4bt swap -- 95 Explorer

[Snoranger]

The IFS (95+) explorer is a dana 35 low pinion, the same as the jeep 35, so the gears and the carrier will fit in the explorer axle...
SVT

Yes, but the jeep is a C-clip axle. The Ex d35 uses circlips to hold the halfshafts in. That makes me think I have to use the Jeep gear (already knew that), jeep carrier (3.54 and down carrier break), and the Ex spider gears ( so the axle shafts can be held in.

Anyway, I have a spare Ex d35 to use for test fitting. That wont slow the build down.

 

[bobbywalter]

i think it will work fine

 

[Snoranger]

I drilled out a few broken exhaust manifold bolt and heli-coiled them. Sandblasted and painted some more parts. I dropped the engine back in the frame and marked the oilpan for the cuts. I'll pop that off and cut it tomorrow. Once its cut, I can drop the engine all the way in and start making some motor mount brackets.

Gotta make her look pretty. (Ignore the black painted fuel filter, its a Fram filter that was on the engine when I got it. I wasnt going to have the pics tarnished by that ugly orange filter. There will be a nice white Donaldson filter on there when I drop it in for the last time.)

note to self--get more paint.

I forgot to post an update yesterday, so here it is a day late:

On a side note, Has anyone tried 13" Cobra brakes on a 4x4? I know the 2wd guys do it, but i cant find anything on a 4x4. I've got a few spare part sitting around and I'm going to try it.

Spare parts I have sitting around:

1 pair of new 13" Cobra rotors
1 pair of new Cobra calipers
1 pair of new Cobra hoses with banjo bolts
1 set of '99 Cobra wheels (17x8)
1 set of 255/75-17 tires (almost new. I needed a little bit taller of a tire for the swap. Every step seems to snowball into something bigger!)

I pulled a wheel and rotor, tried the Cobra rotor on. It will fit with just the slightest mod to the center bore. (good thing i have a machine shop less then 100 yards from me!) So here we sit with the truck up in the air and a Cobra rotor on the hub. I just need to make a caliper mounting bracket and I'm set.

If anyone has a link to a 4x4 13" Cobra brake swap, chime in.

 

[Snoranger]

Lets start with a little more eye-candy.

I got the oilpan cut and the motor dropped back in the chassis. (No pics of the pan yet, I'll take some when I pull it off and fix the gaping hole in it.) Looks like I have a lot of room.

 

[Snoranger]

Lets look at the drivers side now.

Looks like I'll have plenty of room for the steering shaft and tons of room for motor mounts.

 

[Snoranger]

I got some more new parts this week:
water pump
t-stat
exhaust manifold gaskets
front crank seal and wear sleeve
oil pan gasket
turbo oil feed line

I'm not at liberty to say how much I payed, Lets just say it was CHEAP for new actual Cummins parts.

I started making my alt and a/c brackets.

Alt is mounted and aligned. I'm using an Explorer 130 amp alt (it will be rebuilt and painted). I need to clean up the brackets a little bit and paint them.

I've got a 1/2" clearance at the closest point around the alternator.

The upper bracket is a simple piece of angle iron and flat stock welded into a u shape with nuts tacked inside. Yes the holes in the alt are drilled to 1/2". It made it easier.

The A/C compressor bracket took some more thought. So far its bolted under the vacuum pump with 3 bolts and one more in the front into the head. I still have to mount the compressor (sanden sd-7 series), cut the bracket to length, and brace the bottom.

Heres 2 more pics I took.

Mooktank header. (Mooktank is a guy on 4btswaps. He made a few of these headers a couple years back):

Last, but not least: The ZF S-542

 

[84bluebronco2]

I digging the progress!! Totally hoping that frame will see some TLC before reassembly though lol.

 

[Snoranger]

I digging the progress!! Totally hoping that frame will see some TLC before reassembly though lol.

Thanks, but that frame will see the scrapyard when i'm done with it. I'm just using it for mock-up. I'm still DD'ing the truck its going in. The frame is from a '96 Exploder I needed the tranny out of, the engines going in my '95.

 

[Twister]

Is there suppose to be a different picture after you said "Last, but not least: The ZF S-542
" on you last post, because it is the same as the pic for the header.

 

[Snoranger]

Is there suppose to be a different picture after you said "Last, but not least: The ZF S-542
" on you last post, because it is the same as the pic for the header.

Yup. Fixed it.

 

[gribly]

How close is that pan to that diff housing? From the pics it almost seems that when the motor mounts get worn later on down the road, you could get contact there.

 

[Snoranger]

How close is that pan to that diff housing? From the pics it almost seems that when the motor mounts get worn later on down the road, you could get contact there.

The closest point will be about 1" so I'm not worried. The pics are a little deceiving.

 

[Snoranger]

Started making my engine mount crossmember.

Top:

Bottom:

We need to update our archaic welding technology at work, but i'll make do with the stick welder:

 

[TEK4x4]

i would love to do this swap in my b2 but currently funds dont permit me to do that but ya keep this thred going should be sweet. way jelouse by the way haha.

 

[kevinsranger]

is this thing finished yet when you get closer let me know, i'm gonna have to come by and check it out.