
• Engine Mounts
• Transmission Mount
• Power Steering Belt
• Water Pump Belt
• Removed broken A/C condenser, compressor, and lines (may convert to modern refrigerant eventually)
• Starter Motor (bump started this bitch in reverse on flat ground on my first try, FWM)

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Cooling System​

• Dual-Row Radiator (From junkyard 1994 Explorer)
  • Truck rarely gets about the 'n' in normal on the dummy gauge, HIGHLY recommended upgrade especially with this engines head warping concerns)
  • Drop in install besides hose mentioned below
• Fan Shroud (Original to 1994 Explorer Radiator)
• Thermostat
• Thermostat Seal
• Thermostat Gasket
• Thermostat Housing
  • The female threads in my engine were totally stripped out, which led to significant coolant leakage under pressure. I ended up drilled out existing threads, and re-tapped with 3 M6 x 1.0 inserts.
• Locking Radiator Cap
• Upper Radiator Hose
• Lower Radiator Hoses
  • For Automatic 1994 Explorer
• Coolant Flush
• Water Pump
• Water Pump Gasket

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Drivetrain & Transmission​

• Transmission Fluid
• Transfer case Fluid
• Front differential Fluid
• Rear differential Fluid
• Front Driveshaft U-Joints
• CV Axle U-Joints
• Rear Driveshaft U-Joints
• Rear Pinion Seal
• Power Steering Fluid
• Rear Output Bearing + Sleeve + Seal
• Warn Manual Locking Hubs
  • Replaced my functional Automatic hubs, but got a great deal on FB Marketplace.

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Chassis, Steering, Suspension, Brakes, Tires​

• Front Brake Rotors
• Front Brake Pads
• Front Wheel Bearings
• Front Wheel Seals
• Upper Ball Joints
• Lower Ball Joints
• Front Shock Absorbers
• Rear Shock Absorbers
• Upper Rear Shock Absorber Mounts (Bolted Connection)
• Leaf Spring Bushings
  • Ended up having to take the front driver side mount and leaf spring to a diesel shop to press the front bushing out
• Leaf Spring Mounts (Bolted Connection)
• Inner Tie Rods
• Outer Tie Rods
• Tie Rod Sleeves
• Firestone Lifetime Alignment
• 4x Armstrong Tru-Trac AT Tires (235/75R15XL 109T)

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Exterior & Interior​

• Driver Side Mirror
• Passenger Side Mirror
• Antenna Delete
• Tailgate Handle
• Muffler
• Side Exit Exhaust from Cat Back
• Seats
  • Bucket Seats from Explorer, if you have standard cab you will need to swap the tracks, extended cab with drop in
• Center console delete
• Shift Knob
• New Keys
• Horn
• Toolbox
• Bed Liner
• Mud Flaps (from 1993 Ranger, some welding required for mounts)
• Replaced Exterior Tailgate Trim
• Air Vent Trim
• Shift Boot with Cupholders
• 3rd Brake Light Conversion
• 1995-1997 Rear Window Latch Conversion

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Misc:​

• Wire wheeled, rust reformed, and undercoated the rear half of the frame
• Wire wheeled, rust reformed, and primed the truck bed before liner install

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Planning to keep this up to date!

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Current Repair Shortlist (by Priority):​

High:

Brake Fluid

Drum Brake Replacement

Clutch Fluid

Spare Tire setup



Medium:

Catalytic Converter Investigation (terrible exhaust rattling)

Weld exhaust, replace clamps, and fabricate a new exhaust hanger for side exit, currently supported by a zip tie



Low:

Topper with tailgate replacement? (ARE Walk In), would unlock the functionality of locking the back of the truck

R134 A/C Conversion/Install

Tint?

Speakers?

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Photos
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[SenorNoob]

Looks like a VERY nice truck to save, AND you seem to be doing everything the right way. Awesome!

 

[Heather’s94]

The Wranglers (Walmart?) look good on there. If you intend to keep the 4wd functional, a Dextero DAT1 (again, Walmart) is a solid option in 235/75r15, as it is an XL instead of an SL rating. And just a bit more aggressive, handles heavy rain better.

Add front shock boots. I have those blue/yellow Bilseins on one of my trucks. Good shocks, but the rod is corrosion prone.

Install a heavier duty rear spring pack set. 2+1 are barely adequate for a 2wd with a 2.3/5spd. Too much axle wrap during a one wheel peel on damp surfaces. A B2/Explorer rear swaybar is worth the sweat equity to adapt it while the bed is out of the way. Will be adding one, and a B2 style trac bar set, to my 94 2wd. Got spoiled by the huge (1.5”) rear bar on my 1t 4wd.

Looks like a fun project. Wish my 92 had not been totalled by my brother in law, the 83-92 have so much more character than the 93-11 models.

 

[kdenmcfish]

The Wranglers (Walmart?) look good on there. If you intend to keep the 4wd functional, a Dextero DAT1 (again, Walmart) is a solid option in 235/75r15, as it is an XL instead of an SL rating. And just a bit more aggressive, handles heavy rain better.

Add front shock boots. I have those blue/yellow Bilseins on one of my trucks. Good shocks, but the rod is corrosion prone.

Install a heavier duty rear spring pack set. 2+1 are barely adequate for a 2wd with a 2.3/5spd. Too much axle wrap during a one wheel peel on damp surfaces. A B2/Explorer rear swaybar is worth the sweat equity to adapt it while the bed is out of the way. Will be adding one, and a B2 style trac bar set, to my 94 2wd. Got spoiled by the huge (1.5”) rear bar on my 1t 4wd.

Looks like a fun project. Wish my 92 had not been totalled by my brother in law, the 83-92 have so much more character than the 93-11 models.

Wranglers are actually 14 years old, lol... pretty much brand new tread on them which is promising for the mileage of the truck I suppose. Coincidentally the truck is getting some new shoes this weekend, took advantage of Gigatire sale on these puppies. Not KO3's, but should be a huge step up to the current unbalanced, dry rotted, and visually bulging 14 year old tires.

Noted on the rear springs, this thing has been babied so far during rehab, but should be just about ready for some more interesting tests very shortly!

 

[Heather’s94]

Those Armstrongs are NOT the TruTrac of old… Very soft compound. Thin above the bead, tear easily. Tire shop destroyed 1 mounting a set as steer tires on my K3500. They are a decent winter tire, not worth a hoot when it is hot out.