'94 buildup

'94 buildup, transmission swap and more ...

Well here it is ... my 1994 4.0 4x4 auto (A4LD). 120k miles, still running strong.
On its second transmission, and it's letting go again, definitely not good for any off-roading, as mild as it is. I wanted a manual forever, but didn't wanna pay 1000$ to get it from a scrapyard.

Been waiting for a decent deal for a while ... and found this puppy. 1991 Exploder, brand new orange paint, but dead engine, rotten underbody, leaky brakes ... but the transmission is perfect. All I needed.

This means I'm somewhat committed to the Ranger now, and can plan a bunch of little mods that will make it a decent offroader.

Plans you ask?

In order...

M5OD swap
Manual BW1354
(will do both of these at the same time)

Snorkel

Regear to 4.10, using an FX4 axle if possible.

lift (4-6", with extended radius arms if possible) and tires (33")

In the middle of all this, I want to add in some cosmetic imrpovements, like not opaque and dull headlights, a paint job, some interior upgrades, possible a sunroof.

Of course I will take my time to do these and will include "shakedown" periods after each mod to be sure it was done properly and actually improves the truck.

If there's any interest, I can keep y'all updated with pics and comments ...

Here are pics of the beasts ...

Sounds like a good idea, however if you plan on runnin 33s when your done, i would get a set of 4.56s instead of 4.10s. 4.10s are a much better combo for 31s. As for the paint on your truck, i would get rid of the pinstriping/graphics you got going and slap some bedliner on the rocker panels.

Issue with 4.56s is that they are not OEM, meaning I would have to actually re-gear. I've been convinced it's far easier to just swap the whole assembly rather than re-gear. 4.10s it will be.
I do plan on making it FX4 kinda looking ... black/charcoal tough paint on the bottom, and still undecided for the top. Blue? Red? Paint? Vynil wrap? I'll see. Pinstriping has to go fo sho'! I'm sick of those gay arse graphics! LOL

Here's a quick walkthrough of what I quickly did tonight ... slow pace.

Jacked it as high as I could. Truck jackstands under the axles. Comfy enough under there, I don't have craawwwwwl to get out.


I proceeded to take the wheels off, only for cosmetics purposes.

Pre-op shot! Everything's still there! It is incredibly clean and not rusty ... I was expecting mayhem under there.


Grab that 1/2 swrench and remove the 4 bolts holding the skid plate. Gone.


Remove the rear driveshaft from the transfer case, 4x 9/16 bolts/nuts.


Next victim is the crossmember supporting the trans and TC


I first added some support via a jack and jack stand, then removed 6x 18mm nuts holding the crossmember.


Then removed the front driveshaft, 4x 5/16 12 point.


Disconnected 2 connectors (the red one and one at the top) and the speedo cable.



Next step is making room inside to reach the plate that sits on the tunnel. It should make the top TC to transmission bolts easily reachable. But that's for tomorrow.

Hope no one minds such detailed posts ... ever since I wanted to swap transmissions I wanted to see pictures and details of what I was getting into ... now I'll know

Made progress on the interior.
Basic stuff, just old rusty moldy crap. Glad I was through with it within an hour.

One seat out, they're held by 4x 13mm bolts and one Torx 50 for the seatbelt rail.


Other seat and console removed (bunch of screws and 4x 8mm holding the armrest thing). Steering wheel cover was removed for aerodynamic purposes.


Everything fits in the trunk, no wasted garage space!


Carpet and plate removed. Need to remove a plastic trim and a half to get the carpet out cleanly.The 4x 8mm bolts holding the plate are very uncooperative, btw.


Now I can actually remove that transfer case.

looks good!

Added a strap for extra security. I'm alone in the garage and don't remember how much a transfer case weighs ... I don't want my crushed remnants to be found in a few centuries.

Removed the 5x 13mm bolts between the extension and transfer case.
Nothing moved. Tried prying it open, nothing. Well a tiny gap at the bottom, but no more.


Ok, I guess I'll look into the manual.

Aforementioned manual suggests removing the TC and extension alltogether. Mmmmk.

So I take out the 7x 14mm bolts and gently pry it ... oh shit oil is dripping. Oil pan isn't far, Flash saves the day, only a few drops on the floor, and nothing on myself. I rule. I couldn't drain it before starting because ... err ... because ... err. Yeah, because.


Minutes later, the oil has drained, and I slide the TC off. That shaft is at least 3 miles long. Gotta be careful to keep things aligned and smooth going.


TC's out. Dolly not included. Wood pile worked great as a shock absorber as I kicked the TC to the back. Do as I say, don't do as I do.


I fight for 30mins getting that extension off. Stupid centering pin is jammed. Took a bit of convincing and my buddy Prybar. Funnel only for decorative purposes.


I had planned to open up the transmission before re-installing it to make sure all was fine ... but I wish I could've left the extension on during removal. As a matter of fact, I'll probably put it back on. I don't like seeing the internals while I wrench around in rust and dust.


Good progress. I'm where I wanted to be in terms of schedule so far. I still have to work so I can't spend 6h/day in the garage. I don't have the patience anyways. Ah!
May start fiddling with the exhaust tonight to make some room for the trans removal ... I will see.

great pics dude, i enjoy the commentary too, i will be following this for a laugh!

Im with Compleckz. This is a terific write up. And the commentary is more than welcomed.

compleckz said:

great pics dude, i enjoy the commentary too, i will be following this for a laugh!

Click to expand...

+1. you're making good progress. I had a hell of a time getting my t-case off last weekend as well. I was able to get it off without taking the tail section off the tranny but like you said, the alignment dowl was pretty stubborn.

This will be an entertaining build. Looking forward to more progress.

Not much done today. Since when do we actually have to work to earn a living? WTF?

Only repositioned the jackstands under the frame (it's not as precarious as the picture makes it look!), as I want to remove the crossmember that holds the radii arms and exhaust to make the trans removal as easy as possible. I still added ramps under the tires. Once again, being crushed is not on the agenda.


Hopefully I can find some time tonight to get going on that crossmember.



Edit -
Look at it. Man that crossmember was trying to stare me down! I couldn't leave it at that.


I half-pwnt him. Got one side. And that's a PITA. Used a combination of eleventy billion wrenches and sockets to get that damn thing. The 4 bolts in the middle are 13mm, then 15mm and 18mm for the bolts holding the radius arm bracket. You have to hold the 2 side nuts on the other side with a wrench. Yes it's tight. And dirt crumples on your face as you try to fit the damn wrench in the slot.
But hey, veni vidi vici. (aka pwnt.)




I don't need it hanging any lower. I just wanted the extra room to get the trans out that much more easily. I guess I'll get on the other side later.

What are you planning to do with that front D35? Interested in selling it?

You got a PM!

Had a helper, so I removed the exhaust. Snapped 3 out of 4 bolts ... dayum I'm strong.


Note I put the trans cap back on. And I vacuumed the flor before going wrenching. That's how tidy I am. My mom would be proud.

Next step, transmission removal! I couldn't help but notice there are at least 2 electrical connectors going in the transmission ... wasn't really expecting that. I'll have to figure out what they're for. Annoying little buggers.

In terms of schedule, I was planning a week for removal ... then re-adjusted to 3 days after the beginning went so smooth. I guess 4 days it will be. Cool.

Have been busy with a bunch of little stuff.

Completely gutted the interior, some corner bolt holding the rear seats was a decent fighter. Knew all the tricks in the book, rusted, jammed, no accessibility from either side ... beautiful fight. I still won.


Found some 3 way Alpine speakers in the doors too. Cool. Stole the dash bezel thingie as well. Looks cleaner than the Ranger's.

Took the roof rack as well, hopefully I can fit it on the Ranger. Well, I can fit it, but I hope I can make some solid mounting points.

More in relation to the swap, I removed the clutch master cylinder, easy peasy.

Then checked this thread for a bit of guidance.
http://www.therangerstation.com/forums/showthread.php?t=10123

Pedal assembly is a bit more of a hassle, at least I can lay down on my back and tuck my head under there to make sure all the dirt and grime lands in my eyes.

For the lunatics willing to accomplish the same thing, I unbolted the steering column, and resting on my (muscular) stomach (keep in mind, I'm on my back, head tucked next to the pedals), it allowed more room to get to the pesky 2 top bolts. They are 14mm, not 13mm. I also had 2 reinforcement bars held down by 10mm bolts.

Out. Damn that thing is built to withstand a direct nuclear hit!!!! WTF? Does Ford think all Ranger drivers are 500lbs and stand on the pedals?

Note the little ratchet wrenches ... these came in really handy. Well worth the 2,7 billion pesos price tag.



It is starting to dawn on me that I will have to do all of this all over again in my truck ... and then re-assemble!

I'm meticulously arranging the bolts and nuts to know what each is.

looks like it's coming along