Rebuilding my '96?

[Defective]

Looking for advice on what to do with my '96 4x4 4.0 5spd.

It's got 210k+ miles on it now and It's needing a new clutch, smokes when it's started, and has valve tick and lower end knock as well as some cosmetic issues.

I have a motor from a '98 or '99 explorer with 64k or something like that on it.

I also have a motor/tranny/t-case from a '96 ranger with 47k.

I would like to put the combo from the 96 in, but also want to build it a bit while it's out.

My intentions are to have a quick 4x4 that is also a lasting truck. I commute long distance in harsh weather and like to use 4x4 whenever I need or want it, no matter what the speed (so far the stock t-case rocks). I drift around corners more often than not in winter, usually in 4x4 with all 4 spinning. I hit my rev limiter almost every day, often several times. Basically, I rally my truck but keep it pretty legal. You could say I'm just a very spirited driver.

I'd like to warm the motor over a bit and strengthen any weak areas of the drivetrain and try to get rid of the axle hop when taking off.

I have to go right now, but that should be enough to get started. Ask any questions you need to or flame as you feel necessary!

Thanks!

 

[97ranger4x4]

Lol a "spirited driver." I have not heard that one!

Just curious but how long have you had your truck? I am guessing you have not put all 210k on it? So putting a newer motor seems like a no brainer a long with a new tranny right? I would keep your motor stock. As for strengthening your week areas, with your driving style I would make sure that it is runing in tip-top shape before you go rallying.

Do you have a l/s or a locker out back? Also have you converted your front hubs to manual locking ones? They are a much stronger unit. Ill assume you have because i dont think the autos would have lasted this long. These trucks are pretty sturdy so since it seems like your mostly on snow covered roads, you should break to much...

 

[Defective]

Have had the truck since '99 and 32k miles.

I'm pretty sure the engine would hold together for 20-30k more, but the clutch is dooming me right now.

I have manual t-case and hubs. Limited slip rear, but don't know the ratio. don't seem like 4:10, feel more like nice highway geers, like maybe 3.75? I'll find out later.


I knew I wanted a new motor, thats why I waited and waited till I found some low mile possibilities.

I do kind of want to do some motor mods just becuase I've never done it before or had this kind of opportunity. I did a little research and it sounds like the head from the 98 should be used on the 96 engine after a port and polish. Then cam and headers and I'll be off to a good start. I have dreams of turbo or s/c but for now NA all the way, with boost in mind for later.

I don't have all the knowledge to do this yet, but I learn fast and once I get into it, I know I can do just about anything.

 

[97ranger4x4]

You must have 3.73s for your front and rear end. There should be an tag on the rear axle with some numbers on it. the last few digits is the ratio.

Do you have another vehicle in case your truck breaks down or anything?

 

[Defective]

I was going to fix the cavalier's clutch first and drive it, but I think I'm going to have my wife find a minivan to buy and start driving the f150 she uses until the ranger is done. Right now if the ranger takes a shit I have some quick hard decisions to make.

I will get the axle numbers soon.

I was kinda thinking to find a low milage explorer axle with discs though....

 

[97ranger4x4]

yeh then you just need to reweld the spring perches to the top. You may also need to reweld the shock attachments. I think its a lot of work for disk breaks on a truck as light as the ranger. if I was doing a lot of towing it may be worth it.

 

[85_Ranger4x4]

yeh then you just need to reweld the spring perches to the top. You may also need to reweld the shock attachments. I think its a lot of work for disk breaks on a truck as light as the ranger. if I was doing a lot of towing it may be worth it.

You also get a stronger axle out of the deal as well... but I wouldn't worry about it unless you have axle problems and are replacing the axle anyway.

 

[Defective]

Well, my limited slip is not working like it used to.

The fluid has never been changed in it either. I drive for at least an hour at a time going 65-80 miles an hour, mostly 75, two times a day. In the winter I spin my tires around corners all the time. I'm not afraid to spin on pavement or hit dry pavement when sliding either. Do it all the time. I also submerged it once, but obviously must not have gotten anything in it or it would be toast by now since I didn't change fluid.

I don't know what kind of wear this treatment has put on it. I have never really been nice to it unless I'm hurtin for gas money.

 

[97ranger4x4]

Well I am not really familiar with limited slips, but I think you can repack the clutch pack so that they grab better. also when you change the gear fluid you have to add some friction modifier or something.

 

[85_Ranger4x4]

After 100k miles the clutches in a limited slip are usually shot and need replaced. Not that it will hurt anything, it will just act like a regular open differential.

Clutches are pretty cheap to get and you are overdue for a axle juice change anyway... and they would be two things you would probaby need to do to an Explorer axle anyway.

 

[Defective]

Have had a few more days to think this through.

After considering everything, I'm going to have to keep this stock and make it a just a quick engine/trans/t-case swap with a few other repairs. Minimal time and expense.

Will be doing drive-shaft u-joints and rear brakes at the same time.

Questions:
1. What's the best way to remove the combo in one chunk? Or can it be?
2. Would I be ahead to replace the clutch/slave cylinder with the tranny out now?
3. What else should I do to this combo before sliding it in?
4. Missing the coil, just get an OE one?
5. new motor mounts/shocks?
5. Any other suggestions?

Project starts thursday night and hopefully I'll be done by Monday by morning.