The most important part about a 4x4
conversion is having all of the parts you need to do the conversion. This
conversion is for '91-'94 Explorers with manual transmissions.
Complete front axle
assembly with gears to match your rear ratio.
Warn manual Locking
4x4 brake rotors
4x4 steering linkages
4x4 radius arms
Transmission hump plate
New interior shifter
Front drive shaft
4x4 rear drive shaft
T-case skid plates
4x4 speedometer cable
Tail Shaft for 4x4
4x4 output shaft for
Mazda 5-speed (25 spline)
Manual Shift Borg
Manual Shift linkages
How I did it!
First Thing I did was do about a year and a half of research. The good thing is
I am writing this out for anyone who is crazy as I was to do this.
I started by buying the
parts I knew I would need. Prior to the conversion I
had the rivets cut out of the rear I-beam drop brackets to make the job go
easier. The rivets were replaced with bolts which I could easily remove.
I also replaced the speedometer cable at this time.
It is a good Idea to have
two people work on this conversion.
Place car on Jack stands.
I placed the Explorer on four Jack stands two at the rear end and two at
the radius arm cross member.
Removing the transmission.
Remove the interior shifter, Y-pipe,
catalytic converter, drive shaft, starter, and transmission cross member.
Support the engine and disconnect all wiring to the transmission.
Remove the bellhousing bolts then
remove the transmission from the car.
At this point the trans
work was beyond my knowledge. I
Took the transmission, 4x4 output shaft, and the 4x4 tail shaft to a Ford
transmission tech who installed the new components.
While the transmission was
getting its new output shaft I started work on the front end.
First remove the
Remove the steering linkages, springs, and radius arm bolts. Then
disconnect the shocks. Remove the I-beam bolts
and removed the front axle assembly.
After they were removed the
rear I-beam drop bracket must be changed out.
On the 2wd it is on the inside of the engine cross member on the 4x4 it
is on the outside.
Change out the drivers side
I-beam bumper. Attach the passenger
side 4x4 I-beam, and then the driver side.
Reassemble in the same order as the removal of the 2wd.
You will need new rotors,
but not new calipers. New pads are optional.
Install the manual Locking hubs. Put the wheels back on.
Note: most wheels will need new center caps. In my case I removed them
While waiting for the transmission
to be finished or your father to get off of work to help.
Install the new transmission hump plate and cut the carpet for the
transfer case shifter.
Next I reinstalled the transmission.
I put it back together as it came out. Replace
cross member, starter, new drive shaft, cat, and
Y-pipe. Bolt up the transfer case, connect wiring, install front drive
shaft. Install new shifter.
When your finished with the
reassembly go to an alignment shop and get the front end aligned.
Is this A Good Idea?
For any one that is interested in this. Think
twice this is not an easy project. The
major flaw with this is the cost of parts (not Labor)
I spent about $1500 in parts alone.
I got good deals too. Figure
it will take 5 to 8 months gather all of the pieces.
What about Auto Trannys?
I Have no Idea!!!!!!