91 Ranger 4.0 A4LD to M5OD R-1 swap...

[zachis4wheeling]

Well the A4LD in my truck has already shit out on me twice and I have always wanted to throw a manual in it and just be done with it. Well recently, I acquired a trashed out 4x4 explorer sport for an extremely good price. It came with the same 4.0 as my truck but with a 5 speed Mazda M5OD R-1 in it instead of the A4LD like my truck. It's got all the pedals and everything, so I hope this shouldn't be too bad of a swap.

Before the server meltdown last year, I had talked about doing this with a couple people on here and all of them told me the best and easiest way to do this was to pick up a donor vehicle instead of trying to source out everything, so that's what I did. I wish I still had access to that post, but I don't....

Anyways, here is a list of stuff that I somewhat remember people telling me I'd need from the donor truck if I wanted to do this.

-M5ODR-1 transmission
-clutch assembly (clutch, pilot bearing, throwout bearing)
-internal slave cylinder
-master clutch cylinder & reservoir....(up on firewall by the brake master cylinder)
-flywheel (resurfaced)
-starter
-ECM
-pedals assembly
-shifter

Is this it or is there more I'd need?

I think I remember people telling me the length on the M5OD is the same as my A4LD so my stock transmission crossmember should work in the spot it is in.

Basically I'm looking for pointers or someone who can point me in the direction of pointers or maybe a thread someone else did in the past that gives a pretty goood outline of what I need to do..

Zach

 

[91exploreron37]

Make sure you replace the slave cylinder while its all apart especially since its already used. The hardest part is the pedals but it helps if you remove the parking brake assembly. And also grab the floor plate from the manual truck.

 

[zachis4wheeling]

Make sure you replace the slave cylinder while its all apart especially since its already used. The hardest part is the pedals but it helps if you remove the parking brake assembly. And also grab the floor plate from the manual truck.

Yea, I plan on throwin a new clutch and slave cylinder while the drivetrain is apart. I plan on making up my own console to house the trans. shifter, the transfer case doubler's shifters I'm workin on...and the ox lockers levers for the ox selectable diff. lockers......Do you know if I need to pull the dash to do the pedals? Does it make it any easier at all or is it still a PITA with the dash removed.....?

 

[mjonesjr]

get yourself a new flywheel. It will only cost you $60....i got a quote for $60 to have a used one resurfaced..

it will be easier to get a new floor pan plate....one that is for a manual transmission hump...


here is my how-to thread i am working on.....i just got done with the swap in late December....it has all the parts you will need....
http://www.therangerstation.com/forums/showthread.php?t=10123

 

[91exploreron37]

Yea what he said and also pulling the dash probably would make it easier but the work involved pulling the dash probably wouldn't make it worth while. The pedals arent too hard once you remove the parking brake assembly it's just time consuming.

 

[mjonesjr]

The pedals arent too hard once you remove the parking brake assembly it's just time consuming.

you don't need to remove the parking brake assembly.....there are 4 lower bolts that hold the brake master cylinder to the fire wall, then there are 2 upper bolts (which be ready for use of swival sockets and ratcheting wrenchs)......no need to remove the dash or parking brake...

 

[91exploreron37]

you don't need to remove the parking brake assembly.....there are 4 lower bolts that hold the brake master cylinder to the fire wall, then there are 2 upper bolts (which be ready for use of swival sockets and ratcheting wrenchs)......no need to remove the dash or parking brake...

What?? How does that make the clutch pedal easier to install? I must be missing something

 

[bobbywalter]

i dont remember totally removing the park brake assembly either.

 

[91exploreron37]

why cant he use the explorer pcm? maybe the sploder is a 91 too.


i dont remember totally removing the park brake assembly either.

How did you get your clutch/brake pedal assembly in? It was taking to long trying to get it past the park brake so I removed it and they went right in, Maybe explorers are a little different.

 

[mjonesjr]

What?? How does that make the clutch pedal easier to install? I must be missing something

you must install the pedal assembly, you can't just put in the clutch pedal as the brake pedal is too wide. there are 6 bolts total that hold the assembly in, 4 are the brake master cylinder studs that have nuts on them, and 2 are bolts that go into the fire wall...

why cant he use the explorer pcm? maybe the sploder is a 91 too.

Explorers have different wiring than a Ranger......so what is on 1 pin in the Explorer PCM plug might be on another pin in the Ranger plug

 

[bobbywalter]

oh....its not a breeze, though not too bad either.

 

[bobbywalter]

you must install the pedal assembly, you can't just put in the clutch pedal as the brake pedal is too wide. there are 6 bolts total that hold the assembly in, 4 are the brake master cylinder studs that have nuts on them, and 2 are bolts that go into the fire wall...


Explorers have different wiring than a Ranger......so what is on 1 pin in the Explorer PCM plug might be on another pin in the Ranger plug

the pcm on the sploder is different in that it has data output later on as well...then post 93 they really start getting shitty.


but a 91 pcm is fine in a 91 ranger. the body harnesses are a bit different, but that also changes the main pinout on a ranger depending on how its optioned. a ranger harness from a base 4 popper may be different then a loaded ext cab 4.0. theres alot of rpo,s in those years with 4 powertrains. the sploder is just 1.

91's are the dumbest and easiest years to do...the pdb is split and the pcm is completely stand alone. its literally a ten minute job to mod them to work in anything...from a lawnmower to a suzuki sidekick.



the parking brake and service brake/clutch assembly are identical between the two, and the service/clutch assembly you definatly want together.

 

[bobbywalter]

Explorers have different wiring than a Ranger......so what is on 1 pin in the Explorer PCM plug might be on another pin in the Ranger plug

that is not the case for 91.

 

[91exploreron37]

Ohh you replaced the whole pedal assembly bracket. On my explorer, and I believe the rangers are the same way, The brackets are the same between auto and manual so I pulled the e-clip from the brake pedal, slid it out and slid the brake/clutch pedal into the original bracket if you get what I'm saying. Theres no need to replace the whole bracket from the firewall just the pedals thmselves.

 

[91exploreron37]

Also and since they slide out to the left, it makes it easier if you remove the parking brake assembly to give you more room.