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Project 96 Explorer


16 posts and still no pics...I think I call:bsflag: Hey Chris, just messin with ya, but seriously,:worthless:
SVT
 
Okay guys!!! I still havent found the USB cable, but I got a few photobucket pics fro ya!

Before ANYTHING was removed, tweeked, or modded. The day she came home with me.

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The FREE 13-54 manual shift t-case and driveshafts I scored!!!

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And a really crappy pic of the D60 front I will be using. Thats a GENUINE 78 D60!!!

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Its about time!! Hey Chris, u can have the 60, I want the axles out of that 550 for my ranger!!:yahoo:
 
That 550 is only a 2wd.

And as many problem as Matt has been having with it, Im sure he'd sell you the whole truck WAY CHEAP if he could!!!
 
i would not use the d60 out back. get a 14 bolt, its a stronger axle and cheaper to lock & gear and go 35spline etc... also going disc brake swap is cheaper.

There are no full spools, 35 sp shafts or anything 35sp for a 14 bolt. Unless you go COMPLETELY custom and have it machined as a one-off piece.

I'll stick with my D60 rear as I got it free, and its already factory discs. :thefinger:
 
Okay...

I found the USB wire, so on with the pics!!!

Got her up on jack stands.....and removed the tires to get a better look at what I am working with....

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Close up of the front...
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Close up of the rear...
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Now lets put her on a diet.....starting with the butt....its a little to small and narrow for me:icon_rofl:

Out with the old rear end...
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What she's getting...(32sp D60 with FACTORY discs!!)
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Mocking up the new...
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(I think I need taller jackstands!! I still have a 2" lift block donated from a 92 Ranger to put in there!!!)
 
Now with the rear end mocked up for now (still gotta set the pinion angle after I convert the 2wd auto to an M5OD and manual 13-54)....

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Lets start on the front....

With the front suspension removed...
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Ive got some grinding and brackets to be removed...

But lets take a look at whats going in its place shall we? (78 D60 front)
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Anyone care to help?
 
I still have the other side to go....

But lets get rid of some brackets I dont need....

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That upper "A" arm makes a handy place to hold the brake caliper out of the way :)

Yes, I ground the remnants of the bracket that is completely hidden on the INSIDE of the frame rail. :thefinger: and I even ground the welds and made them match the contours of the frame rail....like where the 2 factory pieces were welded together.

Call me anal :icon_twisted:, but to me it makes for a cleaner looking build rather than having bits and pieces of old brackets hanging everywhere. Plus, if I get rid of them now, its easier to make any furture mods.
 
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Well after about 3 days of grinding off brackets and junk on the front suspension, I decided to go on and set the pinion angel for the rear.

This was also brough on by the fact I wanted to slide a 2x4 block under the jackstands so I can fit my 2" lift block between the axle and the spring. All I had to use to lift both sides of the rear at once was the bumper. Mixed with the fact I dont have a suitable floor jack This problem will be cured next thursday as I will be buying one off the Cornwell truck), just a cheap Wal-Mart $20 job, almost lead to a major disaster!! The damn thing started leaning HARD to one side, and almost fell!! And I am working on this alone!!! :scare:

I managed to save it and still get the blocks under the stands, but there was a very LONG tense moment or 2 there!!!

Heres a pic showing how much it moved!! (The axle was in perfect alignment with the spring pins before I started the lift.)
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So with the blocks under the stands, lets get to work...

1st thing I had to do was pull the auto tranny. I wont be using it cause its and auto, and its 2wd. So out it comes!
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I will be going with the M5OD, so I used an old empty trans case and empty t-case for mock-up purposes. They were lighter than the real thing, and Im not exactly ready to install the trans or t-case yet.
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So with the "firewall seam" mod completed, I bolted the empty cases to the motor, reinstalled the crossmember (for now till I make my custom one) and began.
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And I found an old coax wire, tied it to a 1/2" drive 6" long extension, rested it against the bearing cuts inside the axle housing, and then ran it through the pinion hole, and tied the other end through a hole in the t-case yoke. This wire was flexible enough to be pulled tight, yet stiff enough to make a straight line. And so I installed the lift blocks,set the pinion angle, rechecked all my measurements, and then marked my spring pads for welding.
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Now tomorrow I have to go and find some u-bolts and something to make the u-bolt plates out of. Im probably gonna use 1/4" plate so I can weld shock tabs to them
 
Nice build and pics, but whats taking so damn long, your slow! Turn around, you'll get it done faster!!:D Just messing with ya, keep it up, I'll send ya mine when your done
SVT
 
I want to send out a HUGE thanks to my buddy Nick Ogden for the kick ass welding he did on my perches!!! Also filled in the old grinding gouges from where I got happy with a grinder and removed the old perches!

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In his defense.....they are good clean welds, I just havent cleaned up the splatter and slag yet!!
 
your going with all this 1 ton running gear yet your installing an m5od which is a very weak tranny.
 
If I know Taragon like I do, he'll be doing dual tcases, but I think he's looking for an explorer V8 to drop in...
SVT
 
your going with all this 1 ton running gear yet your installing an m5od which is a very weak tranny.

you seem to have only negative comments so far that make no sense. I have an FM145 and 1tons. I bet i would break a D60 before i break that FM145.

Good job so far Taragon. I would reconsider a few things like the lift blocks though. There is no reason to have them, new springs and/or shackles are cheap enough, you can also do it without having to reset the pinion angle most likely.:icon_thumby:
 
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