axle/t-case swap...

[adsm08]

Yeah, RBVs have always been a 5 x 4.5 pattern.

F-150 and Bronco had a 5 x 5.5 pattern.

 

[Ivy Mike]

I highly advise against TTB for a couple reasons...the explorer frame is wider than the ranger, so getting it aligned will be a job, along with the difference in frame widths, the X-member that supports the beam pivot mounts again will be a job both fabricating and aligning... It will be much easier to grab some coil buckets (after clearing the frame of the IFS mounts) set your axle position, mount the buckets, then your tracbar mount, then set your radius arm mounts and your done...
SVT

Agreed. The only other option I can think of would be a Dana 44 TTB from a 96 and earlier F150 or Full Size Bronco. Even then you would still have to fabricate mounts for the beams. Radius arm mounts are a bolt on affair but coil buckets and shock mounts would have to be fabbed up.

In short, with all the work and money you would put in to a TTB setup, you could have a coil spring solid axle up front. Just beware of low pinion Dana 44s. They will not provide the increase in durability he seems to be after compared to the IFS Dana 35 he already has.

 

[twoll86]

another option tho not much stronger would be a dana 30 out of a jeep or even a rubicon 44 depending on what you are willing to spend