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Protowrxs
New Member
- Joined
- Aug 10, 2011
- Messages
- 67
- Reaction score
- 1
- Points
- 0
- Location
- Shawnee,OK
- Vehicle Year
- 1989
- Make / Model
- Ford
- Engine Size
- 2.9 - 4.0 Waiting
- Transmission
- Manual
Rescued Ranger / Yet Another 4.0 Swap (YA4.0S)
Little back story:
1989 2.9L 5sp XLT 4x4 - given up for dead, PO had pulled intake, said it was getting gas in the oil and filling up the pan, left it sitting open topped and no rear window. I picked it up for $400 which may have been a bit much looking back but was looking for a cheap 4x4 and thinking I’d swap in a 2.3Turbo I had sitting around if the 2.9 was not worth the trouble. After getting it home it was obvious that the little truck was ridden hard and put up wet quite often. Nasty, dirty, caked with mud, and bent up in some places. But really solid overall with little rust body wise.
Ended up putting the 2.9L back together and getting it running without problems BUT not a fuel in the oil problem but definitely anti-freeze in the oil problem. Checked the heads and both are cracked but otherwise it does run. Massive 2.9 lifter noise as well but after stuffing it full of radiator fix no more anti-freeze in the oil and it gets me around for now. Had to pressure wash about 100 lbs of Oklahoma red clay off the bottom of the thing and clean/purge the fuel tank and lines as well but it’s a "Rescued Ranger" now.
The 2.3T idea didn’t go over so well ( Thread Here ) so I kept an eye out for 4.0 options while throwing a few other upgrades to the old truck. New used wheels, 31s, bucket seats and console out of a 93 or 94 Mazda, gauges in the ash tray location to keep tabs on the non-existent oil pressure, some front lights, new headlights, a rebuild on the D28 u-joints, pulled the bent up rear bumper, and a spare tire mount made it more fun to look at and drive.
The Plan:
Just ran across what was advertised as a 92 Explorer chassis including 4.0, M5OD, D35 and 8.8. Seemed like a good deal for $375 so I picked it up for a future swap. The vehicle had burned inside so body and wiring was missing but the seller had already picked up a new headlight harness, engine harness, and X2X2 computer for a 92 Explorer including the airbox, mass air, and intake pipe. The seller had purchased the chassis earlier and was planning on a B-II swap but sold the Bronco instead so a perfect setup for me IMHO.
Doing a little homework revealed the “92” chassis is apparently really a “93+” after finding a couple “F3” parts on board. It has an EGR and the cam position sensor in the distributor hole so it appears to be at lest a 93 chassis. The existing 93 engine harness had been hacked up at the connectors so no big loss there as I will have to use the 92 version anyhow.
The Confusion:
At this point I’ve figured out nearly all the wiring swap / re-pinning I will need to do to merge the 92 computer/engine harness with the 93 trans harness and the 89 headlight harness and do not plan using the Explorer headlight harness as I just do not see that as the easiest route for my configuration.
The computer harness easily separates from the headlight harness and can be wired up without headlight harness changes for the most part. Maybe a new connector at the left rear area but otherwise pretty straight forward I think. I’ll just leave the EGR or pull and block it off, leave the cam sensor to fill the hole and use the 92 engine harness.
One downer is I guess the 93 injectors will NOT work with the 92 X2X2 computer? Right experts? So I will have to pickup a set of 92 and earlier versions. Anyone know what, if any, other Ford injectors are the same for the up to 92 Explorers? I have extra 19lb versions from a 87-93 Mustang EEC-IV but no clue yet as the compatibility.
What's Next?
Current plan is to pull the engine out of the chassis, check, clean and detail the 4.0 over the winter, new oil pump and other items as needed, and do the swap in the Spring. Don’t want to be caught short if we get bad weather this winter... if it ever gets here. Will use the M5OD as well and mix up a starter harness using the existing 89 parts. Eventually I’ll build an A/C harness and have to figure out how to make A/C lines work but that can wait. Plan on keeping my manual transfer case as well. I've already dropped a 4.0 radiator in and lower hose and plan on re-using that.
Other challenges I guess ahead are:
I am open to all those that have done this before and have read most of the swaps listed. It seems each one is unique however depending on year of the Ranger vs the donor. So many combinations possible.
I want to say a big "Thanks" to fellow TRS member Steve Lewis - sbrslewis for some sway bar parts, some Rancho shocks, and a borrowed engine stand for this project. I also plan on following his Fender Cutting tech to open up the fenders on this old truck while also removing the bedside cancer on the backside.
I know, thread is useless without pics so here are a few before and currents. Will put up some others on the wiring soon as well just because I have them.
As found dead to the world:
Cleaned up, replaced rear window, in the driveway:
Cleaned up 2.9L Intake - running again:
Dropped in some gauges to track the non-existent oil pressure:
It's not a Squirrel cage - it's a RAT cage:
New eyes and painting the grill:
Looks much better:
New to it wheels and 31s:
Another good spot for a gauge IMHO:
Cracked 2.9L Head:
And the snot that comes with it:
Fixed this for now with a bunch of stop leak - nothing in the oil now.
Not a long term solution but I knew an upgrade/replacement was going to happen.
New(er) buckets and console - much nicer:
Testing a Driving Light Mount, all four are on now:
93 Explorer 4.0 Chassis:
Trans view: Note the cut out O2 sensor - Hope my existing 2.9 Exhaust works or I'll be patching this:
Perfect spot for this - screw holes even lined up on the mount:
Full Album to date is here if anyone cares:
http://s1221.photobucket.com/albums/dd480/nolenbucket/89%20Ranger%204x4/
I'll post up some harness pics soon. With the help of the 89 Ranger EVTM and the 92 Explorer EVTM it appears I can re-pin the black connector on the left side (tranny harness) of the 93 version, re-pin the gray chassis version to match up, use the existing power connectors on the passenger side, and only have to do some real splicing on the main engine to chassis harness in the left rear of the engine compartment.
The key is figuring out the functions for each connector and then matching up the function for each one with the new harness. Too back the EVTM doesn't have connector diagrams (that I can find at least) for the inline connectors showing function like they do for the end point ones.
-Stephen W Nolen
Little back story:
1989 2.9L 5sp XLT 4x4 - given up for dead, PO had pulled intake, said it was getting gas in the oil and filling up the pan, left it sitting open topped and no rear window. I picked it up for $400 which may have been a bit much looking back but was looking for a cheap 4x4 and thinking I’d swap in a 2.3Turbo I had sitting around if the 2.9 was not worth the trouble. After getting it home it was obvious that the little truck was ridden hard and put up wet quite often. Nasty, dirty, caked with mud, and bent up in some places. But really solid overall with little rust body wise.
Ended up putting the 2.9L back together and getting it running without problems BUT not a fuel in the oil problem but definitely anti-freeze in the oil problem. Checked the heads and both are cracked but otherwise it does run. Massive 2.9 lifter noise as well but after stuffing it full of radiator fix no more anti-freeze in the oil and it gets me around for now. Had to pressure wash about 100 lbs of Oklahoma red clay off the bottom of the thing and clean/purge the fuel tank and lines as well but it’s a "Rescued Ranger" now.
The 2.3T idea didn’t go over so well ( Thread Here ) so I kept an eye out for 4.0 options while throwing a few other upgrades to the old truck. New used wheels, 31s, bucket seats and console out of a 93 or 94 Mazda, gauges in the ash tray location to keep tabs on the non-existent oil pressure, some front lights, new headlights, a rebuild on the D28 u-joints, pulled the bent up rear bumper, and a spare tire mount made it more fun to look at and drive.
The Plan:
Just ran across what was advertised as a 92 Explorer chassis including 4.0, M5OD, D35 and 8.8. Seemed like a good deal for $375 so I picked it up for a future swap. The vehicle had burned inside so body and wiring was missing but the seller had already picked up a new headlight harness, engine harness, and X2X2 computer for a 92 Explorer including the airbox, mass air, and intake pipe. The seller had purchased the chassis earlier and was planning on a B-II swap but sold the Bronco instead so a perfect setup for me IMHO.
Doing a little homework revealed the “92” chassis is apparently really a “93+” after finding a couple “F3” parts on board. It has an EGR and the cam position sensor in the distributor hole so it appears to be at lest a 93 chassis. The existing 93 engine harness had been hacked up at the connectors so no big loss there as I will have to use the 92 version anyhow.
The Confusion:
At this point I’ve figured out nearly all the wiring swap / re-pinning I will need to do to merge the 92 computer/engine harness with the 93 trans harness and the 89 headlight harness and do not plan using the Explorer headlight harness as I just do not see that as the easiest route for my configuration.
The computer harness easily separates from the headlight harness and can be wired up without headlight harness changes for the most part. Maybe a new connector at the left rear area but otherwise pretty straight forward I think. I’ll just leave the EGR or pull and block it off, leave the cam sensor to fill the hole and use the 92 engine harness.
One downer is I guess the 93 injectors will NOT work with the 92 X2X2 computer? Right experts? So I will have to pickup a set of 92 and earlier versions. Anyone know what, if any, other Ford injectors are the same for the up to 92 Explorers? I have extra 19lb versions from a 87-93 Mustang EEC-IV but no clue yet as the compatibility.
What's Next?
Current plan is to pull the engine out of the chassis, check, clean and detail the 4.0 over the winter, new oil pump and other items as needed, and do the swap in the Spring. Don’t want to be caught short if we get bad weather this winter... if it ever gets here. Will use the M5OD as well and mix up a starter harness using the existing 89 parts. Eventually I’ll build an A/C harness and have to figure out how to make A/C lines work but that can wait. Plan on keeping my manual transfer case as well. I've already dropped a 4.0 radiator in and lower hose and plan on re-using that.
Other challenges I guess ahead are:
- Fuel line differences (they even cut the fuel lines for some reason?)
- Possible clutch line differences
- Shifter options (existing isolation rubber is melted)
- A/C Line Differences (but that can wait until summer)
- What other things to consider esp 93 Differences engine wise?
I am open to all those that have done this before and have read most of the swaps listed. It seems each one is unique however depending on year of the Ranger vs the donor. So many combinations possible.
I want to say a big "Thanks" to fellow TRS member Steve Lewis - sbrslewis for some sway bar parts, some Rancho shocks, and a borrowed engine stand for this project. I also plan on following his Fender Cutting tech to open up the fenders on this old truck while also removing the bedside cancer on the backside.
I know, thread is useless without pics so here are a few before and currents. Will put up some others on the wiring soon as well just because I have them.
As found dead to the world:
Cleaned up, replaced rear window, in the driveway:
Cleaned up 2.9L Intake - running again:
Dropped in some gauges to track the non-existent oil pressure:
It's not a Squirrel cage - it's a RAT cage:
New eyes and painting the grill:
Looks much better:
New to it wheels and 31s:
Another good spot for a gauge IMHO:
Cracked 2.9L Head:
And the snot that comes with it:
Fixed this for now with a bunch of stop leak - nothing in the oil now.
Not a long term solution but I knew an upgrade/replacement was going to happen.
New(er) buckets and console - much nicer:
Testing a Driving Light Mount, all four are on now:
93 Explorer 4.0 Chassis:
Trans view: Note the cut out O2 sensor - Hope my existing 2.9 Exhaust works or I'll be patching this:
Perfect spot for this - screw holes even lined up on the mount:
Full Album to date is here if anyone cares:
http://s1221.photobucket.com/albums/dd480/nolenbucket/89%20Ranger%204x4/
I'll post up some harness pics soon. With the help of the 89 Ranger EVTM and the 92 Explorer EVTM it appears I can re-pin the black connector on the left side (tranny harness) of the 93 version, re-pin the gray chassis version to match up, use the existing power connectors on the passenger side, and only have to do some real splicing on the main engine to chassis harness in the left rear of the engine compartment.
The key is figuring out the functions for each connector and then matching up the function for each one with the new harness. Too back the EVTM doesn't have connector diagrams (that I can find at least) for the inline connectors showing function like they do for the end point ones.
-Stephen W Nolen
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