2003 Ranger Edge 4x4 build/fix up

[CamTheHedgehog]

After a looong weekend, I did it. I got the engine out.

Getting it to clear the core support was interesting....my hoist kept hitting the top of my open garage door. So I took the front wheels off and lowered the front down until it cleared. Not the easiest way to do it, but it worked.

 

[CamTheHedgehog]

Ironically enough,
A) Despite having a 4x4, I don't have a balance shaft for some reason. Guess I can return those parts.
B) the guide that failed was the front cassette guide, and not the far more common rear guide, though I suspect it's not far behind.

 

[CamTheHedgehog]

This update has been a long time coming!

After an entirely too long Christmas break, the timing repair is done. Everything I could have replaced I did, no cheaping out with a job this big. Both cassettes, sprockets, chains, tensioners, rear main, upper and lower oil pan gaskets, water pump, front crank seal, etc.

Finally back in the truck and runs like a top though! Did fall victim to the 5th and 6th spark plug leads being backwards though.... for the second time.

Passed inspection and she's back on the road! Needs a good detail, but next on the list is replacing that front diff with a new one, and fixing the passenger rear door latch.

 

[CamTheHedgehog]

Yet another update rambling. I have fixed the jump door handles finally, both sides since I had the handles and cable ends.

I've also done the passenger spring hanger, as it had a giant rust speed hole through it. The previous guy only did the drivers side, and only when the hanger rotted to the point where the spring broke free and rested on the bed. Just do both of them!

Here's the (mangled) hanger after about an hour of grinding and pry bar-ing.

Up next on the list is the front diff swap with the rebuilt one, and now shift tube bushings are on the list too, as they are far worse than I thought they were.

 

[CamTheHedgehog]

Put in the resealed diff today. Ford's instructions sure makes it sound easy to do, it isn't.

Snaking out the CV axles without removing the knuckle is interesting to say the least, but possible. After that it was smooth sailing, aside from the one annoying diff mount bolt.

I can't complain too much though, the axles are original, with nearly 255,000 miles on them and are in perfect shape. I gave them a once-over and a cleaning while they were out, and no issues. Smooth, no play, no damaged boots, and articulates through the full range of motion. So I put them back in.

Also installed the driveshaft, complete with new CV joint and U joint, both OE from spicer.

Discovered a tear in both tie rod ends as well, from where they rub up against the brake shield. It appears to be unavoidable, which is annoying because I will inevitably have to replace them again. But new ones are on the way.