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Thread: 5spdman's 91 Explorer XLT build

  1. #1
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    5spdman's 91 Explorer XLT build

    I'll try to make this short for now...full build thread can be found at http://www.explorerforum.com/forums/...d.php?t=403765.

    I bought my 1991 Explorer XLT a year and a half ago after my 1993 Explorer Sport blew it's head gaskets. I don't have to tell you all how bad rust can get in Ohio, but the Sport was so far gone that it wasn't worth my time or money to fix. I found the XLT sitting behind someones house being used for storage and inquired about the vehicle. $200 later and it was mine!



    After gutting the interior, running new wiring for stereo, lights, CB and emergency lighting, it was time do get it drivable. The truck had been sitting for a little over a year, and had just been overhauled, but there was no transmission. Lucky for me both the Sport and XLT were manual transmission vehicles, so I swapped the M5OD from the Sport to the XLT. Few days and some more work later, I was able to drive it from AZ (where I work) to Ohio for Christmas.

    Being that I lived in AZ, I was getting the itch to build and hit some harder trails than non-maintained roads. With some help from members on explorerforum, I got info on parts and ways to go with my build, and got my hands on a few parts from members themselves. With parts gathered and ideas in my head, I started on the build in October, in hopes to again drive it home for the holidays (which ended up not happening).

    At this point suspension and gearing were modified (list at end of post), body was painted and was waiting alignment. Due to a brake issue, I left the Explorer in AZ and resumed the build when I got back.



    Fixed the brake issue, took it to the closest town for an alignment (100 mi away) and managed to get a deal on new tires. After a few cosmetic touch-ups and additions over the last few months, this is how the Explorer sits today:





    List of modifications/details to-date:

    Engine: 4.0L V6, stock
    Transmission: M5OD (manual)
    T-case: Push-button BW1354
    Gearing: 3.73, LS rear
    Axles: DANA 35 TTB front w/ manual hubs, Ford 8.8 rear w/ disc brakes (axle pulled from '95 Explorer)
    Suspension (front): 4" TTB drop brackets, 4" TuffCountry coils, 1" home fabbed coil spacers, NAPA Response shocks (5" longer than stock), swaybar drop brackets and quick disconnects, MOOG camber/caster bushings
    Suspension (rear): SOA conversion, stock leafs and shackles, rear sway bar delete, NAPA Response shocks
    Steering: SkyJacker FA600 pitman arm
    Brakes: '95 Explorer MC, custom made 8" extended brake hoses
    Wheels: 33x10.50x15 BFG All-Terrains on painted stock rims

    Other modifications to-date:
    -Spray can paint job (easy to fix trail damage)
    -Custom built tire carrier, carrying a spare front hub and 33" BFG
    -Custom built luggage rack (3/4" and 1/2" EMT conduit)
    -Front recovery points welded to frame
    -Towing receiver welded into frame, with added recovery points
    -Rear "rollpan"
    -Completely re-wired stereo
    -CB Radio
    -Interior tool mounts for axe, hatchet, shovel and fire extinguisher
    -Undercover LED emergency lighting and siren (volunteer FF)

    Lighting:
    -4 130w roof lights
    -2 55w rear work lights (roof mounted)
    -1 20" LED light bar
    -2 flush mount LED fog lights

    Modifications to be made in the next few months:
    -F250 shock tower conversion up front (have)
    -Shocks replaced with ProComp ES9000 (have)
    -Extended radius arms w/ Ballistic joints (will be made from stock arms)
    -New rear springs (need)
    -Roof lights replaced with 40" LED light bar (waiting for me in Ohio)
    -Manual t-case swap (will have in a week)

    Modifications to hopefully make in the next year or two:
    -35x12.50x15 BFG Mud-Terrains
    -4.88 gearing
    -Front locker
    -New LS clutch pack (rear)
    -T-case doubler

    So far this rig has done everything I've asked it to and I'll really be putting it to the test in a few days as I'll be in Moab, UT over Memorial day weekend. We'll see what carnage lies ahead with that trip, and I'll keep you guys posted with the build as a trail rig is never finished! :D

    Stay tuned!
    Last edited by 5spdman; 05-18-2015 at 05:05 AM.

  2. #2
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    Well, anytime I try to post a brief history of my build it never saves. A full thread on the build to-date can be found at http://www.explorerforum.com/forums/...d.php?t=403765.

    I'll keep this thread updated as the build process is still on-going and will more than likely never stop. :D

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    looking forward to seeing you on the trail.
    Paul

    1976 CJ 5 on 37s
    1984 CJ 7 on 36's
    1993 GMC K3500 6.5 Turbo Diesel

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    Thanks! It'll be nice to finally wheel back in Ohio once I get there...two more weeks of living in AZ and I move back.

  6. #6
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    Looking great. Nice work especially on the suspension. Are you planning to put a winch?

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