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'97 Ranger Build


GJ123

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I would like to use this thread to chronicle my build. I've utilized a lot of information from TRS in the last few months, and hopefully someone will find my thread useful as well.

I bought a 2015 GMC new and after a couple years I was completely sick of it. A myriad of repairs and fear about the pending warranty end date lead me to sell.

Shortly before that I bought my 97 ranger after a few months of searching Craigslist. It was exactly what I was looking for - 4.0, 5 speed, 4x4, supercab.

After purchasing a new daily, and realizing the 4x4 system was not operating properly, I decided to build. My goal was to have a vehicle I could drive to work, complete work with (e.g. around the yard, pick up building materials, etc.) and haul my ATV/motorcycles around.

My plans include:
Suspension
- Solo Motorsports Stage I (DONE)
- Kartek Drop Hangers
- Extended Shackle Hangers
- F150 Leaf Pack
- Bilstein 5100s (DONE)

Drivetrain
- Hurst Shifter (DONE)
- Explorer 8.8
- 4:10s
- Locker, rear (type TBD)

Interior
- Buckets (DONE - for now...)
- Explorer Console (DONE)
- Dash mat (DONE)
- Lizard Skin
- Scan gauge (DONE)
- Stereo/backup camera
- Tint

Exterior
- Rims (DONE)
- 33's (DONE)
- Bumpers
- Rack/Storage
- Bedliner
- STX Grille (DONE)
- Headlights (DONE)
- LEDs (DONE)
- Aux Lighting

Below are pics from the ad, and current form, build details to follow. 00000_jy6Fj5kGgUn_600x450.jpg
00C0C_jNJsPWgEfCI_600x450.jpg00H0H_8F1LONZkH9D_600x450.jpg00N0N_hesGxbnIHof_600x450.jpg


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Last edited:


GJ123

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Transmission
Manual
Work started cleaning up the POs (or earlier PO) hack job wiring. There was a vacuum and temp gauge inserted in the dash vents, and some sketchy wiring under the hood that I cleaned up. Fortunately, they had left the old temp gauge in place so I was able to wire it back up easily.

I also used some quik fists to mount my mag lite using existing screws on the rear trim piece - this has worked out wonderfully to-date.

While it was a small win, it felt great to have real vents again 20171111_220430.jpg20171111_220435.jpg20171111_220451.jpg20171112_192324.jpg20171112_192328.jpg

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85_Ranger4x4

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Truck looks great!

You may rethink F-150 leaves. Mine is a standard cab but Explorer leaves were plenty tiff for me.
 

GJ123

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Next I installed the short shifter. This was relatively easy with the provided instructions. This is pictured before the console swap; however, what I found in the front end would mean I wouldn't be driving it again for a while...

I tore the hubs off and noticed I was missing the snap ring on one stub shaft, which is why my hub wouldn't engage. It was also apparent that I was getting some mud/dirt in the hub as a result. The new Warn hubs I picked up would be useless without the snap ring, and that's when things spiraled out of control. 20171116_210320.jpg20171114_184346.jpg20171114_184337.jpg20171201_225232.jpg

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GJ123

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Denisefwd93

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4WD
Total Lift
stock, may get leveling springs in front "somday"
Tire Size
235
If you are referring to the snap ring on the axle that was used for the old bearing lock set up.. Warn says leave it off.. I kept them but seems it only would matter on the passenger side. Love the warn hubs. good that you are getting rid of the auto hubs.
 

GJ123

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After realizing I needed additional parts I made a quick decision (although I knew I wanted this setup anyway) and called Solo Motorsports for their Stage 1 setup. This kit has cut and turned beams, 4" coils, DOM tubing/heim joint radius arms and mounting brackets, extended brake lines, and Bilstein 5100 shocks.

This meant I needed to pull the front end and get things cleaned up and painted - I also pulled the interior I prep for Lizard Skin at this time. Living in Minnesota meant I would go through a lot of WD40 in the process...

I also found that it helps to have the backhoe to get things cleaned up. 20171201_225251.jpg20171202_151653.jpg20171206_193234.jpg20171206_193926.jpg20171206_194242.jpg20171209_113800.jpg

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GJ123

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If you are referring to the snap ring on the axle that was used for the old bearing lock set up.. Warn says leave it off.. I kept them but seems it only would matter on the passenger side. Love the warn hubs. good that you are getting rid of the auto hubs.
Mine had been previously converted to manual hubs at some point, but they seemed to have seen better days...

My understanding was that I needed the spacers and snap ring to ensure the stub shaft stayed in proper position within the hub, at least on the passenger side? Maybe those instructions are the reason mine was not in place when I initially disassembled them.
 

GJ123

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Eventually, after weeks of fighting the MN cold and firing up the wood stove I had the frame painted back to the rear cab mount. I used a wire wheel to clean the frame before using a rusty metal primer and paint. Once I get the explorer 8.8 setup I will do the same in the rear.

I found some rust on the cowl, and some surface rust on the cab. I used rust converter to treat these areas, hopefully I will get some time before the rust takes over.

I also installed new body mounts using some Grade 8 hardware. The existing hardware was rusted tight, so I used the Milwaukee hackzall to slice them perpendicular to the mount right above the mount itself. This seemed to work out alright, but it took some time...20180119_111338.jpg20180119_111357.jpg20180119_111402.jpg

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GJ123

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At this point it was time for assembly. The kit came without instructions, but install was straight forward. The radius arms mount behind the front cab mounts, and before the transmission mount on the passenger side. I did need to eliminate a flare on the bottom of the passenger side frame rail, and cut off the parking brake cable on the drivers side.

I also took this opportunity to install new bushings throughout the front end, along with new rotors.

One issue I encountered was the extended brake lines. I needed to get a new fitting for the junction on the drivers side, and the new lines did not account for the brake bleeders right above the line connection location. We got them spaced out past the bleeders, but I'm not happy with the setup.
20180119_111406.jpg20180119_162640.jpg20180127_110741.jpg20180127_182720.jpg20180128_184736.jpg

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BlackBII

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Wow this is looking really clean! Good job man.

Those beams and radius arms are super nice.

What are you doing for your steering?

For the brake lines, this is what I am using on my '89. I think it'll be the same on yours but you'll want to verify that.

Got a T fitting for the driver side

Part number
Edelmann 127333

 

Jim Oaks

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Automatic
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4WD
Total Lift
6-inches
Tire Size
33x12.50x15
Oh man, can't wait to see how this turns out with the Solo kit.
 

GJ123

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Wow this is looking really clean! Good job man.

Those beams and radius arms are super nice.

What are you doing for your steering?

For the brake lines, this is what I am using on my '89. I think it'll be the same on yours but you'll want to verify that.
Thanks! I've gotta say I've been following your build here for a while and it's awesome, love the direction you're going with it.

I'm running stock steering right now - it works, but it's not ideal. I might just try a drop pitman arm and see how that works, but after reading the steering article here I'm thinking I would be better off with a swing set style linkage.

I'm a little out of order with my build timeline, but I picked up some goodies at the junkyard yesterday - an explorer LS axle with disk brakes, pristine buckets out of a B3000, a swing out spare tire carrier from a Dodge Durango (not sure yet how this will work), and a new oil fill cap.

I'll be swapping the B3000 seats in on my existing tracks. I'll also be purchasing Kartek 1.5" drop hangers, extended shackles, and a Ruffstuff flip kit in preperation for the axle swap.


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GJ123

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Transmission
Manual
Before I could get the truck back on the road I had to wrap up a few things. I started on my explorer center console retrofit with the steel supports, both the center and the attachment to the lower dash support structure.

The ranger floorplan lacks the void for the tabs, so I cut those off, along with the inner HVAC structure. I also had to clearance the front plastic of the console on the passenger side with a dremel to clear the rangers lower dash.

At this time it was clear that the console wouldn't mount flush with the floor. The photos how the gap mid and rear after doing what I could to get it dropped down. At this point it won't go lower without significantly changing the support structure or mount.

I then mounted the hurst boot underneath using the screws leftover from the explorers tray insert, which I had to remove for the shifter. While this worked, it was way too stiff when the weather got down to 10-20 degrees. I'm currently working on a black vinyl shift boot as a replacement.

To fit the console at this point I just modified the old "60" seat and removed the armrest and jump seat. I also replaced the dome lights with LEDs at this time. 20180127_110802.jpg20180128_144630.jpg20180128_144718.jpg20180128_150014.jpg20171122_203248.jpg

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GJ123

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Transmission
Manual
At this point I was ready to put it all back together. Before bolting the inner fender back up (I purchased some new nutserts to replace the rusted/broken originals) I took the sawzall and removed the "tray" from the bottom off the inner fender, which would have otherwise covered the lower fender bolt. It was packed full of dirt, and I'm sure it would have expedited the rust.

After months I finally had it on wheels again. I swapped on an STX Grille at this time, along with clear headlights/corners and LED lights. I used a kit from Superbright LEDs, which seems to be high quality, but I cannot get a decent beam pattern after multiple adjustments. Although, it may be the new headlights themselves... If anyone knows of a better headlight solution let me know.

I had the stockers on while waiting for the tires/rims. I went with pro comp alloys in a 15x8 with 3.85 BS, and 33/12.5 duratracs. I wanted a narrower tire, but I had two readily available. The narrower tire would have helped, as I'm getting a slight rub at full lock on the radius arms. 20180128_192805.jpg20180130_165940.jpg20180201_180115.jpg20180202_174955.jpg20180301_181346.jpg

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