Quick Tips!

Mazda 5 Speed Manual
Transmission


Explorer Wheel Bearings


Explorer Computer Chip


Explorer Fuel Pump RFI


Explorer Dual Batteries


Cleaning Ford Explorer MAS


Explorer Caliper Slide Pins


Explorer Shock Skid Plate


Explorer K&N Filtercharger


Explorer Disc Brake Rear Axle


Explorer Body Lift Install


Explorer Dual Shocks


Explorer Steering Stabilizer


Explorer 2.5" Lift Install


Speedometer Calibration


Explorer Torsion Bar Lift


Explorer Disc Brake Swap


Explorer Rear Axle Seals


Explorer Manual Hubs


Atlas II Transfer Case
in Ford Explorer


KKM Air Filter Review

Explorer White Face Gauges


Ford Explorer Clutch
Bleeding Procedure


Spindle Nut Upgrade


Ford Explorer 2wd - 4wd
Conversion


1991 - 1994 Ford Explorer
Tire Options


1995 - 2001 Ford Explorer
Tire Options


Ford Explorer Spring Over
Axle Conversion


Ford Explorer Vibration Problems


Ford Explorer 5 Link Solid
Axle Swap Dana 44


Installing Rock Sliders on a
Ford Explorer

Ford Explorer Overhead
Console Install


4.0 Valve Clatter in Ford
Explorer and Ranger


Huge List of Maintenance Tips
for the Ford Explorer


Setting up Ford 8.8" Gears


4x4 Shift Motor Rebuild


Body Work 101 w/photos


C4 Transmission Dana 20

 Transfer Case Swap into Explorer


A4LD Rebuild Diary


Dana 44 TTB Knuckles on
 Dana 35 TTB Axle


A4LD Front Seal Info


Max Tire Size for Explorer


Ford Explorer Torsion Bar
 Removal Installation


Front Differential
R&R 1995+ Explorer

Converting R12 to R134A
 in Ford Explorer

700R4 Transmission Swap

Explorer Sport Truck

Fiberglass step by step

Wheel Offset Backspace

Wheel Spacers

IAC Valve Cleaning

Explorer Message Board
 Home PageMessage BoardBookstoreResourcesFAQTipsReviewsReaders RidesAddMore ExplorersExplorer RunsWhoopsSave TrailsLinksHam Radio




Ford Explorer
In the beginning...
The story of the First Ford Explorer

Information for this article was provided by:
Derek Elliott, Former Ford Body & Electrical Engineer


This is the first Ford Explorer to roll off of
the Louisville production line. Sept. 1990

  • The FPV (Financial Planning Volume) objective was 250,000 units per year over a 10 year cycle. From the projected FPV the profit margin goal was set.

  • After all the financial & political mess had been sorted out we could now start the task we had been trained for, design engineering, safety, durability & meet FMVSS, (Federal Motor Vehicle Safety Standards) for certification and sign off by our legal office.

  • Back in Dearborn we got to work with the HAD to get the clay model to a point of feasibility that satisfied styling & all BMDs, (Basic Manufacturing Divisions) as well as outside suppliers.

  • Once the clay model is fully feasible we have reached the first mile stone. The model is then scanned electronically providing engineering with the vehicles outside shape.

  • At clay approval you are telling top executives that you are an an 80% confidence level that can build the UN46 at a given production rate (84 per hour) by the Job #1 date, and that date is set in concrete.

  • My task now was to ensure that we could meet both the timing and feasibility through to Job #1 i.e.

  • Prove out the vehicle ergonomics
  • Package the driveline, engine & suspension
  • Make sure that the vehicles structure will meet both safety & durability requirements.
  • keep the styling theme on track
  • meet all European standards for export units
  • Design/Engineer into the UN46 all safety requirements i.e. restraints both passive & active.
  • Build prototypes in line with PERT timing objective PERT (Program Evaluation & Research Techs)
  • meet the Job #1 timing - less excuses
  • Maintain program cost objectives
  • After 18 months into the program the following changes were asked for by management:

  • Generate a two door sports model
  • Meet 2 1/2 MPH bumper impact without damaging any sheetmetal skin. At 2 1/2 MPH the bumper deflected .75"
  • Mazda Corp. wants a two door sport vehicle restyled to Mazda's image. 
  • We met with Mazda management in LA & worked out how we could meet Mazda's wants without upsetting the UN46 program.

  • We made Job #1 for both the Explorer & the Mazda Navajo at a build rate of 84 units per hour, instead of meeting the objective FPV of 250,000 units per year we have built over 400,000 units since 1990.

  • Prior to Job #1 I was told I had caner of the lung which put me out of action for 6 months.

  • 1995 UPN - (Utility & Pickup of North American Operations)

  • Major facelift to the body styling

  • Add SLA front suspension (short arm - long arm) & delete the I beam front suspension.

  • Redesign the Ranger wit ha major facelift

  • Per Mr. Trottman our new CEO replacing Red Poling he wanted the 302 V8 packaged in the Explorer design & design a new cargo box for the Ranger Sports Pickup

  • And so we start all over again, but this time we had to have all of the engineering done & go to Job #1 in less than 36 months from clay approval.

Derek Elliott

| Back to Page 1 |

| HOME |

 


Copyright 2017 - 2000 Rick Horwitz Photography
All Rights Reserved