My Explorer (Solid Axle Swap)

[94cobra69ss396]

Ever since we decided to do a run I'm been working hard to finish my Explorer. It started out as an independent front suspension that had about an inch and a half lift from twisting the torsion bars. Now it's about 4 inches higher with a Dana 30 front axle out of a '88 Cherokee. The only part of it that I didn't do myself was the steering which was done by Randy at Randy's Offroad in Azusa. However, I have to redo it because the tie rod bar is just twisting. I've started the conversion over to high steering which will move the drag link above the passenger spring.

The only things I have left is to make the drag link, have the driveshaft lengthened (should be done in a couple days), install 4.56 gears and then put it up on 33's.

Here's some pictures of the work.

http://www.motorgen.com/pic/data/741/DSCF3193.JPG

http://www.motorgen.com/pic/data/741/2053115_22_full.jpg

http://www.motorgen.com/pic/data/741/2053115_21_full.jpg

http://www.motorgen.com/pic/data/741/2053115_25_full.jpg

http://www.motorgen.com/pic/data/741/2053115_19_full.jpg

http://www.motorgen.com/pic/data/741/DSCF3187.JPG

http://www.motorgen.com/pic/data/741/DSCF3194.JPG

http://www.motorgen.com/pic/data/741/DSCF3195.JPG

http://www.motorgen.com/pic/data/741/DSCF3198.JPG

http://www.motorgen.com/pic/data/741/DSCF3199.JPG

http://www.motorgen.com/pic/data/741/DSCF3200.JPG

[SeanPlunk]

What engine is in that Explorer? Is it a V6 or a V8?

[94cobra69ss396]

It's the stock 160hp 4.0 V6. In '95 Ford only put the 4.0 in the 4x4. The 5.0 V8 is all wheel drive so you don't have a low range which I wanted when I bought the truck. Eric (eric97srad) has a '97 with the 5.0.

[enkeivette]

Sorry bro but you're going to need to jack it up another inch for some 35s. 35s on Exploders look sweeet. :judge:

http://i33.tinypic.com/ofan3l.jpg

This was Justin Singh's Exploder in Trabuco Canyon.

[94cobra69ss396]

Sorry bro but you're going to need to jack it up another inch for some 35s. 35s on Exploders look sweeet. :judge:

This was Justin Singh's Exploder in Trabuco Canyon.

I do want to lift it about another 2 inches but I don't want to run 35's. To run 35's I would have to cut the rear quarters and I don't want to do that. Also, I'm only running a Dana 30 and would be afraid of breaking an axle with 35's.

[enkeivette]

I do want to lift it about another 2 inches but I don't want to run 35's. To run 35's I would have to cut the rear quarters and I don't want to do that. Also, I'm only running a Dana 30 and would be afraid of breaking an axle with 35's.

For problems there are only solutions.

My friend never cut his fenders, the tires would rarely tuck underneath, and the few times that they did they left barely any evidence of it on the tire. He had Deavers, they were pretty soft too. Also, he ran the stock diff and he beat the sh*t out of it, it always held up fine.

If you think it would look cool, consider it. And remeber, tire diameter is the only way to gain diff clearance.

[enkeivette]

Also if you're handy with a welder you should consider plating the underside of the front crossmember. And maybe even adding a strut tower brace. Those spots can crack on exploders after big jumps. I speak from experience.

[SeanPlunk]

Sorry bro but you're going to need to jack it up another inch for some 35s. 35s on Exploders look sweeet. :judge:

http://i33.tinypic.com/ofan3l.jpg

This was Justin Singh's Exploder in Trabuco Canyon.

Correct me if I'm wrong, but didn't Justin crack the frame on his Explorer? I'm not sure he's the guy I'd want to emulate if that's the case :sm_up_there:

[enkeivette]

Correct me if I'm wrong, but didn't Justin crack the frame on his Explorer? I'm not sure he's the guy I'd want to emulate if that's the case :sm_up_there:

Yup, read the post above yours. But that had to do with the way he hit the jump, he hit the brakes just before the jump, causing the nose to dive. And it was a massive jump, he got at least 5 feet of air at the lowest spot and came down on the front end. And he didn't have enough suspension for the jump.

That has nothing to do with tire size, if anything, more tire would offer more cushion.

[94cobra69ss396]

Also if you're handy with a welder you should consider plating the underside of the front crossmember. And maybe even adding a strut tower brace. Those spots can crack on exploders after big jumps. I speak from experience.

I no longer have the cross member I cut it all out to do the solid axle swap. The stock front suspension had about 5 inches of travel and my new front has 10 inches straight up and down.

As for the rear travel, I only have home made springs in the rear but I have issues with my 31's rubbing. I also have the longest shock I can fit under the truck which I believe has 10 inches of travel but it might be 12 and if I unbolt the shocks the rear axle will drop another 4 inches before the brake line starts to pull.

In this picture you can see how far up the wheel goes.

http://www.motorgen.com/pic/data/741/2053115_3_full_1_.jpg
Sorry I no longer have a large picture.

[94cobra69ss396]

I received my front and rear 4.56 gears and finished installing the rears today. I still have to pick up my ARB air locker for the front and then get an install kit and an air compressor but I should have it ready for the November 8th run. I can't wait to get it out again. It's been down for over a year.

[SeanPlunk]

I received my front and rear 4.56 gears and finished installing the rears today. I still have to pick up my ARB air locker for the front and then get an install kit and an air compressor but I should have it ready for the November 8th run. I can't wait to get it out again. It's been down for over a year.

That's awesome Ron, are you going to do the gears yourself?

[94cobra69ss396]

That's awesome Ron, are you going to do the gears yourself?

I do everything myself. It took me about 5 hours to do the rears.

[Vettezuki]

I do everything myself. It took me about 5 hours to do the rears.

Someday I'd like to regear the Jeep to return it to stcok total ratio. I'm running 31.5" tires, so it's considerably taller gearing than with the original 27" tires (as I recall). Maybe you could help a brother out someday. ;)

[Leedom]

Gears scare me. From what I know they are pretty easy to do but at the same time...f-em up and that is one expensive mistake. I had the gears done in my F-150 years ago and had a ring gear bolt "fail" on me as the installer said about 10 months later. Then after new bearings, L/S, ABS sensor, diff cover ($600) the same thing happened again 2 years later (on 2 more of the bolt). Went back to the same guy pissed and he said he would look at everything for me and re-do everything for the price of a fluid change ($100) just to be fair. Butthole already had $1200 of my money so I told him to piss off. Went down to Currie and bought new ring gear bolts that happened to be about .25" or so longer than the ones in there and with a bigger head. Did not take out the gears. Un-screwed every other bolt and installed the new ones with good old red locktite and then did the remaining ones. No problems since. been at least 15K miles. That was a total tangent but Jay over at PDC in Brea pisses me off, oh did I just name drop. :mad:

BTW Ron if you have an extra seat I would love to ride in the Exploder.

[Vettezuki]

I don't know about Jeeps and Exploders, but I'm assuming it's the same story as any rear end, most of it is fairly straight forward, you just better get the backlash right, which requires the correct tools, a little paying attention, and some experience doesn't hurt.

[94cobra69ss396]

BTW Ron if you have an extra seat I would love to ride in the Exploder.

I do and your welcome to take it. However, my wife and daughters will be in the truck so remember the language.


I don't know about Jeeps and Exploders, but I'm assuming it's the same story as any rear end, most of it is fairly straight forward, you just better get the backlash right, which requires the correct tools, a little paying attention, and some experience doesn't hurt.

There's more to it than just the back lash. You also have to have the pre-load correct on the pinion and carrier bearings as well as the correct pinion depth. The rear is a Ford 8.8 so the it uses a crush sleeve which makes it easier. The pattern on the ring gear was perfect so I didn't have to shim the pinion.

I haven't done the front yet because I haven't picked up the ARB or the install kit but my brother told me it's going to take a lot longer. The front is a Dana 30 and it uses shims to set the pre-load on the pinion. So unless I get lucky and get it right the first time I'm going to have to add or remove shims to get it right which requires removing the pinion and re-installing it.

Ben, what gear ratio is in you Jeep now? The Explorer also had 27 inch tires with 3.73 gears stock. When I went to 31's I lost a little bottom end but I also have the 4.0 V6 so it wasn't too bad. I imagine it hurts a little more with the 4 banger in the Jeep. On my truck it made a difference of 3mph at 70mph. When my speedometer said 70 I was actually going 73.

I'd be happy to help you re-gear your Jeep. It will be a little easier on yours because you won't be replacing the carriers just the ring and pinions. One thing that you need to know though is that the Dana use two different carriers. One for 3.55 and lower (numerically) gears and one for 3.73 and higher gears. The Dana 30 I used in my front has 3.55 gears so for me to move to 4.56 gear I have to change the carrier which I was going to do anyways.

[94cobra69ss396]

Thought I'd bring back this old thread with some new pictures. The trans is going out in the Explorer so I went to the wrecking and pulled one from another truck which ended being the wrong trans. Anyways, while I was there I saw another Explorer with a prerunner bumper and it was bolted on so I pulled it to see how much they wanted for it. I ended up only paying $30 for it! What do you think of it? It is all DOM tubing even.

http://www.motortopia.com/files/cars/album_dezert_rangers/4b427a290db36/100_0001jpg_Thumbnail1.jpg

http://www.motortopia.com/files/cars/album_dezert_rangers/4b427a3b9bcfd/100_0004jpg_Thumbnail1.jpg