Project Sapphire, Cramming An Explorer Into A Ranger

[absentminded102]

Just wanted to show off my progress so far. Basically I have a 95 Ranger STX and a 97 Explorer Limited. I bought the Explorer mainly for the 5.0L, but with all the nice luxuries it had, I figured I'd swap over all the upgrades I could. Still a long way from done, but check it out.

First, I had to get rid of the 4.0L and transmission.

Next I removed the Explorer's powertrain.

Tore down the engine and sent it to the machine shop.

Tore down the transmission for overhaul and Advance Adapter to transfer case.

After that, it was off with the bed and cab.

Painted the rusty frame at this point.

Got the engine and transmission put back together and installed. I used Ford Racing headers and modified the stock motor mounts.

Found a clearance issue with the rear drain plug, and a temporary solution. Wish I knew about this going into this project.

I had to sit the cab and bed back down on a 3 inch body lift due to clearance issues. Time for Explorer interior upgrades. Gutted out Ranger stuff in cab and modified Explorer harness. (This has probably been the worst part of this entire swap.)

Ever seen a fully functional keyless entry pad wired into a Ranger before? You have now. I gotta admit I was a bit nervous drilling into my door.

Gutted the mirrors because Explorer mirrors are not a bolt on swap. Hopefully they will defrost like they should.

Redid the headliner, it was looking crappy. Upgraded sun visors, mirror, and overhead console.

Installed Ford factory coil spacers to lift the front a little.

I'll have to get more pics later but I also have the nice center console with message center installed, Explorer Limited seats and the memory seat buttons wired in and working. Still a long way from done but eager to show off the progress made. BTW, if anyone has a spare one piece steel driveshaft they want to get rid of, let me know. Also, I want to give a huge thank you to my employer, Kenly Ford for letting me use the shop since Feb 2017. They have been incredibly patient with me. Also my co workers have been very helpful along with you guys here at TRS. Ever since I first saw the 5.0 swap in the tech articles, I wanted to do this. The amount of info on this site is incredible.

 

[alwaysFlOoReD]

Am I the only one not seeing pics? I can see that there are links to a google pic site but they don't show for me.

 

[absentminded102]

I think it's fixed now. Hope y'all enjoy.

 

[JoshT]

Looking good. Where did you come up with the Ford Headers? I've been watching for a used set of those or the Ford Racing Mustang "P" headers, but had no luck. Looks like you've got a brand new set there.

 

[absentminded102]

I bought the headers new a couple of years ago, just kept google searching the part number (M-9430-E52) until a set came up. I wasn't too impressed with the quality for the price though because I had to grind out excess material that would have greatly restricted flow.

 

[ATX]

Like the build so far brotha


Sent from my iphone while gettin sidewayz!!!

 

[85_Ranger4x4]

I ran into the drain plug issue too.

I so wish I had pulled the engine back out, dropped the pan and welded in a pipe bushing on the other side of the pan and just used a pipe plug.

I hate how it dumps oil all over the pivot bracket when I change oil.

Looks great though, very clean truck to boot.

 

[Junglejoe]

Love it. Where are you at this point on the swap and build

 

[absentminded102]

Thanks for all the kind words guys. I really need to remember to snap a few more photos and post them. At the moment, I've got the engine running but it's not ready to be driven yet. I originally planned to keep the Ranger's transfer case for 4x4 HI and LO, so I installed the Advance Adapters kit. I later realized that since I'm practically swapping over all of the Explorer's electronics (including GEM module) there was going to be an issue with controlling the transfer case. I found a thread in the Explorer forums where a fella converted his AWD Explorer to 4x4 by using a V6 Explorer's transfer case with Advance Adapters kit and GEM, so that's the route I took. As a result, I now need to lengthen the front driveshaft and shorten the rear. Had I known this would happen originally, I would have never bought the adapter kit and would have instead installed a transfer case from an Expedition. Hindsight is 20/20, right? Since the rear driveshaft has to be modifiedanyway, I figured I'd go ahead and get the one piece design (still looking.) Also, all of the metal brake lines were rusted and I couldn't find new ones anywhere, so I had to bend and flare tubing. Debating on bleeding the lines now and drive it for a while, or go ahead and swap Explorer rear axle first. I'll have to find someone to weld on the spring perches though. Once I know that it's drive-able, I'll take it to a muffler shop for exhaust. The only other loose ends I can think of at the moment, is dealing with the different EVAP systems, and figuring out how/where to put the amps and sub from the Explorer. Going to install bigger tires and alignment also. By the way... with a 3 inch body lift and coil spacers on the front, would a set of 32/11.5R15 tires fit without rubbing? I still have plenty of work to do, but this project has came a long way. I can't wait to drive it, I'm sure it will be worth all of the effort I've put into it.

 

[alpine67]

That's a nice looking build! I'll be following along as I prepare to go down this road with a 94 Ranger I picked up last week. And its good to know there's someone close by, so I hope you don't mind if I ask stupid questions, and maybe eventually take a look at how you do some of the mods.

 

[absentminded102]

Yeah man, come on down sometime. I'd be glad to answer any questions you'll have as best I can. Just know that if you're planning on putting all those Explorer parts into a Ranger, that you're in for a lot of hard work. This hasn't exactly been cheap either, haha. Not trying to discourage you, it's had it's fun moments, but plenty of headaches also.

 

[bobbywalter]

yeah....didn't understand the cramming part...then seen you were keeping the civil society features....lots of work.

I put a complete mark 7 dash in one once....never again for free. put the keyless entry behind the cab though.

 

[Ranger850]

for some reason i got no pictures, but sounds like you got a nice build going there.